Servo Transfer Controller Abnormality Detection for Press Line Interference
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Solution Overview
Problem
Existing servo press line systems face interference issues when an abnormality occurs in the master signal, leading to potential collisions between servo presses and transfer devices, which existing techniques fail to adequately prevent.
Innovation Solution
A method and device that utilize a transfer controller to receive a master signal, detect abnormalities, and generate a stop signal to independently control servo transfer devices, preventing interference by stopping the motor of the servo transfer device when an abnormality is detected, thereby avoiding collisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the system uses a master signal to synchronize servo press and servo transfer device, then synchronized operation is achieved, but interference occurs when abnormality happens in the master signal
Solution Approach 1:
The control system is segmented into two independent control paths: the master controller generates master signals for normal synchronized operation, while the transfer controller independently monitors the master signal and generates stop signals when abnormalities are detected. This segmentation allows the system to maintain simple synchronized control during normal operation while adding targeted safety functionality without overwhelming complexity.
Solution Approach 2:
The transfer controller acts as an intermediary between the master controller and the servo transfer device. It receives the master signal, monitors for abnormalities, and intervenes by generating stop signals when needed. This intermediary role allows the system to maintain the simple master signal-based synchronization while adding abnormality detection and interference prevention capabilities.
2Reliability
If the system stops all devices when master signal abnormality occurs, then interference is prevented, but productivity is reduced due to complete shutdown
Solution Approach 1:
Instead of applying a uniform stop command to all devices when an abnormality occurs, the system applies the stop signal locally only to the servo transfer device through the transfer controller. This localized response prevents interference at the critical interface while allowing the servo press and other transfer devices to continue operating, thereby maintaining productivity while ensuring safety.
3Loss of time
If the transfer controller generates stop signal independently, then response time is reduced, but control coordination becomes more complex
Solution Approach 1:
The transfer controller continuously monitors the master signal in advance, maintaining readiness to detect abnormalities. This preliminary monitoring action allows the system to immediately generate stop signals when abnormalities occur, reducing response time without requiring complex real-time decision-making during the abnormal event itself.
Data Source
AI summary
A servo press line operation method operates a servo press line in which a servo press and a servo transfer device are disposed in a workpiece transfer direction. The servo press line operation method includes causing a transfer controller to receive a master signal that causes the servo transfer device to make a motion in synchronization with the servo press, the transfer controller controlling a motor of the servo transfer device using a motor instruction, causing the transfer controller to determine whether or not an abnormality in the master signal has occurred, and causing the transfer controller to generate the motor instruction based on a stop signal that stops the motor of the servo transfer device, instead of the master signal, when the transfer controller has determined that an abnormality in the master signal has occurred.