Linear driven hybrid actuator for the production of complex workpieces

在小零件的生产中(例如，紧固件、保险丝帽、灯座、套筒形状的零件)使用机械路径联动压力机进行大量的切割、拉拔、压花或弯曲加工。在这种压力机中，冲头的路径-时间曲线在结构上是固定的。因此，对于需要工艺优化的冲头运动学的成形工艺，不能保证高质量生产的最佳成形条件。基于直线电机和磁致动器的组合，项目第一阶段研究的压力机混合驱动概念实现了各种控制方法，每个过程的控制变量具有可变的优先顺序。通过所提出的项目，将通过模拟和实验研究所描述的混合式压力机驱动的级进模中多个过程的相互作用。假设通过采用适当的控制技术的混合式压力机驱动，级进模中的高质量切割-拉伸-弯曲-冲压零件的生产可以实现质的飞跃，具有比传统冲压机更高的工艺稳定性和相同或更高的产出率。目前，对单个工艺的扰动补偿是通过过程依赖的控制来实现的，例如压花时的力控制或拉深时的路径控制。在目前所需的级进模操作中，从驱动的角度来看，几个成形过程是重叠的，这导致在控制方法的选择上目标冲突。例如，施加预定的压纹力与要求最快的剪切速率或在拉深过程中指定路径-时间过程是相冲突的。对于混合新闻运动的相关业务情景，探索这一目标冲突是必不可少的。

In the production of small parts (eg. fasteners, fuse caps, lamp sockets, sleeve-shaped parts) using cutting, drawing, embossing or bending processes in large quantities with high output rates mechanical path-linked presses are used. In such presses the path-time curve of the ram is structurally fix. As a result, optimal forming conditions for high-quality production can not be guaranteed for forming processes requiring process-optimized ram kinematics. Based on a combination of linear motors and magnetic actuators, the hybrid drive concept for presses which was researched during the first phase of the project, enables various control approaches with variable prioritized controlled variables for individual processes. By means of the proposed project, the interactions of several processes in progressive dies with the described hybrid press drive will be investigated simulatively and experimentally.The hypothesis is that by means of the hybrid press drive using suitable control technology approaches, a qualitative quantum leap in the production of high-quality cutting-drawing-bending-stamping components in progressive dies with higher process stability and the same or higher output rate can be achieved than with conventional stamping machines.The compensation of the disturbances is currently realized for individual processes by means of a process-dependent control, e.g. force-controlled during embossing or path-controlled when drawing. In the now desired operation of progressive dies, several forming processes are superimposed from the perspective of the drive, which leads to a conflict of objectives in the choice of the control approach. For example the application of a predetermined embossing force is in conflict with the desire for the fastest possible shear rate or the specification of a path-time course in deep drawing. For relevant operating scenarios for the hybrid press drive, the exploration of this target conflict is essential.