Sheet Metal Handling Test Station for Tactile Element Verification
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Solution Overview
Problem
Existing sheet metal handling processes lack a reliable method to consistently verify the functional state of control devices, particularly in the separation process, leading to potential operational issues and delays.
Innovation Solution
A machine handling device with a test station that checks the functionality of tactile elements in the control device using a test contact body, measuring contact-dependent electrical values and comparing them to reference values to ensure the control device's electrical conductivity, allowing for identification of worn-out elements and enabling timely replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If no testing station is provided to verify the functional state of control devices, then the handling process can proceed without additional equipment, but operational failures may occur and manufacturing processes may be interrupted
Solution Approach 1:
The testing station performs preliminary verification of the control device's tactile elements before the handling process begins. By proactively detecting worn-out or non-functional probe elements through electrical conductivity testing, the system prevents operational failures and interrupts before they occur, ensuring reliable sheet metal handling without adding complex operational procedures
Solution Approach 2:
The testing station acts as an intermediary between the control device and the handling process. It provides a dedicated testing interface with test contact bodies that enable verification of the control device's functionality without interfering with the main handling operations. This intermediary system ensures reliability while maintaining the simplicity of the core handling process
2Productivity
If the functionality of control device elements is not verified, then the handling process can continue without interruptions, but worn-out elements may cause operational failures and delays
Solution Approach 1:
The testing station performs preliminary verification of the control device's tactile elements before the handling process begins. By proactively detecting worn-out or non-functional probe elements through electrical conductivity testing, the system prevents operational failures and interrupts before they occur, ensuring reliable sheet metal handling without adding complex operational procedures
Solution Approach 2:
The testing station provides feedback on the functional state of the control device's tactile elements by measuring electrical conductivity between probe elements and test contact bodies. This feedback mechanism enables continuous monitoring of control device health, allowing timely identification and replacement of worn-out elements, thus maintaining both productivity and reliability
3Reliability
If a testing station with test contact bodies is added to verify control device functionality, then operational failures are prevented, but the device complexity and setup requirements increase
Solution Approach 1:
The testing station is designed as a segmented, modular system with separate test contact bodies that can be independently positioned and electrically insulated from each other. This segmentation allows for simplified assembly and maintenance, as individual test contact bodies can be replaced or adjusted without affecting the entire system, thereby reducing manufacturing complexity while maintaining verification reliability
Solution Approach 2:
The testing station acts as an intermediary between the control device and the handling process. It provides a dedicated testing interface with test contact bodies that enable verification of the control device's functionality without interfering with the main handling operations. This intermediary system ensures reliability while maintaining the simplicity of the core handling process
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
Ensures permanent functional verification of the control device, preventing operational failures and maintaining uninterrupted manufacturing processes by identifying and replacing faulty tactile elements, thus ensuring seamless sheet metal handling operations.
Implementation Method 1
by means of the control voltage source of the control evaluation device, a control voltage can be applied to the touch elements of the touch element pair when the touch elements of the touch element pair are arranged in the control touch position, wherein, by means of the control measuring unit of the control evaluation device, when the control voltage is applied to the touch elements of the touch element pair, an actual value of an electrical current flowing between the touch elements of the touch element pair due to the control voltage
Implementation Method 2
the suction grippers of the suction frame resting on the sheet metal workpiece are connected to a vacuum source
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A mechanical handling device has a test station (21) at which the functionality of a control device of the handling device is tested by means of a test device (22a). The test device (22a) comprises an electrically conductive test contact body (23, 24) for each of the tactile elements (13) of a pair of tactile elements of the control device, against which each of the tactile elements (13) can be arranged in a test position. A test voltage can be applied to the tactile element (13) arranged in the test position and to the test contact body (23, 24) by means of a test evaluation device (26) of the test device (22a).The actual value of an electric current flowing due to the applied test voltage is measured by a test measuring unit (29) of the test evaluation device (26) and compared by a test comparison unit (30) of the test evaluation device (26) with a reference value, which indicates the existence of an electrically conductive contact between the sensing element (13) arranged in the test position and the test contact body (23, 24). A machine arrangement for sheet metal processing is equipped with the aforementioned machine handling device. A method for handling an electrically conductive sheet metal workpiece is carried out using the aforementioned machine handling device.