Servo Press Speed Synchronization for Variable Part Arrival
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Solution Overview
Problem
Existing press installations with servo presses and conveyor devices face inefficiencies due to variable times for pieces to reach the origin position, leading to potential downtime and increased power consumption, as the actuation speed of the servo press and conveyor device cannot be consistently optimized.
Innovation Solution
A control method and press installation that utilize a synchronized master signal to adjust the actuation speed of the servo press and conveyor device based on detection of piece passage through a predetermined reference position, ensuring continuous operation and reducing downtime by adapting speed according to the time elapsed between piece passages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the actuation speed of the servo press is maintained at a constant high speed, then productivity is improved, but the servo press must stop waiting for pieces to reach the origin position, increasing downtime and power consumption
Solution Approach 1:
The actuation speed of the servo press is made dynamic rather than constant. The controller continuously adjusts the actuation speed based on real-time detection of piece passage through the origin position. When a piece is detected, the servo press accelerates to optimal pressing speed; when no piece is approaching, the speed is reduced or halted. This dynamic speed adaptation eliminates idle waiting time while maintaining high pressing throughput, directly resolving the contradiction between productivity and downtime.
Solution Approach 2:
A feedback mechanism is implemented where a detector monitors the passage of pieces through the origin position and provides real-time information to the controller. The controller uses this feedback to continuously adjust the master signal that controls the servo press actuation speed. This closed-loop feedback system ensures the servo press operates at optimal speed only when pieces are available, eliminating unnecessary operation during downtime and reducing power consumption while maintaining productivity.
2Loss of time
If the actuation speed of the servo press is reduced to match variable piece arrival times, then downtime is reduced, but productivity decreases due to slower operation
Solution Approach 1:
The system employs dynamic speed adjustment rather than uniform speed reduction. The servo press operates at high speed during active pressing cycles when pieces are available, and reduces or stops during idle periods when no pieces are approaching. This dynamic operation pattern maintains high productivity during working periods while minimizing downtime, avoiding the need for continuous slow operation that would reduce overall productivity.
Solution Approach 2:
The actuation speed parameter of the servo press is continuously changed based on detected piece arrival patterns. The controller modifies the master signal to adjust speed parameters in real-time, accelerating before expected piece arrival and decelerating or stopping during idle periods. This parameter adaptation allows the system to maintain high productivity during active cycles while reducing downtime, avoiding the productivity loss associated with consistently reduced speed.
3Productivity
If the servo press operates continuously at high speed, then productivity is improved, but power consumption increases during idle periods when no pieces are available
Solution Approach 1:
The feedback mechanism detects when no pieces are approaching the origin position and signals the controller to reduce or halt servo press operation. This feedback-driven control ensures the servo press consumes high power only during active pressing cycles when productivity is being achieved, and reduces power consumption during idle periods, directly addressing the contradiction between productivity and energy usage.
Solution Approach 2:
The servo press operates in periodic cycles of high-speed pressing followed by low-speed or stopped idle periods, rather than continuous high-speed operation. The periodic activation is synchronized with piece availability detected by the monitoring system. This periodic action pattern maintains high productivity during active cycles while significantly reducing average power consumption during idle periods when no pieces are available for pressing.
Data Source
Figure 1~2
AI summary
Control method for a press installation and installation, where said installation (1000) comprising a servo press (1), a conveyor device (2) for conveying pieces (3) from a position of origin (PO) to the servo press (1), and a controller. The controller controls the movements of the conveyor device (2) and of the servo press (1) by means of one and the same master signal, causing a synchronized actuation of both. In the method, the pieces (3) are conveyed to the position of origin (PO) and during the travel thereof until reaching said position of origin (Po), the passage of said pieces (3) through a predetermined position of reference (PREF) before the position of origin (PO) is detected, and depending on said detection, the master signal is adjusted for adapting the actuation speed of the servo press (1).