Sensor-Integrated Pressure Pin for Adaptive Forming Force Control
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Solution Overview
Problem
Existing forming press technologies fail to directly measure forming forces in the force flow, and they require spacers to vary pressure distribution, which limits their ability to adjust pressure during the forming process optimally.
Innovation Solution
A pressure pin with a sensor element and an actuator unit integrated in the pin body, using adaptive materials that can modify rheological properties in response to electrical or magnetic fields, allowing for direct force measurement and adjustment during the forming process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If hydraulic cylinders are used to vary pressure distribution, then pressure adjustment capability is improved, but device complexity and response time are worsened
Solution Approach 1:
The patent combines the sensor element and actuator unit into a single integrated pressure pin, merging measurement and actuation functions into one component. This eliminates the need for separate hydraulic cylinders and spacers, reducing system complexity while maintaining pressure adjustment capability.
Solution Approach 2:
The patent replaces the hydraulic cylinder system with an electrically or magnetically actuated unit. The actuator uses electrical or magnetic fields to modify the rheological properties of adaptive material, substituting complex hydraulic mechanisms with simpler field-based actuation.
2Stress or pressure
If spacers are used to vary pressure distribution, then pressure control is improved, but manufacturing precision and process control are worsened
Solution Approach 1:
The sensor element in the pressure pin provides real-time feedback on the actual force transmitted through the pin. This feedback enables closed-loop control of the forming process, allowing precise adjustment of pressure distribution during forming to achieve optimal forming results.
Solution Approach 2:
The actuator unit with adaptive material enables dynamic adjustment of the pressure pin's characteristics during the forming process. The rheological properties of the adaptive material can be modified in real-time by electrical or magnetic fields, allowing continuous optimization of pressure distribution.
3Measurement precision
If force measurement is implemented in spacers, then force monitoring is improved, but measurement precision and reliability are worsened
Solution Approach 1:
The patent divides the force measurement function into individual pressure pins, each with its own sensor element. This segmentation allows direct measurement of force at multiple discrete locations where it is actually transmitted, improving both measurement precision and reliability compared to measuring only in spacers.
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 precise on-line measurement and adjustment of pressure distribution between the panel and panel holder, enhancing forming process control and robustness against pressure peaks without the need for spacers or hydraulic media, with a compact design.
Implementation Method 1
a sensor element arranged or integrated in the pin body for measuring a force which can be transmitted via the pressure pin
Implementation Method 2
The actuator unit has a functional body made of an adaptive material, wherein the rheological properties and/or length and/or volume of the adaptive material can be modified selectively as a function of an electrical and/or magnetic field
Data Source
AI summary
A pressure pin of a press, in particular a forming press, for transferring a force to a tool component of the press includes a pin body, a sensor element arranged in the pin body for measuring a force which can be transferred via the pressure pin, and an actuator unit arranged in the pin body which has a functional body made of an adaptive material. The adaptive material is designed such that the rheological properties thereof and/or the length thereof and/or the volume thereof can be selectively modified as a function of an electrical and/or magnetic field.