Segmented Press Brake Punch for Uniform Bending of Thick-Thin Workpieces
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Solution Overview
Problem
Conventional press brakes face difficulties in achieving uniform curvature when bending workpieces with non-uniform thickness, requiring varying pressing forces and stroke amounts, which complicates the process and reduces efficiency and forming quality.
Innovation Solution
A press brake with individually adjustable punch elements that can be positioned to accommodate varying workpiece thicknesses, allowing for uniform curvature without the need for shims and enabling precise control of pressing forces across the workpiece.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a constant vertical distance between the die groove and punch tip is used, then the press brake structure is simple, but uniform curvature cannot be achieved on workpieces with non-uniform thickness
Solution Approach 1:
The punch is divided into multiple independent punch elements (first punch element and second punch element) that can be individually adjusted. Each punch element can be positioned independently to accommodate different workpiece thicknesses at different locations, enabling uniform curvature on non-uniform workpieces while maintaining a relatively simple overall structure.
Solution Approach 2:
The punch elements are made dynamically adjustable through position controllers that can change the vertical distance between each punch element and the die groove. This dynamic adjustment capability allows the system to adapt to varying workpiece thicknesses and achieve uniform curvature without requiring a completely complex fixed structure.
2Manufacturing precision
If shims are placed to adjust pressing force, then uniform curvature can be achieved, but work efficiency decreases due to additional manual work
Solution Approach 1:
The manual mechanical adjustment method using shims is replaced with an automated control system. Position controllers automatically adjust the positions of punch elements based on pre-stored pressing force information corresponding to different workpiece thicknesses, eliminating the need for manual shim placement and significantly improving work efficiency while maintaining uniform curvature.
Solution Approach 2:
The system changes the pressing force parameter dynamically by adjusting the position of punch elements according to the workpiece thickness. The control unit retrieves appropriate pressing force data from storage and applies it by positioning the relevant punch elements, enabling automatic adaptation to different workpiece conditions without manual intervention.
3Manufacturing precision
If the punch shape is manually adjusted, then pressing force distribution can be optimized, but the process becomes complex and time-consuming
Solution Approach 1:
Pressing force information for different workpiece thicknesses is pre-stored in the control unit. When a workpiece is to be processed, the system quickly retrieves the appropriate pre-calculated pressing force data and applies it by positioning the punch elements, eliminating the need for time-consuming manual trial-and-error adjustments while achieving optimal pressing force distribution.
Data Source
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AI summary
There is provided a press brake (1) that, when subjecting a workpiece (90) having non-uniform thickness to bending, can efficiently give uniform curvature to the workpiece (90). The press brake (1) includes: a die (2) supporting the workpiece (90); a punch supporting member (4) arranged so as to be opposed to the die (2); a moving mechanism (5) that moves the punch supporting member (4) relative to the die (2); a punch (3) that is supported by the punch supporting member (4), is opposed to the die (2) or the workpiece (90) in a relative movement direction of the punch supporting member (4), and includes punch elements (3a) lined up in a direction orthogonal to the relative movement direction; and punch element adjusting mechanisms that are disposed so as to correspond to the respective punch elements (3a) and adjusts positions of the punch elements (3a) relative to the punch supporting member (4) in the relative movement direction.