Proximity Sensor Angular Misalignment Detection Forged Blanks
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Solution Overview
Problem
Progressive forming machines often produce defective parts due to angular misalignment of blanks during transfer between workstations, which is not effectively detected in high production environments, leading to customer dissatisfaction and financial losses.
Innovation Solution
A system that detects angular misalignment by using a proximity sensor to detect resistance when a blank tries to enter a tooling cavity, interrupting the machine operation to allow manual removal of misaligned blanks, utilizing the 'go, no go' nature of the blank and tooling alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If progressive forming machines operate at high production speed, then productivity increases, but defective parts due to angular misalignment are not detected and quality deteriorates
Solution Approach 1:
The system performs preliminary detection of angular misalignment before the blank is fully formed. The proximity sensor detects resistance to entry at the tooling interface before the forging process completes, allowing early identification of defective blanks while maintaining high production speed.
Solution Approach 2:
The system establishes a feedback loop where the proximity sensor continuously monitors blank alignment and provides real-time signals to the controller. When misalignment is detected, the controller immediately interrupts the forming cycle, creating a closed-loop quality control system that maintains both high productivity and part quality.
2Productivity
If the machine operates continuously without interruption, then productivity is maintained, but misaligned blanks produce defective parts that are not detected
Solution Approach 1:
The proximity sensor acts as an intermediary detection device that monitors the interaction between the blank and tooling without interrupting the continuous production flow. It detects resistance to entry caused by angular misalignment and transmits this information to the controller, enabling detection within the continuous production process.
Solution Approach 2:
The system replaces complex mechanical detection methods with a simpler electronic proximity sensing system. The proximity sensor electronically detects the resistance force when a misaligned blank fails to enter the tooling, substituting mechanical measurement with electronic sensing for easier and more reliable detection.
3Device complexity
If traditional detection methods are used, then device complexity remains low, but angular misalignment of blanks cannot be detected
Solution Approach 1:
The proximity sensor serves as an intermediary detection device that indirectly measures angular misalignment by detecting resistance to entry at the tooling interface. This indirect measurement approach maintains relatively simple device complexity while achieving the precision needed to detect angular misalignment that traditional direct measurement methods would miss.
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
Effectively prevents the production of misshapen parts by identifying and removing angularly misaligned blanks, ensuring the quality of the final product and reducing financial losses associated with defective parts.
Implementation Method 1
Displacement, i.e. sliding, of the tool is detected by a proximity sensor
Data Source
AI summary
A method and apparatus for detecting a turned blank at a workstation in a progressive forging machine comprising simultaneously monitoring both the force on a tool in the workstation and the crank angle of the machine, determining a reference crank angle when the tool is subjected to a force at the workstation about to deliver a blow and a blank in the workstation is properly angularly aligned, operating the machine to forge blanks in a normal manner when a force on the tool at the workstation occurs substantially at the reference crank angle, and interrupting said normal manner when the force on the tool at the workstation occurs before said reference crankshaft angle to enable the blank being formed at the workstation to be separated from remaining blanks being forged in the machine.