Variable Speed Press Control for Robot Synchronization
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Solution Overview
Problem
Conventional synchronization methods for mechanical presses in manufacturing processes are inefficient due to their reliance on flywheel-driven systems, leading to slower acceleration and deceleration, which increases production cycle times and reduces productivity when synchronized with robots.
Innovation Solution
Implementing a method to control the speed of mechanical presses by decelerating before the unloading stage and accelerating during the loading stage, allowing for adaptive synchronization with robots based on estimated time points, enabling optimal cycle times and energy management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If conventional flywheel-driven synchronization methods are used, then the press can maintain stable operation, but the acceleration and deceleration speeds are slow, increasing production cycle times
Solution Approach 1:
The patent applies dynamics by making the press speed variable rather than constant. The control system dynamically adjusts the press speed during the cycle, accelerating faster during loading stages and decelerating smoothly before unloading stages, allowing the press to adapt its speed profile to match robot operations and minimize idle time
Solution Approach 2:
The patent changes the speed parameter of the press from a fixed value to a variable parameter that can be adjusted in real-time. By modifying the speed profile based on the synchronization state with the robot and the current stage of the press cycle, the system achieves faster acceleration and deceleration while maintaining stable operation
2Productivity
If the press speed is increased to reduce cycle time, then productivity improves, but the synchronization with loader/unloader robots becomes difficult, risking collisions
Solution Approach 1:
The patent implements feedback control by continuously monitoring the actual press speed and position, comparing them with the desired speed profile, and adjusting the motor control signals accordingly. This closed-loop control ensures that the press maintains accurate synchronization with the robot while operating at higher speeds, preventing collisions and ensuring reliable operation
Solution Approach 2:
The patent applies preliminary action by predicting future synchronization points and pre-adjusting the press speed profile accordingly. The control system calculates anticipated synchronization requirements based on robot cycle times and pre-modifies the press acceleration and deceleration phases to ensure timely alignment, rather than reacting to synchronization errors after they occur
Data Source
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AI summary
A method for synchronising a first machine of a manufacturing process section arranged to carry out a production cycle comprising a working part and a non-working part, which said first machine is operated in conjunction with at least one second machine. The first machine carries out a process during the working part of the cycle on a workpiece which is loaded into and/or unloaded out of said first machine by said at least one second machine during the non-working part of each process cycle. The first machine is preferably a mechanical press and the second machine is preferably an industrial robot arranged to carry out a loader and/or unloader function. A system for carrying out the method and a computer program are also described.