Punching Tool Position Monitoring via Barrier Optical Sensor
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Solution Overview
Problem
Existing multi-press punching machines face challenges in accurately and efficiently measuring the position, stroke, and speed of multiple punching tools due to high costs and complex structures, necessitating a simpler and more cost-effective solution for real-time monitoring.
Innovation Solution
The implementation of barrier optical sensors, specifically laser through beam sensors, allows for the detection and measurement of the position, stroke, and speed of punching tools without requiring significant mechanical or structural modifications, enabling precise control of tool movement based on the material and thickness of the workpiece.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a measurement sensor is provided for each punching tool, then measurement precision and reliability are improved, but device complexity and manufacturing costs increase
Solution Approach 1:
A single barrier optical sensor is designed to detect the position and stroke of multiple punching tools simultaneously. The sensor serves as a universal measurement device for all tools in the punching head, eliminating the need for individual sensors for each tool while maintaining measurement precision.
Solution Approach 2:
The patent combines multiple measurement functions into a single sensor unit. By merging the detection of multiple tools' positions and strokes into one barrier optical sensor, the system reduces the total number of components while achieving comprehensive measurement coverage.
2Device complexity
If barrier optical sensors are used to reduce the number of sensors, then device complexity and costs are reduced, but measurement precision and reliability may deteriorate
Solution Approach 1:
The barrier optical sensor creates optical copies or projections that allow simultaneous detection of multiple tool positions. The light beam system effectively creates virtual measurement points for each tool without requiring physical contact or individual sensors, maintaining precision through optical field division.
Solution Approach 2:
The patent transitions from one-dimensional sequential measurement (one sensor per tool) to multi-dimensional simultaneous measurement using optical fields. The barrier optical sensor utilizes light beam spatial distribution to detect multiple tools at different positions along the punching head row simultaneously, adding a spatial dimension to the measurement capability.
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
This solution provides accurate, real-time monitoring of punching tool operations, reducing costs and simplifying assembly while ensuring optimal processing conditions for the workpiece, enhancing machine efficiency and reducing downtime.
Implementation Method 1
capable of generating a light beam L substantially flat and linear
Data Source
AI summary
A punching apparatus includes punching tools and actuators positioned above and aligned with the respective punching tools to actuate the punching tools along an operating direction so as to interact with a piece to be worked. The punching tools and the actuators are arranged side by side along at least one row. The punching apparatus includes at least one barrier optical sensor, suitable to generate a light beam that is put side by side to the row of punching tools and actuators, and reference elements, each of which is associated to a respective punching tool and/or actuator to intercept the light beam. The barrier optical sensor is arranged to detect changes in the light beam produced by one of the reference elements moving along the operating direction so as to measure a position and/or a stroke and/or a speed of a punching tool associated to the reference element.