Tool Exchange Alignment Control for Bending System Stockers
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Solution Overview
Problem
The existing bending systems face challenges in accurately aligning tools during the tool exchange process, particularly when the stocker is moved to the exchange position, leading to misalignment issues that disrupt the automatic tool exchange operation.
Innovation Solution
The system employs a control device that uses servo motors and tool exchange units to detect and correct tool misalignment by aligning the tool retention members with the tool engagement holes, ensuring proper positioning and alignment of tools in the stocker and tool holders.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the stocker moving mechanism performs horizontal reversal operation to move the stocker to the exchange position, then the tool exchange operation can be performed, but tool misalignment occurs in the stocker
Solution Approach 1:
The pressing member presses the tool in the left-right direction before the stocker is positioned at the exchange position, preliminarily correcting any misalignment that may have occurred during the moving operation. This preliminary action ensures the tool is properly aligned before the exchange operation begins.
Solution Approach 2:
The detection member detects the position of the tool in the stocker and provides feedback to the control device, which then controls the pressing member to apply corrective force. This closed-loop feedback system continuously monitors and corrects tool alignment during the stocker moving operation.
2Manufacturing precision
If the tool is pressed by a pressing member such as a ball plunger in the stocker, then misalignment is attempted to be prevented, but stable prevention of misalignment cannot be achieved
Solution Approach 1:
The pressing member acts as an intermediary mechanism between the detection member and the tool. It translates the detection signal into physical corrective force, mediating the alignment correction process more effectively than direct pressing alone.
Solution Approach 2:
The system replaces simple mechanical pressing with a controlled actuating mechanism that can precisely adjust the pressing force and position based on detection feedback, substituting passive mechanical action with active controlled action.
3Power
If the lower table is deflected by pressurizing force at the time of bending, then the bending operation can be performed, but outward force is applied to the tool causing misalignment
Solution Approach 1:
The pressing member applies a preliminary counteracting force to the tool in the left-right direction before the bending operation causes deflection. This preliminary anti-action prevents the tool from shifting due to the outward force generated during bending.
Solution Approach 2:
The system provides beforehand cushioning by positioning the pressing member to support the tool against the outward force that will be generated during bending, preventing misalignment before it occurs.
4Productivity
If the number of times of unclamping by the tool holder increases, then the tool holder can serve more bending operations, but misalignment of the tool occurs more frequently
Solution Approach 1:
The detection member continuously monitors tool position and the pressing member continuously corrects alignment throughout the entire service life of the tool in the holder, maintaining alignment precision across all bending operations rather than only during initial installation.
Data Source
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AI summary
In a case where a vacant space ES exists on only one side in a holder area 66a of a stocker 66 positioned at an exchange position, a first upper tool exchange unit 96 is first moved in the left-right direction, and located in the vicinity of the vacant space ES. Next, the first upper tool exchange unit 96 is moved forward and thereafter moved to the left, so that a tool retention member 104 of the first upper tool exchange unit 96 is brought into contact with one side surface of a tool 12. Then, under the contact state, the first upper tool exchange unit 96 is moved to the right until the other side surface of the tool 12 abuts on a stopper 72.