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Model-based Design of Self-Correcting Strategy for a Punch Bending Machine

机译：基于模型的冲床弯曲机的自我校正策略设计

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The precise reproduction of geometrical form often constitutes a challenge in manufacturing of metal parts, The reasons for form deviation can be e.g. varying properties of the semi-finished product as well as wear of the punch-bending machine or the punch-bending tool themself. Usually the process parameters are manually adjusted on the introduction of new production scenario or after the deviation between the actual form of produced pieces and the designed form become clear. The choice of new process parameters is normally based on the experience of the machine operators. It leads to a time-consuming and expensive procedure right on the early stages of production scenarios as well as during the established production process. Furthermore, the trend of miniaturization of part sizes along with narrowing tolerances and increase in the strengths of materials drastically pushes up the requirements on the production process. Aiming at reduction of scrap rate and setup-time of production scenarios, a self-correcting control strategy has to be developed. The strategy is designed by modeling the bending process. In the first step the bending model has to be analyzed by varying of process variables (e.g. the strength or the geometrical properties of the material) influencing the process significantly. It is done by corresponding simulations. After that, the correlations between input and output variables were defined and different self-correcting control strategies were designed and tested. In order to identify and validate the simulation and to test the quality of the self-correcting control strategies, a special experimental tool, representing the most important bending operations, was built up at the University of Paderborn. The experimental tool is equipped with an additional measurement device and can be operated on a universal testing machine. Finally, the self-correcting control strategies were tested under real production conditions on the original tool in order to address further influences of the punch-bending machine on the deformation process. In this paper, recent investigations of a collaborative project of the University of Paderborn and two industrial partners will be presented. The paper includes the results of model analysis and the influence of various process variables. Besides that, the paper focuses on the development of self-correcting control strategy and a suitable measurement methods. The first implementation of the developed control strategy on the basis of real production facility is described.
机译：几何形式的精确繁殖通常在制造金属部件方面构成挑战，形成偏差的原因可以是例如。半成品的不同性能以及打孔机或打孔弯曲工具的磨损。通常，在引入新的生产方案或在生产件的实际形式之间的偏差后，手动调整过程参数，并且设计的形式变得清晰。新工艺参数的选择通常基于机器运营商的经验。它导致生产情景早期阶段的耗时和昂贵的程序以及在既定的生产过程中。此外，部分尺寸的小型化的趋势以及窄的公差和材料强度的增加急剧推动生产过程的要求。旨在减少废速率和生产过程的设置，必须开发自我纠正的控制策略。该策略是通过建模弯曲过程来设计的。在第一步中，必须通过改变过程变量（例如，材料的强度或几何特性）显着影响弯曲模型。它是通过相应的模拟完成的。之后，定义了输入和输出变量之间的相关性，并设计并测试了不同的自我校正控制策略。为了识别和验证模拟并测试自我纠正控制策略的质量，代表最重要的弯曲行动的特殊实验工具是在帕德博克大学建立的。实验工具配备有附加的测量装置，可以在通用测试机器上操作。最后，在原始工具上的实际生产条件下测试了自我校正控制策略，以解决冲床弯曲机对变形过程的进一步影响。在本文中，将介绍帕德博恩大学和两个工业伙伴大学合作项目的调查。本文包括模型分析结果和各种过程变量的影响。此外，本文侧重于自我纠正控制策略的发展和合适的测量方法。描述了基于实际生产设施的开发控制策略的第一次实施。

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