Servo Turning Station Torque Profiling for Low-Vibration Packetizing
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Solution Overview
Problem
Servo-motor-driven twisting stations in punching presses face challenges in optimizing movement profiles due to varying inertias of rotor and stator laminated cores, leading to inefficient energy use, unnecessary wear, and vibrations, as current systems lack the ability to set targeted movement profiles.
Innovation Solution
A method is introduced to determine a target rotational acceleration profile and reference acceleration run to optimize the movement profiles of twisting stations, allowing for energy-efficient operation without large accelerations, by calculating target drive torque and supply current based on the dynamic behavior of the twisting station, enabling quick adjustment and optimization without extensive experience.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the twisting station uses high accelerations to complete the rotation increment within available time, then the productivity is improved, but the energy consumption increases and unnecessary wear occurs
Solution Approach 1:
The patent applies dynamics by implementing adaptive motion profiles that adjust acceleration and deceleration values based on the specific inertia of the lamination stack. The control system dynamically modifies the motion parameters to match the actual physical characteristics of the workload, enabling energy-efficient operation without compromising productivity. This is achieved through iterative adjustment of acceleration values until optimal energy consumption is reached.
Solution Approach 2:
The patent changes parameters by systematically varying acceleration and deceleration values to find the optimal combination. The control system modifies motion profile parameters (acceleration, deceleration, peak velocity) based on measured inertia and performance feedback. This parameter optimization allows the system to complete rotation increments within available time while minimizing energy consumption and wear.
2Productivity
If the twisting station uses high accelerations to complete the rotation increment within available time, then the productivity is improved, but vibrations occur that negatively impact production quality
Solution Approach 1:
The patent applies dynamics by implementing adaptive motion profiles that adjust acceleration and deceleration values based on the specific inertia of the lamination stack. The control system dynamically modifies the motion parameters to match the actual physical characteristics of the workload, enabling energy-efficient operation without compromising productivity. This is achieved through iterative adjustment of acceleration values until optimal energy consumption is reached.
Solution Approach 2:
The patent addresses mechanical vibration by optimizing acceleration and deceleration profiles to minimize vibratory effects. The control system adjusts motion parameters to avoid resonance frequencies and reduce impact forces during direction changes. By carefully shaping the motion profile, the system completes rotation increments within available time while suppressing harmful vibrations that would affect production quality.
3Adaptability or versatility
If the twisting station is adjusted iteratively by experience to match different production orders, then the adaptability is improved, but the device complexity and time required increase
Solution Approach 1:
The patent applies self-service by enabling the twisting station to automatically determine its own inertia characteristics through reference acceleration runs. The system performs self-diagnosis and self-adjustment by measuring actual acceleration behavior and calculating optimal motion profiles without requiring external intervention or operator experience. This automated self-configuration simplifies the adjustment process while maintaining high adaptability to different production orders.
Solution Approach 2:
The patent implements feedback through reference acceleration runs that measure the actual dynamic behavior of the twisting station with different lamination stacks. The control system uses this feedback information to automatically calculate and adjust optimal motion profiles for each production order. This closed-loop approach eliminates the need for manual iterative adjustment by operators and provides automatic adaptation to varying inertial loads.
4Productivity
If the twisting station uses suboptimal motion profiles with large accelerations, then the rotation increment is completed within available time, but wear on production equipment increases
Solution Approach 1:
The patent applies dynamics by implementing adaptive motion profiles that adjust acceleration and deceleration values based on the specific inertia of the lamination stack. The control system dynamically modifies the motion parameters to match the actual physical characteristics of the workload, enabling energy-efficient operation without compromising productivity. This is achieved through iterative adjustment of acceleration values until optimal energy consumption is reached.
Solution Approach 2:
The patent changes parameters by systematically varying acceleration and deceleration values to find the optimal combination. The control system modifies motion profile parameters (acceleration, deceleration, peak velocity) based on measured inertia and performance feedback. This parameter optimization allows the system to complete rotation increments within available time while minimizing energy consumption and wear.
Data Source
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AI summary
The invention relates to a method for operating a turning station (5, 6, 7), driven by a servomotor (10), of a packetizing tool for a punch press. It comprises the following steps: a) defining a setpoint rotational acceleration characteristic of the turning station (5, 6, 7) in the acceleration phase (A) of the rotational increment (D); b) performing a reference acceleration run on the turning station (5, 6, 7) with the servomotor (10) providing a particular reference drive torque or while feeding the servomotor (10) with a particular reference infeed current; c) ascertaining the reference angular velocity (ωref) of the turning station (5, 6, 7) present in the reference acceleration run when a particular turning angle is reached; d) determining, from the setpoint rotational acceleration characteristic, the setpoint angular velocity (ωsoll) that should be present when a particular turning angle is reached; e) calculating a setpoint drive torque of the servomotor that gives the setpoint angular velocity (ωsoll) from the relationship, which is known from the reference acceleration run, between the reference angular velocity (ωref) and the drive torque of the servomotor (10); and f) accelerating the turning station (5, 6, 7) by way of the servomotor (10) in the acceleration phase (A) of the turning increment (D) with the servomotor (10) providing the setpoint drive torque.