Straightening Hammer Feedback Control for Bar Deformation Accuracy
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Solution Overview
Problem
Existing straightening machines for bar-shaped materials face challenges in predicting the exact forming stroke required to achieve target plastic deformation due to unpredictable elastic and plastic deformation functions, leading to inefficiencies and increased processing time.
Innovation Solution
A method and machine design that incorporates an integrated measuring probe within the straightening hammer to measure actual plastic deformation, using a characteristic diagram to determine subsequent forming strokes, ensuring high probability of achieving target deformation within a specified range, thereby reducing the need for repeated deformation cycles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If statistical methods are used to predict the target stroke, then the straightening process can proceed without repeated cycles, but there is a considerable probability that the material will be plastically deformed too little or too much
Solution Approach 1:
The patent applies preliminary action by performing a first forming stroke before final measurement and calculation. This initial deformation step creates a basis for subsequent precise calculation of the second forming stroke, allowing the system to gather actual material response data before committing to the final deformation amount, thereby improving both precision and productivity
Solution Approach 2:
The patent implements feedback by measuring the actual plastic deformation after the first forming stroke and using this measurement to calculate the precise stroke for the second forming operation. This closed-loop feedback mechanism ensures high deformation accuracy while maintaining efficient processing by avoiding unnecessary repeated cycles
2Manufacturing precision
If the workpiece is lifted off the straightening anvils again, measured and placed back on the straightening anvils and straightened again, then the required straightness can be achieved, but this is very time-consuming
Solution Approach 1:
The patent replaces the mechanical repositioning system with a calculation-based system. Instead of physically lifting and repositioning the workpiece for repeated straightening attempts, the system uses mathematical calculations based on measured deformation to determine the precise second forming stroke parameters, eliminating time-consuming mechanical repositioning operations while ensuring straightness tolerance is met
3Device complexity
If a function between the elastic portion and the plastic portion of the forming stroke is assumed to be constant or predictable, then the target stroke can be calculated in advance, but the function actually depends on many conditions such as residual stresses, strain hardening, and material fluctuations
Solution Approach 1:
The patent uses preliminary action to perform the first forming stroke as a test operation that reveals actual material behavior. This initial step allows the system to observe how the specific material responds to deformation, accounting for residual stresses, strain hardening, and material fluctuations without requiring complex predictive models
Solution Approach 2:
The patent implements feedback by measuring the actual deformation outcome of the first forming stroke and using this real data to calculate the second forming stroke. This approach replaces unreliable theoretical predictions with actual measured data, significantly improving prediction accuracy while keeping the calculation process relatively simple
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
This approach allows for precise determination of forming strokes, minimizing the risk of under or over-deformation, and significantly reduces processing time by iteratively refining the deformation process to meet straightness tolerances with high accuracy.
Implementation Method 1
determining a target plastic deformation at a forming position of the bar-shaped material
Implementation Method 2
Only after elastic deformation does plastic deformation take place and remain permanently
Implementation Method 3
plastically deformed with the straightening hammer until the workpiece achieves the required straightness
Implementation Method 4
The forming stroke of the straightening hammer must correspond to the elastic deformation plus the plastic deformation
Data Source
AI summary
The invention relates to a method for straightening non-straight bar-shaped material (1) by determining a target plastic deformation (s_soll) at a forming position (12) of the bar-shaped material (1), moving a straightening hammer (8) with integrated measuring probe (7) to the forming position (12), a first forming stroke (h_1) of the straightening hammer (8) is carried out, an actual plastic deformation (s_ist) caused by the first forming stroke (h_1) is determined by means of the integrated measuring probe (7), a second forming stroke (h_2) is determined from the actual plastic deformation (s_ist) caused by the first forming stroke (h_1) and the target plastic deformation (s_soll).