Sensor-Controlled Pressing Jaws to Prevent Over-Compression Wear
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Solution Overview
Problem
Existing hand-held pressing machines for tubular workpieces face issues with unnecessary wear and power consumption due to the direct pressing of dies, which leads to over-compression and lack of further deformation, as they rely on a permanently set pressure relief valve to terminate the pressing operation.
Innovation Solution
A pressing machine equipped with a motor, driven pressing jaws, a power transmission unit, and a sensor unit that measures pressing parameters, with a controller determining the slope of the press parameter curve to automatically terminate the pressing operation before reaching maximum force, preventing further deformation and reducing wear and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a permanently set pressure relief valve is used to terminate the pressing operation, then the pressing machine can achieve sufficient compression force, but the pressing jaws directly abut each other causing strong wear on the tool, power transmission parts and drive motor
Solution Approach 1:
The control unit continuously monitors the pressing parameter (force, pressure, or motor current) and automatically terminates the pressing operation when a predetermined criterion is met, such as when the pressing parameter increases by less than a threshold value over a predetermined time period. This feedback mechanism prevents the pressing jaws from directly abutting each other, thereby eliminating strong wear on the tool, power transmission parts, and drive motor while maintaining sufficient compression force for secure press fit.
2Strength
If pressing continues until maximum pressure is reached, then sufficient compression is ensured, but unnecessary electrical energy is consumed
Solution Approach 1:
The control unit monitors the pressing parameter in real-time and automatically terminates the pressing operation when the predetermined criterion is satisfied, such as when the rate of increase of the pressing parameter falls below a threshold. This feedback-controlled termination prevents unnecessary continuation of the pressing process after sufficient compression is achieved, thereby reducing electrical energy consumption while ensuring adequate compression force for a secure press fit.
3Manufacturing precision
If the pressing operation is terminated by a pressure relief valve, then the pressing process ends, but the pressing jaws are already abutting each other preventing further deformation
Solution Approach 1:
The control unit continuously monitors the pressing parameter and automatically terminates the pressing operation when a predetermined criterion is met, such as when the pressing parameter increases by less than a threshold value over a predetermined time period. This feedback mechanism allows for precise control of plastic deformation by detecting when the workpiece has reached its deformation limit, thereby preventing the pressing jaws from directly abutting each other and enabling better manufacturing precision without significantly increasing device complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution allows for a secure and durable press fit without unnecessary wear or power consumption, as the controller stops the motor when the slope of the press parameter curve indicates maximum deformation, ensuring efficient plastic deformation of the workpiece.
Implementation Method 1
The pressing machine also has at least one sensor unit (42) for measuring at least one pressing parameter (P), in particular force, pressure or current flowing through the motor (20)
Implementation Method 2
The pressing machine comprises a motor (20), pressing jaws (30), which are driven by the motor (20) and can apply a force to the workpiece (110) during operation
Implementation Method 3
The pressing machine is for plastically deforming a workpiece (110), in particular a fitting, and a method for operating a pressing machine for plastically deforming a tubular workpiece
Data Source
AI summary
A pressing machine is described for plastically deforming a tubular workpiece, in particular a fitting. The pressing machine has a motor, and pressing jaws which are driven by the motor and can apply a force to the workpiece during operation. The pressing machine also has a power transmission unit coupled to the motor and the pressing jaws for transmitting power from the motor to the pressing jaws. The pressing machine also has at least one sensor unit for measuring at least one pressing parameter P and a controller which receives the currently measured value of the pressing parameter P from the sensor unit and determines therewith the pitch or slope of a press parameter curve K of the press parameter P. The controller terminates a pressing operation before reaching a maximum possible pressing force Pmax when the pitch or slope of the press parameter curve K of the press parameter P satisfies a shutdown criterion. Also described is a corresponding method for operating a pressing machine.