Press Force Feedback for Recliner Ring Gap Control
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Solution Overview
Problem
Existing methods for bending recliner rings to prevent interference with ratchets often fail to generate a proper gap due to variations in component sizes and material characteristics, leading to potential interference issues.
Innovation Solution
A press device comprising a punch, punch holder, damper, press die, presser, controller, and pressing force detector that stops pressing after a specific displacement when a threshold pressing force is exceeded, ensuring proper springback and gap formation between the bent part and ratchet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If plastic deformation is applied to the recliner ring to generate a gap, then interference between the bent part and ratchet is avoided, but the gap may be improper due to variations in component sizes and material characteristics
Solution Approach 1:
The press device incorporates a pressing force detector that provides real-time feedback on the pressing force applied to the recliner ring. The controller uses this feedback information to dynamically adjust the pressing process, ensuring that the desired springback and gap are achieved despite variations in component sizes and material characteristics. This closed-loop control system monitors the pressing force and adjusts the pressing parameters accordingly to maintain consistent gap generation.
Solution Approach 2:
The system changes the pressing parameters (force, duration, displacement) based on the detected pressing force and displacement of the press die. By dynamically adjusting these parameters during the pressing process, the system compensates for variations in component sizes and material properties, ensuring consistent springback and gap formation. The controller modifies pressing parameters in real-time to achieve the target gap dimension regardless of initial component variations.
2Manufacturing precision
If pressing force is increased to ensure proper deformation, then bending precision is improved, but component damage or excessive deformation may occur
Solution Approach 1:
The pressing force detector provides continuous feedback on the actual pressing force applied to the recliner ring. The controller compares this detected force with the target pressing force and adjusts the pressing parameters accordingly. This feedback mechanism prevents excessive pressing force that could damage the component while ensuring sufficient force is applied to achieve the desired bending precision and springback.
Solution Approach 2:
The pressing process is made dynamic through real-time adjustment of pressing parameters based on detected force and displacement. Rather than applying a fixed pressing force, the system dynamically modifies the pressing parameters during the process to optimize both bending precision and component integrity. This dynamic control allows the system to adapt to the actual state of the component being pressed.
3Shape
If pressing continues until complete deformation is achieved, then shape accuracy is improved, but springback control becomes difficult leading to interference issues
Solution Approach 1:
The system performs preliminary action by stopping the pressing process at a specific displacement point before complete deformation is achieved. The controller is programmed to terminate pressing when the press die reaches a predetermined displacement, which is calculated to account for the expected springback. This preliminary stopping point ensures that after springback occurs, the final shape achieves the desired gap and prevents interference, rather than pressing to complete deformation.
Solution Approach 2:
The pressing parameters are changed by stopping the pressing process at a specific displacement threshold rather than continuing to complete deformation. The controller monitors the displacement of the press die and terminates pressing when the specific displacement is reached. This parameter change in the pressing process allows the material to exhibit proper springback while achieving the target shape accuracy and gap formation.
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
The solution effectively prevents interference between the bent part and ratchet by ensuring a consistent gap, regardless of component size variations, through controlled plastic deformation and springback mechanisms.
Implementation Method 1
a damper configured to exert an elastic force that presses the punch in the pressing direction of the punch
Implementation Method 2
subjects a recliner ring to plastic deformation such that a bent part having a ring shape is formed
Implementation Method 3
generates a gap between the bent part and the ratchet by taking advantage of springback occurred upon the plastic deformation
Data Source
AI summary
A controller of a press device causes a presser to stop pressing upon a press die being displaced by a specific dimension after a time point when a detection value provided by a pressing force detector has exceeded a threshold value.