Method and system for monitoring peak compressive and tensile process severity levels of a press machine using acceleration data

• US 6,481,295 B1
• Filed: 10/18/2000
• Issued: 11/19/2002
• Est. Priority Date: 10/19/1999
• Status: Expired due to Term

• Current Assignee: The Minster Machine Company (Nidec Corporation)
• Original Assignee: The Minster Machine Company (Nidec Corporation)
• Inventors: Schoch, Daniel A.
• Primary Examiner(s): NOORI, MAX H
• Application Number:
  US09/691,381
• Time in Patent Office: 762 Days
• Field of Search: 737/96, 738/620.6, 737/88, 735/11, 734/88
• US Class Current: 73/862.06
• CPC Class Codes: B30B 15/0094 Press load monitoring means B30B15/281 takes precedence
• CPC Class Codes: B30B 15/28 Arrangements for preventing distortion of, or damage to, presses or parts thereof
• CPC Class Codes: G05B 23/0235 based on a comparison with predetermined threshold or range, e.g. "classical methods", carried out during normal operation; threshold adaptation or choice; when or how to compare with the threshold
• CPC Class Codes: G05B 23/0272 Presentation of monitored results, e.g. selection of status reports to be displayed; Filtering information to the user

Abstract

A system for monitoring the operation of a press machine employs a sensor to measure the peak acceleration levels of a slide assembly. The sensor measurement data represents peak load levels being developed within the press machine. A data means provides load level capacity data representing the maximum allowable compressive and tensile load levels for the press machine. The capacity data is provided in the form of plural press machine operating zones each representing a corresponding range of load values and having a respective rating factor which indicates the relationship of the particular operating zone to a respective one of the maximum allowable compressive/tensile load levels. A processor evaluates the peak load levels in relation to the operating zone data to determine which respective ones of the plural press machine operating zones encompass each respective one of the peak load levels. The operating condition of the press machine is determined in accordance with the peak operating load levels and the respective rating factors associated with the respective press machine operating zones which are determined by the processor to encompass the peak load levels.

Claims

1. An assembly for use in monitoring the operation of a press machine, comprising:

data means for providing load level capacity data associated with said press machine;

measurement means for providing a measure of the acceleration activity present within said press machine, wherein said acceleration activity measurement being representative of a load level measurement; and

evaluation means for comparing said load level measurement with said load level capacity data and for providing an indication of an operating condition of said press machine based upon said comparison.

2. The assembly as recited in claim 1, wherein said data means further comprises:

means for providing operating zone data defining a plurality of press machine operating zones each representing a corresponding range of load values.

3. The assembly as recited in claim 2, wherein said evaluation means further comprises:

processing means for evaluating said load level measurement in relation to said operating zone data to determine which ones of said plurality of press machine operating zones encompass said load level measurement.

4. The assembly as recited in claim 3, wherein said evaluation means further comprises:

means for providing each respective one of said press machine operating zones with a respective rating factor indicating the relationship of said respective one press machine operating zone to at least one of a threshold compressive load level and a threshold tensile load level; and

means for determining the operating condition of said press machine in accordance with the acceleration activity measurement provided by said measurement means and the respective rating factors associated with the respective press machine operating zones determined by said processing means to encompass the load level measurement represented by said acceleration activity measurement.

5. The assembly as recited in claim 2, wherein said measurement means further comprises:

peak detector means for generating at least one peak acceleration signal each representing a respective peak load level developed within said press machine.

6. The assembly as recited in claim 5, wherein said evaluation means further comprises:

processing means for evaluating the at least one peak load level generated by said peak detector means in relation to said operating zone data to determine which respective one of said plurality of press machine operating zones encompasses each respective one of the at least one peak load level.

7. The assembly as recited in claim 6, wherein said evaluation means further comprises:

means for determining the operating condition of said press machine in accordance with at least one of said at least one peak acceleration signal and the respective press machine operating zone determined by said processing means to encompass the respective peak load level represented by the at least one of said at least one peak acceleration signal.

8. The assembly as recited in claim 1, wherein said load level capacity data includes a representation of a maximum allowable compressive load level and/or a representation of a maximum allowable tensile load level.

9. The assembly as recited in claim 1, wherein the monitoring of said press machine operation by said assembly is performed dynamically over at least one press operating cycle.

10. The assembly as recited in claim 1, further comprises:

display means for displaying the indication of an operating condition of said press machine as provided by said evaluation means.

11. The assembly as recited in claim 1, wherein said measurement means and said evaluation means are arranged to form a portable instrument unit.

12. The assembly as recited in claim 1, wherein said measurement means further comprises:

an accelerometer.

13. The assembly as recited in claim 1, wherein said evaluation means further comprises:

analysis means, responsive to a plurality of acceleration values provided by said measurement means during a corresponding press cycle interval, for identifying ones of said plurality of acceleration values meeting a selectable signal characteristic criteria to thereby define a selected acceleration signal group, comparing the respective operating load level represented by each respective one of said selected acceleration signal group with said load level capacity data, and providing an indication of an operating condition of said press machine in accordance with said comparison performed by said analysis means.

14. The assembly as recited in claim 13, wherein the selectable signal characteristic criteria represents a peak acceleration condition.

15. The assembly as recited in claim 1, further comprises:

control means arranged to selectively activate at least one of said measurement means and said evaluation means only when the press machine designated for monitoring satisfies an authorization condition.

16. The assembly as recited in claim 15, wherein the authorization condition is satisfied when the press machine designated for monitoring corresponds to at least one of an authorized press machine, an authorized family of press machines, and a press machine from an authorized manufacturer.

17. The assembly as recited in claim 1, further comprises:

selection means responsive to a control signal for selectively activating said evaluation means in accordance with said control signal to thereby enable operation of said evaluation means during a selective one of press machine compression activity and press machine tensile activity.

18. The assembly as recited in claim 17, further comprises:

means, responsive to the acceleration activity measurement provided by said measurement means, for determining whether said acceleration measurement corresponds to a one of compression activity and tensile activity and for generating a signal based upon this determination to control said selection means.

19. The assembly as recited in claim 1, wherein said measurement means operates dynamically to generate a plurality of acceleration measurements.

20. The assembly as recited in claim 19, further comprises:

recordation means for recording the respective operating load level corresponding to each respective one of said plurality of acceleration measurements generated by said measurement means; and

retrieval means for controllably accessing and retrieving from said recordation means selectable ones of said recorded operating load levels corresponding to a selective one of press machine compression activity and press machine tensile activity and applying the selected ones of said recorded operating load levels to said evaluation means for comparison with said load level capacity data.

21. The assembly as recited in claim 1, further comprises:

annunciator means, responsive to the occurrence of an out-of-bounds operating load level condition as indicated by the load level comparison result generated by said evaluation means, for providing an indication of the occurrence of said out-of-bounds operating load level condition.

22. The assembly as recited in claim 1, further comprises:

timer means for selectively activating at least one of said measurement means and said evaluation means to enable respective operation thereof over a selectable time period.

23. The assembly as recited in claim 1, further comprises:

means for selectively controlling the operation of said measurement means to make a selectable number of acceleration measurements.

24. A system for use with a press machine, comprising:

data means for providing load level capacity data associated with said press machine;

a sensor assembly operatively arranged to dynamically measure the acceleration activity occurring within said press machine to thereby generate a plurality of acceleration signals representing a corresponding plurality of load level values; and

processor means, responsive to said plurality of acceleration signals generated by said sensor assembly, for determining an operating state of said press machine based at least in part upon a comparison between said load level capacity data and at least one of said plurality of load level values.

25. The system as recited in claim 24, wherein said processor means determines the operating state of said press machine by identifying ones of said plurality of acceleration signals each representing a respective peak acceleration condition to thereby define a peak acceleration signal group, comparing the corresponding load level value for each respective one of said peak acceleration signal group with said load level capacity data to thereby generate a peak level comparison result, and providing an indication of the operating state of said press machine in accordance with said peak level comparison result.

26. The system as recited in claim 25, wherein said data means further comprises:

means for defining a plurality of press machine operating zones each representing a corresponding range of load values;

wherein said processor means provides said indication of the operating state of said press machine in accordance with a determination of which respective one of said plurality of press machine operating zones encompasses each respective one of said peak acceleration signal group.

27. The system as recited in claim 26, wherein said load level capacity data includes a representation of a maximum allowable compressive load level and/or a representation of a maximum allowable tensile load level.

28. A system for use in monitoring the operation of a press machine, comprising:

data means for providing load level capacity data associated with said press machine;

measurement means for providing a measure of the peak load levels developed within said press machine; and

evaluation means for determining an operating state of said press machine based at least in part upon a comparison between said peak load levels measurement provided by said measurement means and said load level capacity data.

29. The system as recited in claim 28, wherein said measurement means comprises:

an accelerometer.

30. The system as recited in claim 28, wherein said data means further comprises:

means for defining a plurality of press machine operating zones each representing a corresponding range of load values;

wherein said evaluation means determines the operating state of said press machine in accordance with a determination of which respective one of said plurality of press machine operating zones encompasses each respective one of the measured peak load levels provided by said measurement means.

31. The system as recited in claim 30, wherein said measurement means further comprises:

signal means for generating at least one peak acceleration signal each representing a respective peak load level within said press machine.

32. The system as recited in claim 31, wherein said plurality of press machine operating zones being defined in relation to at least one of a maximum allowable compressive load level and a maximum allowable tensile load level.

33. A method of monitoring the operation of a press machine, comprising the steps of:

providing a measure of the load level being developed within said press machine;

providing capacity data indicating load level capacity values for said press machine; and

evaluating the operation of said press machine by comparing said load level measurement with said capacity data.

34. The method as recited in claim 33, wherein the step of providing said load level measurement further comprises the step of:

generating a plurality of acceleration signals representative of the acceleration activity occurring within said press machine.

35. The method as recited in claim 34, wherein said step of providing capacity data further comprises the step of:

defining a plurality of press machine operating zones each representing a corresponding range of load values.

36. The method as recited in claim 35, wherein said evaluation step further comprises the steps of:

identifying which ones of said generated plurality of acceleration signals represent the occurrence of a respective peak acceleration condition to thereby define a peak acceleration signal group;

determining which respective one of said plurality of press machine operating zones encompasses each respective one of said peak acceleration signal group; and

determining an operating state for said press machine in accordance with the respective press machine operating zone determined to encompass each respective one of said peak acceleration signal group.

37. The method as recited in claim 36, wherein said plurality of press machine operating zones being defined in relation to at least one of a maximum allowable compressive load level and a maximum allowable tensile load level.

38. A method of monitoring the operation of a press machine, comprising the steps of:

providing a measure of the peak load levels developed within said press machine;

providing capacity data indicating load level capacity values for said press machine; and

evaluating the operation of said press machine by comparing said peak load levels measurement with said capacity data.

39. The method as recited in claim 38, wherein the step of providing a measure of the peak load levels further comprises the step of:

generating at least one peak acceleration signal each representing a respective peak load level within said press machine.

40. The method as recited in claim 39, wherein the step of providing capacity data further comprises the step of:

defining a plurality of press machine operating zones each representing a corresponding range of load values.

41. The method as recited in claim 40, wherein said evaluation step further comprises the steps of:

determining which respective one of said plurality of press machine operating zones encompasses each respective one of said at least one peak acceleration signal; and

determining an operating state for said press machine in accordance with the respective press machine operating zone determined to encompass each respective one of said at least one peak acceleration signal.

42. The method as recited in claim 41, wherein said plurality of press machine operating zones being defined in relation to at least one of a maximum allowable compressive load level and a maximum allowable tensile load level.