Continuous duty press monitoring system

Abstract

A continuous duty press monitoring system includes a linear variable displacement transducer mounted to a press frame as to acquire data related to stresses and strains in the press housing due to completion of a press operation. First and second oppose, spaced apart ends of a rod member are secured to the press housing or frame. The first send is secured to so as to cause axial movement of the rod in accordance with the frame movement at that point. The second portion is secured to the housing so as to allow the second end to be slidable in relation thereto. A linear variable displacement transducer is secured at the slidably affixed end of the rod. A magnetic flux generated by application of current to a coil of the transducer is affected by relative positioning of the rod thereto. Press operation thereby provides an indication, due to stresses or strains resultant on the press housing, as to the characteristics of a particular press operation. Flux variations provide an analog signal representative of these press characteristics. This analog signal is communicated to a continuous plotter, a digitized version of which is further communicated to a microprocessor controller. An alarm is advantageously generated when preselected characteristics have been exceeded by press operation.

Having thus described the invention, it is now claimed: 
     
       1. A press operation data acquisition apparatus comprising: a linear variable displacement transducer including a coil portion movably disposed relative to a core portion such that magnetic flux generated by current impressed on the coil portion is influenced by a position of the core portion relative thereto;   securing means adapted for securing the core portion to a first portion of a housing of an associated press and the coil portion to spaced apart portions of the housing of the associated press such that compression and expansion of the housing will influence a relative position of the core portion to the coil portion;   means for providing an electric current to the coil portion;   means continuously sensing the magnetic flux induced by operation of the associated press by monitoring of current in the coil portion;   position signal generating means for periodically generating a position signal representative of a relative position of the coil portion to the core portion in accordance with sensed magnetic flux; and   calibrating means adapted for automatically calibrating the position signal to a base level prior to completing a press cycle of the associated press;   means for generating a press deflection signal in accordance with the position signal.   
     
     
       2. The press operation data acquisition device of claim 1 further comprising means for generating a display signal in accordance with the press deflection signal. 
     
     
       3. The press operation data acquisition device of claim 2 further comprising means for recording the press deflection signal. 
     
     
       4. The press operation data acquisition device of claim 3 wherein the means for recording the press deflection signal is comprised of at least one of a plotter, a printer and a data storage unit. 
     
     
       5. The press operation data acquisition device of claim 1 wherein the position signal generating means includes: means for acquiring an analog signal representative of sense magnetic flux;   means for digitizing the analog signal; and   means for filtering the digitized analog signal to form the position signal as digitized position signal.   
     
     
       6. The press operation data acquisition device of claim 5 further comprising: comparator means for comparing the digitized analog signal to a comparison threshold value; and   means for generating an alarm signal when the digitized analog signal exceeds the comparison threshold value.   
     
     
       7. The press operation data acquisition device of claim 6 further comprising: means for acquiring data representative of a selected threshold value;   means for communicating the selected threshold value to the comparator means as the comparison threshold value.   
     
     
       8. The press operation data acquisition device of claim 7 further comprising means adapted for disabling an associated press in accordance with the alarm signal. 
     
     
       9. The press operation data acquisition device of claim 7 further comprising a container means for monitoring a minimum output from the monitored press during unloading thereof. 
     
     
       10. A press operation monitoring method comprising the steps of: activating a press to perform a stamping operation;   monitoring deformation of a frame of the press relative to opposed first and second, spaced apart ends of a rod member, the first spaced apart end being mounted to the frame at a first mounting point so as to allow axial displacement of the rod corresponding to frame movement at the first mounting point, and the second spaced apart end being mounted to the frame at a second mounting point such that the rod axis is slidable relative to the second mounting point;   generating, via a linear variable displacement transducer secured to the second spaced apart end, a press deflection signal representative of the deformation induced by operation of the press;   automatically calibrating the press deflection signal to a base level prior to the step of activating; and   generating a display signal in accordance with the press deflection signal.   
     
     
       11. The method of claim 10 further comprising the step of generating a tangible, historic record of the frame deformation in accordance with the press deflection signal. 
     
     
       12. The method of claim 11 further comprising the steps of: comparing the press deflection signal to a comparison threshold value; and   selectively generating an alarm signal in accordance with a result of the step of comparing.   
     
     
       13. The method of claim 12 further comprising the steps of: digitizing the press deflection signal to form a digitized deflection signal;   filtering the digitized deflection signal to form a filtered digitized analog signal; and wherein   the step of comparing includes the step of comparing the filtered digitized analog signal to the comparison threshold value formed as a digitized value.   
     
     
       14. A press operation data acquisition device comprising: securing means adapted for securing a frame of the press relative to opposed first and second, spaced apart ends of a rod member, the first spaced apart end being mounted to the frame at a first mounting point so as to allow axial displacement of the rod corresponding to frame movement at the first mounting point, and the second spaced apart end being mounted to the frame at a second mounting point such that the rod axis is slidable relative to the second mounting point;   a linear variable displacement transducer including a coil portion secured to the frame at the second mounting, and   a core portion secured to the rod at the second spaced part end such that a magnetic flux generated by application of current to the coil portion is affected by a relative position of the core portion thereto;   means for providing an electric current to the coil portion;   sensing means continuously sensing the magnetic flux during operation of the associated press by monitoring of current in the coil portion;   means for acquiring an analog flux level signal representative of sensed magnetic flux from the sensing means;   digitizing means for digitizing the flux level signal to form a digitized flux level signal;   filter means for filtering the digitized flux level signal to form a position signal;   calibrating means adapted for automatically calibrating the position signal to a base level prior to completing a press cycle of the associated press; and   means for calculating a press deflection signal representative of a relative position of the coil portion to the core portion in accordance with the position signal.   
     
     
       15. The press operation data acquisition device of claim 14 further comprising means for generating an output signal representative of the press deflection signal. 
     
     
       16. The press operation data acquisition device of claim 15 further comprising: means for storing a digital threshold value representative of at least one of an upper threshold level and a lower threshold level;   comparator means for comparing the press deflection signal to the digital threshold value; and   means for generating a comparison signal in accordance with a comparison in the comparator means.   
     
     
       17. The press operation data acquisition device of claim 16 further comprising means for selectively generating an alarm signal when the comparison signal indicates that the press deflection signal surpasses the threshold level. 
     
     
       18. The press operation data acquisition device of claim 17 further comprising archiving means for archiving the output signal. 
     
     
       19. The press operation data acquisition device of claim 15 wherein the archiving means includes a plotter. 
     
     
       20. The press operation data acquisition device of claim 19 wherein the archiving means includes a non-volatile digital memory. .Iadd. 
     
     
       21.  A data acquisition apparatus for a metal forming machine, comprising: a linear variable displacement transducer including a coil portion movably disposed relative to a core portion such that magnetic flux generated by current impressed on the coil portion is influenced by a position of the core portion relative thereto;   securing means adapted for securing the core portion to a first portion of a housing of an associated metal forming machine and the coil portion to spaced apart portions of the housing of the associated metal forming machine such that compression and expansion of the housing will influence a relative position of the core portion to the coil portion;   means for providing an electric current to the coil portion;   means continuously sensing the magnetic flux induced by operation of the associated metal forming machine by monitoring of current in the coil portion;   position signal generating means for periodically generating a position signal representative of a relative position of the coil portion to the core portion in accordance with sensed magnetic flux; and   calibrating means adapted for automatically calibrating the position signal to a base level prior to completing a cycle of the associated metal forming machine;   means for generating a deflection signal in accordance with the position signal. .Iaddend..Iadd.   
     
     
       22.  The data acquisition device of claim 21 further comprising means for generating a display signal in accordance with the deflection signal. .Iaddend..Iadd.23. The data acquisition device of claim 22 further comprising means for recording the deflection signal. .Iaddend..Iadd.24. The data acquisition device of claim 23 wherein the means for recording the deflection signal is comprised of at least one of a plotter, a printer and a data storage unit. .Iaddend..Iadd.25. The data acquisition device of claim 21 wherein the position signal generating means includes: means for acquiring an analog signal representative of sensed magnetic flux;   means for digitizing the analog signal; and   means for filtering the digitized analog signal to form the position signal as digitized position signal. .Iaddend..Iadd.26. The data acquisition device of claim 25 further comprising:   comparator means for comparing the digitized analog signal to a comparison threshold value; and   means for generating an alarm signal when the digitized analog signal exceeds the comparison threshold value. .Iaddend..Iadd.27. The data acquisition device of claim 26 further comprising:   means for acquiring data representative of a selected threshold value;   means for communicating the selected threshold value to the comparator   
     
     
        means as the comparison threshold value. .Iaddend..Iadd.28.  The data acquisition device of claim 27 further comprising means adapted for disabling an associated metal forming machine in accordance with the alarm signal. .Iaddend..Iadd.29. The data acquisition device of claim 27 further comprising a container means for monitoring a minimum output from the monitored metal forming machine during unloading thereof. .Iaddend..Iadd.30. A monitoring method for a metal forming machine comprising the steps of: activating a metal forming machine to perform a metal forming operation;   monitoring deformation of a frame of the metal forming machine relative to opposed first and second spaced apart ends of a rod member, the first spaced apart end being mounted to the frame at a first mounting point so as to allow axial displacement of the rod corresponding to frame movement at the first mounting point, and the second spaced apart end being mounted to the frame at a second mounting point such that the rod axis is slidable relative to the second mounting point;   generating, via a linear variable displacement transducer secured to the second spaced apart end, a deflection signal representative of the deformation induced by operation of the metal forming machine;   automatically calibrating the deflection signal to a base level prior to the step of activating; and   generating a display sign in accordance with the deflection signal.   
     
     
        .Iaddend..Iadd.31.  The method of claim 30 further comprising the step of generating a tangible, historic record of the frame deformation in accordance with the deflection signal. .Iaddend..Iadd.32. The method of claim 31 further comprising the steps of: comparing the deflection signal to a comparison threshold value; and   selectively generating an alarm signal in accordance with a result of the step of comparing. .Iaddend..Iadd.33. The method of claim 32 further comprising the steps of:   digitizing the deflection signal to form a digitized deflection signal;   filtering the digitized deflection signal to form a filtered digitized analog signal; and wherein   the step of comparing includes the step of comparing the filtered digitized analog signal to the comparison threshold value formed as a digitized value. .Iaddend..Iadd.34. A data acquisition device for a metal forming machine comprising:   securing means adapted for securing a frame of the metal forming machine relative to opposed first and second, spaced apart ends of a rod member, the first spaced apart end being mounted to the frame at a first mounting point so as to allow axial displacement of the rod corresponding to frame movement at the first mounting point, and the second spaced apart end being mounted to the frame at a second mounting point such that the rod axis is slidable relative to the second mounting point;   a linear variable displacement transducer including a coil portion secured to the frame at the second mounting, and   a core portion secured to the rod at the second spaced part end such that a magnetic flux generated by application of current to the coil portion is affected by a relative position of the core portion thereto;     means for providing an electric current to the coil portion;   sensing means continuously sensing the magnetic flux during operation of the associated metal forming machine by monitoring of current in the coil portion;   means for acquiring an analog flux level signal representative of sensed magnetic flux from the sensing means;   digitizing means for digitizing the flux level signal to form a digitized flux level signal;   filter means for filtering the digitized flux level signal to form a position signal;   calibrating means adapted for automatically calibrating the position signal to a base level prior to completing a cycle of the associated metal forming machine; and   means for calculating a deflection signal representative of a relative position of the coil position of the coil portion to the core portion in   
     
     
        accordance with the position signal. .Iaddend..Iadd.35.  The data acquisition device of claim 34 further comprising means for generating an output signal representative of the deflection signal. .Iaddend..Iadd.36. The data acquisition device of claim 35 further comprising: means for storing a digital threshold value representative of at least one of an upper threshold level and a lower threshold level;   comparator means for comparing the deflection signal to the digital threshold value; and   means for generating a comparison signal in accordance with a comparison in the comparator means. .Iaddend..Iadd.37. The data acquisition device of claim 36 further comprising means for selectively generating an alarm signal when the comparison signal indicates that the deflection signal surpasses the threshold level. .Iaddend..Iadd.38. The data acquisition device of claim 37 further comprising archiving means for archiving the output signal. .Iaddend..Iadd.39. The data acquisition device of claim 35 wherein the archiving means includes a plotter. .Iaddend..Iadd.40. The data acquisition device of claim 39 wherein the archiving means includes a non-volatile digital memory. .Iaddend.