Segmented Press Forming Control for Overload Load Balancing
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Solution Overview
Problem
In press forming methods, inappropriate movement speed ratios between multiple punch tools can lead to excessive loads exceeding the forming load limit, causing forming failures or incomplete material filling, resulting in product defects.
Innovation Solution
A method involving sensors to measure tool deformation and detect overload states, allowing for real-time adjustment of driving forces, speeds, and timing to distribute the load effectively across multiple tool portions, ensuring material flow and preventing excessive loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the movement speed of each tool portion is set at a constant value before forming starts, then the device complexity is reduced and ease of operation is improved, but the manufacturing precision deteriorates due to inability to adapt to material dimension variations and lubrication state variations
Solution Approach 1:
The patent applies dynamics by transitioning from constant speed control to dynamic speed adjustment during forming. The controller modifies the movement speed of each tool portion in real-time based on detection signals from strain gauges, allowing the system to adapt to varying material dimensions and lubrication states while maintaining operational simplicity through automated control.
Solution Approach 2:
The patent implements feedback control by using strain gauges to detect the state of each tool portion during forming and feeding this information back to the controller. The controller then adjusts the movement speed of each tool portion based on this feedback, creating a closed-loop system that maintains manufacturing precision without increasing operational complexity.
2Manufacturing precision
If the movement speed of each tool portion is adjusted according to detection signals during forming, then the manufacturing precision is improved by adapting to material variations, but the device complexity increases due to additional sensors and control systems
Solution Approach 1:
The patent uses feedback control to maintain manufacturing precision while minimizing device complexity. Strain gauges detect the state of each tool portion and provide signals to a controller that automatically adjusts movement speeds, creating an intelligent system that compensates for material variations without requiring complex mechanical modifications.
Solution Approach 2:
The patent replaces complex mechanical speed adjustment mechanisms with an electronic control system. Instead of using mechanical linkages or manual adjustments to control tool portion speeds, the system uses a controller with detection signals from strain gauges to electronically regulate motor speeds, simplifying the overall device architecture while maintaining precision.
3Productivity
If multiple punches are used to form cylindrical protrusions, then the productivity is improved by distributing the forming load, but the reliability deteriorates due to difficulty in maintaining appropriate movement speed ratios between punches
Solution Approach 1:
The patent implements feedback control to maintain reliability when using multiple punches. Strain gauges on each punch detect their respective states, and the controller adjusts the movement speed of each punch based on these detection signals, ensuring appropriate speed ratios are maintained throughout the forming process while distributing the load across multiple tools to improve productivity.
Solution Approach 2:
The patent applies dynamics by enabling dynamic speed adjustment of each punch during forming. Rather than operating at fixed speeds, the punches can dynamically modify their movement rates based on real-time detection signals, allowing the system to maintain optimal speed ratios that prevent material breakage while distributing forming loads across multiple punches to enhance productivity.
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 approach prevents forming failures by maintaining load within the press forming device's limits and ensures complete material filling, enabling stable production of products with predetermined dimensions and shapes.
Implementation Method 1
a strain gauge which detects a state of each portion of the tool
Data Source
AI summary
A press forming method includes a first process of obtaining a pressing force applied to each portion of a tool by an workpiece material during press forming while independently driving the respective each portion of the tool divided into multiple portions and press forming the workpiece material, and a second process of adjusting at least one of an applied driving force, an applied driving speed, and an applied driving timing for each portion of the tool to cause a processing portion of the workpiece material in which the state approaching an overload state is detected based on the pressing force to flow to other processing portions of the workpiece material.