Punch Position Feedback for Continuous Precision Bending
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Solution Overview
Problem
In existing bending machines, operators must frequently stop operations and manually confirm accuracy to stabilize the quality of processed parts, which limits production efficiency and increases the burden of accuracy confirmation work.
Innovation Solution
A bending method that acquires reference values for each processed part before operation, calculates secular change correction values during processing, and automatically adjusts the pushing amount or original position of the punch with respect to the die, allowing for continuous operation without manual accuracy confirmation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual accuracy confirmation is performed periodically to stabilize quality, then manufacturing precision is improved, but productivity deteriorates due to frequent stoppages
Solution Approach 1:
The bending machine performs self-diagnosis and self-correction by automatically detecting secular changes in the punching apparatus position and adjusting the pushing amount or original position without operator intervention. The system acquires reference values, calculates secular change correction values, and resets parameters automatically during continuous operation, eliminating the need for manual accuracy confirmation while maintaining quality stability.
Solution Approach 2:
The system implements a feedback mechanism where the actual position of the punching apparatus is continuously monitored and compared against reference values. Based on the detected secular changes, the system automatically calculates correction values and adjusts the pushing amount or original position, creating a closed-loop control system that maintains manufacturing precision without stopping production.
2Manufacturing precision
If manual accuracy confirmation is performed frequently to stabilize quality, then manufacturing precision is improved, but loss of time increases due to operator burden and stoppages
Solution Approach 1:
The bending machine autonomously performs the accuracy confirmation function that previously required operator intervention. The system automatically acquires reference values of the punching apparatus position, detects secular changes during operation, calculates correction values, and resets parameters without requiring operators to stop the machine and manually check accuracy, thereby eliminating time loss associated with manual confirmation work.
Solution Approach 2:
The system enables continuous bending operation by performing secular change detection and correction automatically during production. The acquisition of reference values, calculation of correction values, and resetting of parameters are performed without interrupting the bending process, maintaining continuous useful action while ensuring quality stability.
3Productivity
If automatic operation is performed without secular change correction, then productivity is improved through continuous operation, but manufacturing precision deteriorates due to secular change accumulation
Solution Approach 1:
The system maintains manufacturing precision during continuous automatic operation by implementing real-time feedback on the punching apparatus position. The control device acquires reference values, detects secular changes as they accumulate during continuous operation, calculates correction values, and resets the pushing amount or original position, preventing accuracy deterioration while maintaining productivity.
Solution Approach 2:
The system acquires reference values of the punching apparatus position before bending operations begin and stores them in association with each processed part. This preliminary action establishes a baseline for detecting secular changes, enabling the system to proactively correct accuracy drift before it affects product quality, thus maintaining precision throughout continuous operation.
Data Source
AI summary
A bending method includes acquiring a reference value of an original position of a punch with respect to a die for each processed part before an operation of bending of a workpiece by a bending machine including the punch and the die is started, storing each of the acquired reference values in association with each of the processed parts, reading the reference value associated with the processed part to which the bending is to be executed, acquiring a measurement value of the original position after the operation of the bending of the workpiece is started, calculating, based on the acquired measurement value, a secular change amount from the reference value or a previous measurement value as a secular change correction value for a pushing amount of the punch with respect to the die or the original position of the punch, and resetting, for each predetermined trigger condition, the pushing amount or the original position by using the secular change correction value during an automatic operation of the bending of the workpiece.