Multi-Point Servo Hybrid Press Ram Control
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Solution Overview
Problem
Hydraulic warm-forming presses face challenges in reproducibility due to varying mechanical and thermal material properties, leading to process fluctuations and inefficiencies in heat transfer and energy consumption, particularly when producing multiple shaped parts with different properties.
Innovation Solution
A method and device for controlling ram movement and forces in multi-point servo hybrid presses, where servo motors interact with hydraulic pressure cushions to independently control positions, speeds, and forces, allowing active control of draw depth and tilt to compensate for process-induced fluctuations and optimize heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If hydraulic presses are used for warm-forming, then heat transfer and shaping capability are improved, but productivity decreases and energy consumption increases
Solution Approach 1:
The patent combines hydraulic and mechanical press technologies into a hybrid system. The hydraulic system provides controlled pressure for heat transfer and shaping, while the mechanical system enables higher speed and productivity. This merging allows the system to achieve both good heat transfer capability and high productivity that neither system could provide alone.
2Strength
If hydraulic presses are used for warm-forming, then shaping capability is improved, but energy consumption increases due to lower efficiency
Solution Approach 1:
The hybrid press merges hydraulic and mechanical systems to achieve both strong shaping capability and energy efficiency. The mechanical component provides high efficiency and low energy consumption, while the hydraulic component ensures adequate shaping capability and heat transfer, thus resolving the contradiction between shaping capability and energy consumption.
3Temperature
If time-controlled movement sequence is used during dwell phase, then heat transfer optimization is improved, but asynchrony with peripheral automation devices increases
Solution Approach 1:
The patent employs feedback control mechanisms that monitor the actual position and state of the press components, and adjust the movement sequence accordingly. This allows the system to maintain optimal heat transfer during the dwell phase while ensuring synchronization with peripheral automation devices through real-time coordination based on feedback signals.
Solution Approach 2:
The system uses dynamic control of the movement sequence rather than rigid time-based control. The dwell phase duration and timing are adjusted dynamically based on actual process conditions and coordination requirements with peripheral devices, allowing optimization of heat transfer while maintaining synchronization flexibility.
4Productivity
If mechanical press with servo-motor is used, then productivity is improved, but ability to compensate process fluctuations decreases
Solution Approach 1:
The hybrid press combines mechanical and hydraulic systems where the mechanical component provides high productivity through servo-motor control, while the hydraulic component adds the ability to compensate for process fluctuations. This merging enables both high productivity and manufacturing precision that neither system could achieve alone.
Solution Approach 2:
The system utilizes parameter changes in the hydraulic component to compensate for process fluctuations. By adjusting hydraulic pressure and flow parameters dynamically, the system can adapt to variations in material properties and process conditions while maintaining the high productivity enabled by the mechanical servo-motor system.
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 enhances the reproducibility of shaped parts, reduces energy consumption, and improves productivity by enabling precise control of ram movement and forces, ensuring optimal heat transfer and minimizing energy usage.
Implementation Method 1
The pressure while at rest can be set such that a fast and optimum thermal transfer takes place between the warm-pressed shaped part and the closed dies which are equipped with cooling
Data Source
AI summary
A method for the control of a ram movement and ram forces of multi-point servo hybrid presses, where the positions, speeds and forces to drive the ram can be controlled independently of each other by the servo motor, which is assigned to each pressure point or each group of pressure points, for the main drive for the ram movement in the main function and the hydraulic pressure cushions, which are separately assigned to each pressure point of the ram, in an auxiliary function, to influence process-induced position and force settings of the ram in a combinatory interaction to achieve an active control of draw depth and tilt.