Split Press Brake Tool Placement to Eliminate Mounting Gaps
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Solution Overview
Problem
When using an automatic tool changer (ATC) to mount multiple divided tools in a press brake, small gaps often remain between the tools due to backlash, deflection, and drawing tolerance, leading to potential bending scratches.
Innovation Solution
A method employing a first and second automatic tool changer to retain divided tools in an immovable state, using a torque detection unit to ensure precise alignment by choosing between abutting against the tool's side surface or engaging with its engagement hole, thereby eliminating gaps between tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If position control based on encoder information is used to move the ATC, then the ATC can be positioned accurately at the instructed position, but small gaps remain between divided tools due to backlash, deflection, and drawing tolerance
Solution Approach 1:
The patent applies preliminary action by first positioning the ATC using encoder-based position control to reach the approximate target position, then performing a secondary movement to bring the tool into direct contact with the workpiece or another tool. This preliminary positioning followed by contact-based final positioning eliminates gaps caused by backlash and deflection, as the final position is determined by physical contact rather than relying solely on encoder precision.
2Adaptability or versatility
If multiple divided tools are combined to correspond to bending length, then storage and management become troublesome, but using divided tools requires automatic tool changers which add device complexity
Solution Approach 1:
The patent implements universality by designing the ATC system to handle multiple divided tools with different width dimensions using a single automated mechanism. The ATC can automatically select, retrieve, and install different tool combinations based on the required bending length, making the system versatile for various workpiece sizes while eliminating manual tool management. The system achieves multi-functionality through automated tool selection and combination capabilities.
3Extent of automation
If divided tools are arranged at tentative positions and then moved by ATC, then installation and removal are automated, but minute gaps remain between tools causing bending scratches
Solution Approach 1:
The patent replaces the purely encoder-based mechanical position control system with a hybrid system that incorporates force sensing or contact detection. Instead of relying solely on mechanical position control, the system uses torque detection or contact sensors to detect when the tool has made contact with the workpiece or adjacent tools, thereby eliminating gaps that cause bending scratches while maintaining automated installation and removal.
Data Source
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AI summary
In a first step, a pulling operation is performed with respect to four tools (P1 to P4) by retaining, in an immovable state, a leftmost tool (P1) from among the four tools (P1 to P4) lined up on a tool mounting unit (9U) by means of a left ATC (13UL) and by moving, toward the left ATC (13UL), a rightmost tool (P4) from among the four tools (P1 to P4) by means of a right ATC (13UR). In a second step, a movement of the right ATC (13UR) is stopped when a torque of a motor (25) for moving the right ATC (13UR) in a left-right direction reaches a preset set value. The first step includes a choosing step of choosing, for the respective left and right ATCs (13UL and 13UL), whether to perform the pulling operation in a state of being abutted against respective side surfaces (PS) of the tools (P1 and P4) or to perform the pulling operation in a state of being engaged with respective engagement holes (PH) of the tools (P1 and P4).