Servo Press Top Dead Center Detection via Pulse Counting
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Solution Overview
Problem
In press machines driven by servo motors, accurately detecting the top dead center is time-consuming and cumbersome, especially when adjusting die height, as it requires manually moving the slide to the exact position and recalculating the die height, which is inefficient and labor-intensive.
Innovation Solution
A press machine with a controller that uses a pulse-outputting angle detector and servo motor to automatically detect the top dead center by rotating the main shaft in predetermined directions, counting pulses, and adjusting the slide position to accurately determine the top dead center, allowing for rapid and precise detection without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the slide is manually moved to the exact top dead center for die height adjustment, then the current die height can be accurately detected, but the operation becomes time-consuming and labor-intensive
Solution Approach 1:
The patent replaces the manual mechanical method of moving the slide to top dead center with an automated control system. The servo motor receives control signals to automatically position the main shaft at the top dead center, eliminating manual intervention and reducing adjustment time while maintaining detection accuracy through the angle detector.
Solution Approach 2:
The system performs self-positioning of the slide to top dead center through automated control. The controller automatically calculates the required rotation amount based on angle detector feedback and commands the servo motor to position the slide, enabling the system to service itself without external manual operation.
2Adaptability or versatility
If the waiting position of the slide is displaced from the top dead center to enable reverse motion and reciprocating motion, then operational flexibility is improved, but the die height adjustment process becomes more complex
Solution Approach 1:
The patent employs feedback from the angle detector to the controller to automatically determine the slide's position relative to top dead center. The controller uses this feedback to calculate the exact rotation amount needed to return the slide to top dead center, simplifying the adjustment process despite the displaced waiting position enabling versatile motion patterns.
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 method enables easy and rapid detection of the top dead center, reducing the time and effort required for die height adjustments, improving operational efficiency and accuracy in press machine operations.
Implementation Method 1
a pulse-outputting angle detector adapted to detect a crank angle of the eccentric portion
Data Source
AI summary
A press machine includes a controller including a top-dead-center detector adapted to: rotate a main shaft in a predetermined direction selected from a normal rotation direction and a reverse rotation direction to place a slide at a first position displaced relative to a top dead center of the slide by a predetermined height; while outputting and counting pulses from an angle detector, rotate the main shaft in a direction opposite to the predetermined direction to move the slide to a second position located at the same height as the first position beyond the top dead center; and rotate the main shaft from the second position in the predetermined direction by an amount corresponding to a half of the counted pulses to detect the top dead center.