Servo Turning Station Motion Profiles for Energy and Oscillation Control
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Solution Overview
Problem
The challenge in producing electric motor components using punch presses is the inefficient and energy-consuming operation of servo motor-driven turning stations due to varying masses and inertias, leading to suboptimal motion profiles and system oscillations.
Innovation Solution
A method to define target turning acceleration processes for servo motor-driven turning stations, optimizing energy efficiency by determining target and reference parameters to achieve uniform acceleration and deceleration profiles without unnecessary high accelerations, using a 'teach-in' operation to set optimal motion profiles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If high accelerations and decelerations are used to complete the turning increment in available time, then the turning speed is improved, but energy consumption increases and equipment wear increases
Solution Approach 1:
The system dynamically adapts the motion profile of the turning station based on real-time parameters such as sheet pack mass, turning increment size, and available time. The control system adjusts acceleration and deceleration values dynamically rather than using fixed high values, optimizing the balance between turning speed and energy consumption for each specific operating condition.
Solution Approach 2:
The invention changes the motion parameters (acceleration, deceleration, velocity) of the turning station based on measured or calculated parameters such as sheet pack mass, turning increment, and cycle time. By calculating optimal parameter combinations that satisfy the turning requirement within available time while minimizing energy consumption, the system resolves the contradiction between speed and energy use.
2Speed
If high accelerations are used to complete the turning increment in available time, then the turning speed is improved, but system oscillations occur
Solution Approach 1:
The control system dynamically determines acceleration and deceleration values that are high enough to complete the turning increment within available time but low enough to avoid exciting system oscillations. This dynamic adjustment based on actual system conditions maintains stability while achieving required turning speed.
Solution Approach 2:
The system uses feedback from sensors measuring actual position, velocity, and potentially vibration/oscillation levels to adjust the motion profile in real-time. This feedback mechanism allows the system to reduce acceleration values when oscillations are detected, preventing instability while maintaining turning speed where possible.
3Manufacturing precision
If iterative adjustment of turning stations is performed to match dynamic characteristics, then the manufacturing precision is improved, but the time required for setup increases
Solution Approach 1:
The system performs preliminary characterization of the turning station's dynamic behavior through reference acceleration runs before actual production. By pre-determining the relationship between drive torque and turning acceleration, and pre-calculating optimal motion profiles for different sheet pack masses and turning increments, the system eliminates the need for time-consuming iterative adjustments during setup while maintaining high precision.
Solution Approach 2:
The control system automatically calculates and configures optimal motion profiles based on input parameters such as sheet pack mass, turning increment, and available time. This self-configuration capability eliminates the need for operator intervention and iterative manual adjustment, reducing setup time while maintaining manufacturing precision.
4Ease of operation
If the motion profile is not specifically set for each production job, then the ease of operation is improved, but energy consumption increases due to unnecessarily high accelerations
Solution Approach 1:
The system automatically determines optimal motion profiles without requiring operator intervention or expertise. The control system inputs basic parameters (sheet pack mass, turning increment, available time) and automatically calculates the energy-optimal acceleration and deceleration values, making the system easy to operate while minimizing energy consumption.
Solution Approach 2:
The system automatically changes motion parameters (acceleration, deceleration, velocity) based on production-specific conditions such as sheet pack mass and turning increment requirements. This automatic parameter optimization maintains ease of operation while eliminating unnecessarily high accelerations that would increase energy consumption.
Data Source
AI summary
A method for operating a servo motor (10) driven turning station (5, 6, 7) of a stacking tool for a punch press includes the following steps: determining a target turning acceleration curve of the turning station (5, 6, 7) in the acceleration phase (A) of the turning increment (D); carrying out a reference acceleration run of the turning station (5, 6, 7); determining during the reference acceleration run the reference angular velocity (ωref) of the turning station (5, 6, 7); determining from the target turning acceleration curve the target angular velocity (ωsoll); calculating a target drive torque of the servo motor, at which the target angular velocity (ωsoll) results, from the relationship, known from the reference acceleration run; and accelerating the turning station (5, 6, 7) with the servo motor (10) in the acceleration phase (A).