Servo Press Torque Profile Analysis for Forming Process Monitoring
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Solution Overview
Problem
Existing methods for determining forming process characteristics of servo presses are complex and require external measurement technology, making it difficult to accurately measure and adapt to servo press operations.
Innovation Solution
A method involving the comparison of torque profiles during a cycle without a workpiece and a cycle with a workpiece to determine forming process characteristics, using both measurement and model-based approaches to analyze the torque profiles and derive key process metrics like forming force, energy, and power.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If external measurement technology is attached to the press apparatus to determine forming process characteristics, then measurement accuracy is improved, but device complexity and ease of operation deteriorate
Solution Approach 1:
The servo press uses its own built-in sensor system to measure torque profile during operation. The control unit processes this data to determine forming process characteristics without requiring external measurement equipment. The servo press essentially measures and analyzes its own operational parameters through the torque sensor already integrated in its drive system.
Solution Approach 2:
The patent replaces complex external mechanical measurement systems with an electronic/data-based approach. By using the existing torque sensor data from the servo drive and processing it through the control unit, the system substitutes physical measurement apparatus with computational analysis of operational parameters.
2Measurement precision
If external measurement technology is attached to the press apparatus to determine forming process characteristics, then measurement accuracy is improved, but ease of operation worsens
Solution Approach 1:
The servo press uses its own built-in sensor system to measure torque profile during operation. The control unit processes this data to determine forming process characteristics without requiring external measurement equipment. The servo press essentially measures and analyzes its own operational parameters through the torque sensor already integrated in its drive system.
3Device complexity
If torque profile comparison method is used to determine forming process characteristics, then device complexity is reduced, but measurement precision may deteriorate
Solution Approach 1:
The control unit compares the measured torque profile with a reference torque profile and uses this feedback to determine forming process characteristics. The system continuously monitors torque during the forming cycle and evaluates deviations from the reference pattern to extract meaningful process information such as forming force, energy, and power characteristics.
Solution Approach 2:
A reference torque profile is established beforehand through measurements taken during the same operating conditions but without the specific workpiece. This reference serves as a baseline for comparing actual forming operations, allowing the system to isolate and identify the torque components specifically related to the forming process.
4Measurement precision
If additional external measurement technology is attached, then forming process characteristic determination is improved, but ease of manufacture worsens
Solution Approach 1:
The servo press uses its own built-in sensor system to measure torque profile during operation. The control unit processes this data to determine forming process characteristics without requiring external measurement equipment. The servo press essentially measures and analyzes its own operational parameters through the torque sensor already integrated in its drive system.
Data Source
AI summary
An analysis unit and method for determining at least one forming process characteristic of a servo press includes the steps of determining a torque profile of a motor of the servo press, wherein the torque profile belongs to a first cycle of the servo press and wherein the first cycle describes a forming process without an item to be processed by the servo press, determining a torque profile of the motor of the servo press, wherein the torque profile belongs to a second cycle of the servo press and wherein the second cycle describes a forming process with an item to be processed by the servo press, and comparing the torque profile belonging to the first cycle with the torque profile belonging to the second cycle to ascertain the at least one forming process characteristic.