Punch Press Numerical Control for Automatic Re-Punching Recovery
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Solution Overview
Problem
In machining processes using punch press machines, errors during punching lead to material waste and increased operator burden due to the need for manual re-machining, as existing systems lack efficient mechanisms for detecting and addressing punching errors.
Innovation Solution
A numerical controller is developed with a punching executor, error detector, and re-punching information storage system that automatically detects errors, stores necessary information for re-execution, and re-executes the punching operation using this information, reducing operator workload and material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual re-machining is performed after punching errors, then the error spots can be corrected, but the operator burden increases significantly
Solution Approach 1:
The system automatically detects punching errors, stores the necessary block information, and performs re-machining without operator intervention. The numerical controller self-services by managing the entire error correction process, from detection to re-execution, eliminating the need for manual identification and re-machining of error spots
Solution Approach 2:
The punching error detector provides feedback about punching completion status to the control system. This feedback mechanism enables the system to automatically identify errors and trigger re-machining operations, creating a closed-loop control system that continuously monitors and corrects punching operations
2Reliability
If workpieces are discarded after punching errors, then defective items are removed from production, but material waste increases and yield rate decreases
Solution Approach 1:
Instead of discarding workpieces with punching errors, the system recovers them by automatically detecting the errors and performing re-machining. The block information is stored and reused to correct the defects, transforming potential waste into recoverable products and improving overall yield rate
3Ease of operation
If automatic error detection and re-machining is implemented, then operator burden is reduced, but device complexity increases
Solution Approach 1:
The numerical controller integrates multiple functions into a single system: it executes punching operations, detects errors through integrated sensors, stores block information in memory, and performs re-machining. This multi-functional integration reduces the need for separate dedicated devices while achieving automatic error correction
4Manufacturing precision
If re-machining information is stored and reused, then re-execution accuracy is improved, but information storage requirements increase
Solution Approach 1:
The system extracts and stores only the essential block information needed for re-machining, such as positioning data and punching parameters, rather than storing complete workpiece data. This selective extraction maintains re-machining accuracy while minimizing storage requirements by keeping only the critical information needed for error correction
Data Source
AI summary
A numerical controller controlling punching performs punching according to a machining program, detects a phenomenon that the punching is not normally completed, collects and stores information required for re-execution of a block in which the phenomenon is generated, and restores a machining state at the time of occurrence of the phenomenon and further re-executes the punching by using the information.