Punch and Die Wear Tracking for Accurate Polishing Decisions
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Solution Overview
Problem
Existing tool management systems in sheet metal processing struggle to accurately determine the state of a tool's blade edge, leading to inconsistent product quality due to worn blades causing burrs, and rely on operator visual checks or hit counts, which are inefficient.
Innovation Solution
A tool management device and method that calculates the accumulated wear amount of a tool's blade edge using arithmetic equations based on clearance values and coefficients, storing this information for each tool to accurately assess when polishing is required, thereby improving blade edge state determination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If operator visually checks blade edge or burrs to determine polishing need, then determination can be made, but determination accuracy is low and task is complicated
Solution Approach 1:
The patent replaces the mechanical/visual inspection method with an automated calculation system. The control device calculates wear amount using arithmetic equations based on clearance values and processing parameters, substituting operator visual judgment with computational analysis to achieve both high accuracy and simplified operation
Solution Approach 2:
The system enables self-assessment of tool wear by automatically calculating wear amounts based on processing data. The control device performs self-diagnosis of blade edge state without requiring external operator intervention, determining when polishing is needed through automated computation of wear metrics
2Extent of automation
If hit count and material parameters are used to determine polishing need, then automation is improved, but determination accuracy is insufficient
Solution Approach 1:
The patent transitions from using discrete parameters like hit count to continuous parameters including real-number clearance values between punch and die. By incorporating clearance variations and processing-specific coefficients into the wear calculation equation, the system achieves both automation and high precision in determining blade edge wear state
Solution Approach 2:
The control device continuously monitors processing parameters and clearance values during operation, feeding this data back into the wear calculation equation. This real-time feedback mechanism allows the system to dynamically update wear assessments and accurately determine when polishing is required based on actual processing conditions
3Ease of operation
If visual inspection by operator is used, then simple method is provided, but product quality consistency deteriorates due to worn blades causing burrs
Solution Approach 1:
The patent replaces manual visual inspection with an automated calculation system that computes wear amounts using clearance values and processing parameters. This substitution maintains operational simplicity while ensuring consistent, objective determination of tool wear state, preventing burr formation through accurate timing of polishing interventions
Solution Approach 2:
The control device performs automated self-assessment of blade wear conditions using processing data, eliminating the need for subjective operator judgment. This self-service capability ensures consistent evaluation criteria are applied uniformly across all processing operations, maintaining product quality standards
Data Source
AI summary
An accumulated wear amount calculation section calculates a wear amount of a blade edge of a punch and a wear amount of a blade edge of a die when a tool set of the punch and the die has processed a sheet metal once. The accumulated wear amount calculation section calculates an accumulated wear amount of the blade edge of the punch and an accumulated wear amount of the blade edge of the die by accumulating wear amounts of respective times when the tool set has processed the sheet metal multiple times. A tool management information managing section manages a state of the blade edge of each punch and each die by causing a tool management information storage section to store tool management information associating a tool identification code given to each punch and each die with the accumulated wear amounts calculated by the accumulated wear amount calculation section.