Redraw Ironing Ram Force Sensing for Friction Control
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Solution Overview
Problem
Existing redraw and ironing systems are unable to effectively measure and control the forces and process conditions during the metalworking process, leading to inefficiencies and potential defects in the production of cylindrical metal articles.
Innovation Solution
A system comprising a ram, a punch, and a sensor system with a first sensor to detect total force and a second sensor to detect sidewall or bottom force, allowing for precise measurement and control of forces during the ironing process, including a spacer to direct the punch nose force onto the ram nose for accurate detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If existing redraw and ironing systems are used without force measurement capability, then the system structure remains simple, but the ability to measure and control forces and process conditions is insufficient
Solution Approach 1:
A force measurement system is introduced as an intermediary component between the ironing system and the control system. This includes force sensors mounted on the ironing die and punch, along with signal conditioning equipment, that mediates the measurement of forces during redraw and ironing operations, enabling precise force detection without fundamentally altering the core ironing process
Solution Approach 2:
Traditional mechanical force measurement methods are replaced with modern electronic force sensors and digital signal processing systems. This substitution enables more accurate force measurement and real-time data acquisition while providing better integration with automated control systems for process optimization
2Reliability
If force measurement systems are added to measure total force and sidewall force, then process control is improved, but the device complexity increases
Solution Approach 1:
The force measurement system is segmented into multiple independent measurement points: a first force sensor measures total force on the ironing die, while a second force sensor measures force on the punch or sidewall. This segmentation allows independent measurement of different force components, enabling comprehensive process control through multiple discrete sensor units rather than a single complex measurement system
Solution Approach 2:
The force measurement system is designed with universal applicability across different ironing configurations. The same sensor architecture and measurement approach can be applied whether measuring force on the ironing die, punch, or sidewall, providing a multi-functional measurement capability that adapts to different process requirements without requiring entirely different system designs
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
Enables direct measurement of total forming force and punch nose force, allowing indirect determination of friction force, thereby improving process control, reducing defects, and enhancing production efficiency and cost-effectiveness.
Implementation Method 1
The first sensor is configured to detect a total force on the ram
Implementation Method 2
the second sensor is configured to detect a force on a sidewall or on a bottom of a can formed from the metal blank
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A can redraw and ironing system includes a ram, a punch, and a sensor system. The ram includes a ram body and a ram nose. The punch is supported on the ram nose and is configured to engage a metal blank during an ironing process. The sensor system includes a first sensor that detects a total force on the ram and a second sensor that detects a force on the ram nose.