US 11,701,700 B2
Variable pulsating, gap control, auto-learning press cushion device
Ethan McLaughlin, Bristol, CT (US); Richard Miller, Akron, OH (US); Steven Reilly, Westlake, OH (US); Michael Culbertson, Cuyahoga Falls, OH (US); and Russ Sasak, Bristol, CT (US)
Assigned to BARNES GROUP INC., Bristol, CT (US)
Filed by Barnes Group Inc., Bristol, CT (US)
Filed on Aug. 24, 2021, as Appl. No. 17/410,120.
Application 17/410,120 is a continuation of application No. 15/783,078, filed on Oct. 13, 2017, granted, now 11,110,506.
Claims priority of provisional application 62/409,639, filed on Oct. 18, 2016.
Prior Publication US 2022/0008979 A1, Jan. 13, 2022
This patent is subject to a terminal disclaimer.
Int. Cl. B21D 24/14 (2006.01); B21D 24/02 (2006.01)
CPC B21D 24/14 (2013.01) [B21D 24/02 (2013.01)] 21 Claims
OG exemplary drawing
 
1. A die press device for a press machine for forming a blank comprising:
an upper press assembly; said upper press assembly including a press slide and an upper die connected to said press slide;
a cushion platform; said cushion platform including a binder; a top surface of said binder configured to support the blank;
at least one hydraulic cylinder supporting at least a portion of said cushion platform; said cushion platform configured to move in response to a force applied thereto by said upper press assembly;
a control valve configured to permit flow, restrict flow, or combinations thereof of hydraulic fluid from a chamber of said at least one hydraulic cylinder; and;
a controller; said controller communicating with a) an upper press position indicator that indicates a positioned of one or more components of said upper press assembly, and b) a cushion platform position indicator that indicates a positioned of one or more components of said cushion platform; said controller configured to maintain a minimum pressure in said chamber of said at least one hydraulic cylinder;
wherein said controller is operative to vary a value of said minimum pressure during a working stroke of said press machine;
wherein said controller is configured to a) determine a thickness of the blank upon detection of contact of said upper press assembly with the blank, b) calculate whether the thickness of the blank is within a thickness tolerance of a preset thickness value, and c) cause increased pressure to be applied by said least one hydraulic cylinder supporting at least a portion of said cushion platform when the thickness of the blank is not within the thickness tolerance, and,
wherein said controller is configured to a) monitor conditions of said die press device during forming the blank using a first force profile; said monitored conditions including at least one of a position of said cushion platform of or a pressure applied by said at least one hydraulic cylinder; b) analyze said monitored conditions to detect occurrence of a defect in the formed blank selected from the group consisting of wrinkling of the formed blank and tearing of the formed blank; and c) alter at least one parameter of said first force profile to create a second force profile when said defect is detected by said controller to reduce recurrence of said defect when processing a subsequent blank by using said second force profile.
 
15. A method of controlling a press cushion device of a press, wherein said method comprises:
providing a die press device for a press machine comprising:
an upper press assembly; said upper press assembly including a press slide and an upper die connected to said press slide;
a cushion platform, said cushion platform including a binder; a top surface of said binder configured to support a blank;
at least one hydraulic cylinder supporting at least a portion of said cushion platform said cushion platform configured to move in response to a force applied thereto by said upper press assembly;
a control valve configured to permit flow, restrict flow, or combinations thereof of hydraulic fluid from a chamber of said at least one hydraulic cylinder; and;
a controller said controller communicating with a) an upper press position indicator that indicates a positioned of one or more components of said upper press assembly, and b) a cushion platform position indicator that indicates a positioned of one or more components of said cushion platform; said controller configured to maintain a minimum pressure in said chamber of said at least one hydraulic cylinder;
determining a thickness of said blank;
causing said controller to increase pressure to be applied by said least one hydraulic cylinder supporting at least a portion of said cushion platform when said determined thickness is not within a thickness tolerance;
forming a first part from said blank using said press under a first preset force profile;
monitoring conditions of said press during said forming of said first part, said monitored conditions including one or more of a) a position of said upper press assembly, b) a portion of said cushion platform, c) a pressure applied to said cushion platform, and d) a position, pressure, or velocity of said cushion platform;
comparing said monitored conditions of said upper press assembly with a) position of said cushion platform, b) pressure of said cushion platform, and c) position of said upper press assembly;
analyzing said monitored conditions to detect a defect in said first part, said analyzing said monitored conditions includes i) comparing position data of said upper press assembly to position data of said cushion platform to detect formation of a wrinkle in said part, ii) detecting a pressure relief spike corresponding to a tear in said part, and iii) detecting a velocity change in said cushion platform indicative of a tear in said part;
altering at least one parameter of said first preset force profile when a defect in said first part is detected so as to thereafter form a second force profile, said second force profile created to reduce recurrence of a defect in a second part; and
forming said second part using said press under said second force profile.