Drive apparatus and method for a press machine
10384412 ยท 2019-08-20
Assignee
Inventors
Cpc classification
B30B15/168
PERFORMING OPERATIONS; TRANSPORTING
B30B15/16
PERFORMING OPERATIONS; TRANSPORTING
B30B1/42
PERFORMING OPERATIONS; TRANSPORTING
B30B15/14
PERFORMING OPERATIONS; TRANSPORTING
B30B1/32
PERFORMING OPERATIONS; TRANSPORTING
International classification
B30B15/16
PERFORMING OPERATIONS; TRANSPORTING
B30B15/14
PERFORMING OPERATIONS; TRANSPORTING
B30B1/34
PERFORMING OPERATIONS; TRANSPORTING
B30B1/42
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A drive apparatus includes a movable member, at least one linear electrical actuator for generating a first force, and at least one linear hydraulic actuator for generating a second force. The at least one linear electrical actuator and the at least one linear hydraulic actuator are arranged such that the first force and the second force act in parallel on the movable member in order to result in a combined force.
Claims
1. A press comprising: a movable member; and drive apparatus for the movable member, the drive apparatus comprising at least one actuator coupled to the movable member for moving the movable member in reversible directions, and at least one energy storage device coupled to the movable member, wherein the at least one energy storage device has a force path characteristic, wherein the force path characteristic of the at least one energy storage device is such that the force exerted by the at least one energy storage device on the movable member changes its direction at a position of the movable member which is within the working range of the movable member, wherein the force path characteristic of the at least one energy storage device is adjustable such that the natural frequency of the drive apparatus is at or close to the movement frequency of the movable member, and wherein the at least one energy storage device comprises: at least one gas spring positioned relative to the movable member and the at least one actuator to store energy that can be released along a first direction along the linear axis of the at least one gas spring, and at least one gas spring positioned relative to the movable member and the at least one actuator to store energy that can be released along a second direction along the linear axis at least one gas spring, where the second direction is opposite to the first direction.
2. The press of claim 1, wherein the force path characteristic of the at least one energy storage device is such that the force exerted by the at least one energy storage device on the movable member provides a positioning of the movable member within an operational range of the movable member.
3. The press of claim 1, wherein the force path characteristic of the at least one gas spring is adjustable by adjusting a gas pressure within the at least one gas spring, by increasing the gas pressure utilizing a pressure gas source or by decreasing the gas pressure utilizing an outlet valve.
4. The press of one of claim 1, further comprising a control unit, wherein the control unit is configured to adjust the force path characteristic of the at least one energy storage device such that the natural frequency of the drive apparatus is at or close to the movement frequency of the movable member.
5. The press of claim 4, wherein the control unit determines a required force path characteristic of the at least one energy storage device for operating at or close to the natural frequency of the drive apparatus by calculating the required force path characteristic on basis of a mass of the moveable member and a desired operating frequency.
6. The press of claim 4, wherein the control unit determines a required force path characteristic of the at least one energy storage device for operating at or close to the natural frequency of the drive apparatus by using selected or predetermined values.
7. The press of claim 4, wherein the control unit determines a required force path characteristic of the at least one energy storage device for operating at or close to the natural frequency of the drive apparatus by adjusting the force path characteristic in dependence on the power consumption of the at least one actuator.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) For the present invention to be clearly understood and readily practiced, the present invention will be described in conjunction with the following figures, wherein like reference characters designate the same or similar elements, which figures are incorporated into and constitute a part of the specification.
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DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
(14) Referring to
(15) As shown in
(16) As stated above, the combination of the one or more linear electrical actuator 130 and the one or more linear hydraulic actuator 125 as shown in
(17) Each linear electrical actuator 130 is arranged in the direction of the main axis 120 and the output of the linear electrical actuator 130 is provided to a rigid post 135 that couples to (for example, attaches to) the movable member 115. The rigid post 135 is movable in both directions along the main axis 120. Each linear electrical actuator 130 is associated with an electrical control device 140, which is connected to the electronic control system 110 to receive a signal from the electronic control system 110. Additionally, the press machine 105 includes position detectors 145 associated with each linear electrical actuator 130 and being positioned to couple to a coupling region of the movable member 115. Each position detector 145 measures an absolute position of the movable member 115 at the coupling region.
(18) The position detector 145 can be any device that is able to detect or measure the absolution position of the movable member 115 at the coupling region and that provides that position to the electronic control system 110 to provide feedback to the electronic control system 110 for operating the linear electrical actuator 130 and the linear hydraulic actuator 125. Thus, the position detector 145 can be a linear encoder using any suitable technology such as, for example, optical, capacitive, magnetostrictive, magnetoresistive, or inductive.
(19) The linear hydraulic actuator 125 is arranged in the direction of the main axis 120 and includes a rod 150 that is the output of the linear hydraulic actuator 125 and that couples to (for example, attaches to) the movable member 115. The rod 150 is movable in both directions along the main axis 120. The linear hydraulic actuator 125 is hydraulically coupled to a hydraulic control member (for example, a valve) 155, the hydraulic control member is mechanically connected to a servo motor or to an electrical actuator 165 through a mechanical linkage system 170, and the electrical actuator 165 is connected to an electrical control device 172, which is connected to the electronic control system 110.
(20) The electronic control system 110 includes a processor 175 that controls operation of the press machine 105 based on program data (including an application program and an operating system) stored in a fixed memory. The control system 110 also includes a temporary memory 180 that can be read and written at any time, one or more output devices 185 such as a display, and one or more input devices 190 such as a mouse and keyboard. The control system 110 is configured to operate such that the linear hydraulic actuator 125 is controlled in accordance with a cyclic operation of the hydraulic control member 155, and such that each linear electric actuator 130 is controlled dependent on position signals in order to ensure a controlled cyclic actuation of the movable member 115.
(21) Referring also
(22) The press machine 105 includes a base plate 210 that is attached to the frame walls 200 and is used to provide support for, among other features, the linear hydraulic actuator 125, the hydraulic control member 155, the mechanical linkage system 170, and the electrical actuator 165. The base plate 210 also includes an opening through which the rod 150 can freely and linearly move along the main axis 120.
(23) The press machine 105 includes a bed 215 that is attached to the frame walls 200 and is used to support a bolster 220. The bolster 220 defines channels or openings 225 that receive the dies (not shown). Correspondingly, the movable member 115 includes a region 230 that defines channels 235 for receiving the punches (not shown). The bed 215 defines openings 240 sized to accommodate the posts 135, and each opening 240 is outfitted with roller bearings 245 to facilitate movement (for example, by reducing friction) of the posts 135 along the main axis 120.
(24) The linear electrical actuator 130 can be any linear actuator that produces a linear movement and whose primary motivating power is supplied by electricity. For example, in a most preferred embodiment, the linear electrical actuator 130 can be a direct drive linear motor 131 (
(25) In this preferred implementation wherein the linear electrical actuators are direct drive motors, the direct drive linear motors 131 are positioned along a side of the movable member 115 and an inside of the frame walls 200. The direct drive linear motors 131 include coil slides (stators) 250 that are fixed to the frame walls 200 and magnet plates 255 that are fixed to the respective posts 135.
(26) As discussed above, the position detector 145 measures an absolute position of the movable member 115 at the coupling region and provides that position to the electronic control system 110 to provide feedback to the electronic control system 110 for operating the linear electrical actuator 130 and the linear hydraulic actuator 125. The position detector 145 can be a linear encoder (for example, a sensor or a transducer) paired with a scale that encodes position. The sensor reads the scale in order to convert the encoded position into an analog or digital signal, which can then be decoded into a digital position. Motion can be determined by change in position over time.
(27) In less preferred embodiments, the linear electrical actuator 130 is a rotary electric motor 847 and a mechanism for converting rotary motion to linear motion. Such mechanisms could include, but are not limited to, lead screw 850 and nut 855 mechanisms 132 (
(28) The linear hydraulic actuator 125 can be any linear actuator that produces a linear movement and whose primary motivating power is supplied by hydraulic fluid. For example, in a most preferred embodiment, linear hydraulic actuator 125 is a piston and cylinder mechanism 126 (
(29) In a less preferred embodiment, the linear hydraulic actuator 125 is a rotary hydraulic motor 848 and a mechanism for converting rotary motion to linear motion. Such mechanisms can include, but are not limited to, lead screw 851 and nut 856 mechanisms 127 (
(30) The hydraulic control member 155 includes a rotatable member or shaft 515 that extends through the base plate 210 and is coupled to one end of the mechanical linkage system 170 and the electrical actuator 165 includes a shaft 520 that extends through the base plate 210 and that is coupled to another end of the mechanical linkage system 170 such that rotation of the shaft 520 causes rotation of the shaft 515. The mechanical linkage system 170 includes a wheel (or gear) 525 rigidly attached to the shaft 520, a wheel (or gear) 530 rigidly attached to the shaft 515, and a pulley or chain 535 that couples at one region to the wheel 525 and at another region to the wheel 530 to transmit rotational energy from the shaft 520 to the shaft 515.
(31) The hydraulic control member 155 is fluidly connected to an accumulator 540 (a high-pressure storage tank) for receiving high pressure hydraulic fluid and to an unpressurized tank 545 (shown in
(32) The drive apparatus 100 also includes devices within the enclosure of the press machine 105 that need not be directly coupled to the electronic control system 110. In particular, the drive apparatus 100 includes one or more energy storage devices 600 that are coupled to coupling points or regions of the movable member 115, and at least one passive force exerting device 605 (which also acts as an energy storage device) that is coupled to a coupling region of the movable member 115.
(33) The one or more energy storage devices 600 are any devices that can store energy supplied by the movement of the movable member 115 (due to the actuation of the linear hydraulic actuators 125 and the linear electrical actuators 130) such that the stored energy can be supplied to and used by the movable member 115 to adjust the motion of the movable member 115. The energy storage device 600 is a linear energy storage device fluidly decoupled from the linear hydraulic actuators 125. For example, the energy storage devices 600 can be gas springs that supply forces along the main axis 120. The energy storage device 600 can have an adjustable force path characteristic that imparts energy to the movable member 115 among the main axis 120. The force path characteristic is the relationship between a differential force needed to achieve a differential change of position at the coupling point. The force path characteristic of the energy storage device 600 is preferably such that the force exerted by the energy storage device 600 on the movable member 115 changes its direction at a position of the movable member 115 that is within the working range of the movable member 115 or provides a positioning of the movable member within an operational range of the movable member 115.
(34) As shown in
(35) The energy storage devices 600 provide a positioning of the movable member 115 within an operational range of the movable member 115. If the energy storage devices 600 are gas springs, then the force path characteristic of the gas springs can be adjusted by changing the gas pressure within the gas springs, in particular by increasing the gas pressure utilizing a pressure gas source or by decreasing the gas pressure utilizing an outlet valve. Alternatively, the energy storage devices 600 can be elastic springs and the force path characteristic of the spring can be adjusted by adjusting a position of an end of the spring that is opposed to the end at the coupling point, such as to increase or decrease the spring force on the movable member 115.
(36) The force path characteristics of the energy storage devices 600 can be adjusted by the control system 110 using input from a user. Moreover or alternatively, the force path characteristic of the energy storage devices 600 can be adjusted such that the natural frequency of the drive apparatus is at or close to the movement frequency of the movable member. Thus, the energy storage devices 600 are particularly useful when operating the drive apparatus 100 in a periodic, harmonic fashion (for example, sinusoidal and having a natural frequency). The control system 110 can adjust the natural frequency of the drive apparatus 100 by adjusting the force path characteristics of the energy storage devices 600 in dependence on a set operation frequency of the drive apparatus 100 such that the natural frequency is close to or identical with the operation frequency of the drive apparatus 100. With that, the energy consumption of the actuators can be significantly reduced. The control unit 110 is preferably configured to automatically adjust the force path characteristic of the at least one energy storage device such that the drive apparatus 100 operates at or close to the natural frequency of the drive apparatus 100. The preferred force path characteristic is characterized by the proportional relationship F=k*x, where F is force, k is a constant and x is the displacement of the energy storage device. The control unit 110 determines the required force path characteristic or the required spring constant of the at least one gas or elastic springs 600 for operating at or close to the natural frequency of the drive apparatus 100: by calculating the necessary force path characteristic or the necessary spring constant on basis of the moving masses and the desired operating frequency; by using selected or predetermined values; or by adjusting the force path characteristic in dependence on the power consumption of the at least one actuator. The latter possibility is the most preferred embodiment because a reduction of the power consumption is one goal of providing the energy storage device 600 and of the adjustment of its force path characteristic. In case of the first possibility, the relationship =(k/m) can be used to calculate the required force path characteristic of the energy storage device where is the natural frequency, m is the sum of the moved masses and k is the proportional spring constant of the force path characteristic, of the drive apparatus 100 or the energy storage device 600, respectively.
(37) The passive force exerting device 605 can be designed as a pressurized cylinder of fluid that provides a force to the rod 510 of the linear hydraulic actuator 125. For example, the device 605 can be a cylinder filled with a gas such as nitrogen gas. Preferably, the passive force exerting device 605 has a force path characteristic that does not or only insignificantly changes the force dependent on the position of the rod 510. This can be achieved by a comparatively large working volume of the cylinder, or by connecting the cylinder to an additional reservoir.
(38) The passive force exerting device 605 applies a force along the first linear direction to the movable member 115 through the rod 510 of the linear hydraulic actuator 125 primarily in a first direction. The passive force exerting device 605 does not require an external energy supply to provide the force. The passive force exerting device 605 primarily receives and stores energy while the movable member 115 is moving in a second direction. Moreover, the force applied to the movable member 115 by the passive force exerting device 605 is a force that adds to or subtracts from the force applied by the linear hydraulic actuator 125 and/or the linear electrical actuators 130. The passive force exerting device 605 is compressed by the actuation of the hydraulic actuator(s) 125 and/or the electric actuator(s) 130. Therefore, the actuation of these actuators in the second direction can be used in order to store energy in the passive force exerting device 605 so that the lifting actuation of the actuators can also be used in order to finally increase the pressing/punching force.
(39) In this way, the passive force exerting device 605, the energy storage device 600, the linear hydraulic actuator 125, and the linear electrical actuators 130 are all arranged in parallel with the main axis 120 of the movable member 115. Thus, each of these devices applies a force that is generally parallel with the main axis 120. The passive force 605 exerting device is fluidly decoupled from the hydraulic actuator 125.
(40) Referring also to
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(42) In a preferred embodiment, an actuation cycle of the drive apparatus 100 includes the steps of: (a) driving the at least one hydraulic actuator 125 and the at least one electric actuator 130 in the first direction, (b) driving the at least one hydraulic actuator 125 and the at least one electric actuator 130 in the second direction, and (c) holding the movable member 115 in a fixed position by positioning the hydraulic control member 155 in the third position, where the at least one electric actuator 130 is, at least during part of this operation step, not operated or not provided or only insignificantly provided with electric current. An advantage of this operation is that the at least one electric actuator 130 has a time interval during a cycle in which the electric actuator(s) 130 can cool down. The blocked hydraulic control member 155 blocks in its third position any movement of the hydraulic actuator 125 and thus the movable member 115 so that also the passive force exerting device 605, if present, can be held in a compressed state without the need of the additional force of the at least one electric actuator 130 (although this additional force can be used to compress the passive force exerting device 605).
(43) The rotation of shaft 515 can be controlled utilizing the electric actuator 165 (which is controlled by the electrical control device 172 and the electronic control system 110) as required by the specific application. The rotation of shaft 515 may operated with a constant frequency and/or a constant speed. The rotation of shaft 515 can be operated at rotational speeds that are dependent on the angle positions of the shaft 515 in order to control the timing of the positions of the shaft 515. In case of a rotation with constant speed, the rod 150 moves up and down close to a sinusoidal function. In addition, the position of the shaft 515 can be controlled by varying the rotational speed dependent on the angle position of the shaft or dependent on the time, respectively. During one cycle, the shaft 515 can also be stopped one or more times, for example, if the rod 150 should be blocked for a comparatively long time period during the cycle in its upper position. Further, if only a very quick downward and subsequent upward movement is required, the rotational speed between the positions shown in
(44) Due to the hydraulic control member 155, the hydraulic actuator 125 can be moved precisely with high speeds, where the hydraulic actuator 125 can provide high pressing/punching forces at the same time. As a result, the control of the force and path characteristics of the hydraulic actuator 125 is improved so that the interaction with the other components of the drive apparatus 100 (for as far as given) is also improved. As a result, a press machine 105 can be operated in a highly variable manner dependent on the requirements of the application.
(45) As already described, the drive apparatus 100 can be operated in various operation modes. In a first mode, only the electric actuators 130 can be used in combination with the energy storage devices 600 (with preferably adjustable force path characteristic). In order to reduce power consumption, the electrical actuators 130 can move the movable member 115, for example, in a sinusoidal manner (regarding path over time graph), where the force path characteristic of the energy storage devices 600 is adjusted to this sinusoidal movement such that the time period of the natural frequency corresponds to the time period of the sinusoidal movement of the electric actuators.
(46) In a second mode, the hydraulic actuator 125, and, if desired, the at least one electric actuator 130, can be used in combination with the passive force exerting device 605. This mode is advantageous in case of higher necessary punching or pressing forces. In this mode, power consumption is reduced by keeping the lifting actuation to a minimum so that the fluid supplied to the hydraulic actuator 125 can be reduced accordingly. As already mentioned, the lifting movement of the hydraulic actuator 125 can be used in order to compress the passive force exerting device 605 for storing additional energy. This mode is preferred in case of high necessary forces and in case of non-sinusoidal movements of the movable member 115. In the latter case, the graph regarding path over time could, for example, be a horizontal line interrupted by short downwardly directed peaks. Or, according to another example, the graph regarding path over time could be a partial sinusoidal graph with only the downwardly directed sinus curves, where the upwardly directed sinus curves are substituted by horizontal lines. As an unnecessary high lifting movement is avoided, also the speed of the drive apparatus 100 can be increased.
(47) Also mixed (third) modes are possible in which the electric and hydraulic actuators are used in combination with the energy storage devices 600 and the passive force exerting device 605, where the spring constant of the energy storage device(s) and the characteristic of the passive force exerting devices can be optimized in order to reduce power consumption (for example, by means of a least squares method).
(48) As a result, the drive apparatus 100 as described above can be used in various manners, depending on the needs of a particular application. The user can use the drive apparatus 100, for example, for a press, in the first mode if a high speed operation with low forces is required, or in the second mode, if higher forces with lower speeds are required.
(49) Without further analysis, the foregoing will so fully reveal the gist of the embodiments of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute characteristics of the generic or specific aspects of the embodiments of the present invention.
(50) It should be appreciated that the apparatus and method of the present invention may be configured and conducted as appropriate for any context at hand. The embodiments described above are to be considered in all respects only as illustrative and not restrictive. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.