Linear driven hybrid actuator for the production of complex workpieces

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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.