Linear driven hybrid actuator for the production of complex workpieces

在生产小零件时(如：紧固件，保险丝盖，灯座，套筒形零件)采用切割，拉伸，压花或弯曲工艺大量高产量的机械路径链接压力机使用。在这种压力机中，滑枕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压件运动学的成形过程，无法保证高质量生产的最佳成形条件。在项目第一阶段研究的压力机混合驱动概念基于直线电机和磁性执行器的组合，实现了针对单个过程的各种控制方法，具有可变优先级控制变量。通过所提出的项目，将模拟和实验地研究级进模具中几个过程与所描述的混合压力机驱动的相互作用。假设通过采用合适的控制技术方法的混合压力机驱动，可以在级进模中生产高质量的切割-拉伸-弯曲-冲压部件，具有更高的工艺稳定性和与传统冲压机床相同或更高的输出速率。干扰的补偿目前是通过与过程相关的控制来实现的，例如压纹时的力控制或拉伸时的路径控制。在现在期望的级进模操作中，从驱动的角度来看，几个成形过程是叠加的，这导致了控制方法选择的目标冲突。例如，预定压印力的应用与在深拉深中尽可能快的剪切速率或路径时间过程的规范相冲突。对于混合压力机驱动的相关操作场景，探索这种目标冲突是必要的。

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.