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Design Innovation Paper

Design of Nonoverconstrained Energy-Efficient Multi-Axis Servo Presses for Deep-Drawing Applications1

[+] Author and Article Information
Francesco Meoni

Department of Industrial Engineering,
University of Bologna,
Bologna 40136, Italy
e-mail: francesco.meoni2@unibo.it

Marco Carricato

Department of Industrial Engineering,
University of Bologna,
Bologna 40136, Italy
e-mail: marco.carricato@unibo.it

Contributed by the Design Innovation and Devices of ASME for publication in the JOURNAL OF MECHANICAL DESIGN. Manuscript received February 17, 2015; final manuscript received March 14, 2016; published online April 20, 2016. Assoc. Editor: Ettore Pennestri.

J. Mech. Des 138(6), 065001 (Apr 20, 2016) (9 pages) Paper No: MD-15-1144; doi: 10.1115/1.4033085 History: Received February 17, 2015; Revised March 14, 2016

Servo-actuated presses may provide maximum pressing force at any ram position in the same manner that hydraulic presses do, while offering several benefits in terms of precision, energy-conversion efficiency, and simplicity, due to their lack of hydraulic circuitry and oil. Several press builders have developed servo-actuated presses; however, issues relating to overconstrained multi-axis architecture have been disregarded. This study proposes an innovative method to avoid overconstrained architectures in multi-axis presses, by implementing a family of modular parallel mechanisms that connect multiple servo-axes to the press ram. Parallel mechanisms, which can be applied in several fields of robotics and industrial automation, exhibit important benefits for the application at hand, including high-load capacity, stiffness, and compactness. A biaxial industrial servo press prototype with a nonoverconstrained and modular architecture was built and presented as a proof of concept. Each axis comprises a servomotor, a gearbox reducer, and a ball-screw transmission. It is shown that such a press may be constructed from commercially available components, achieving high energy efficiency and high press force with relatively simple construction. A direct comparison with an equivalent hydraulic-press model is carried out, thus highlighting the servo press energy efficiency.

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Figures

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Fig. 1

Planar nonoverconstrained press architectures with (a) 2dof and (b) 3dof

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Fig. 2

Joint twists of a PUU (a) and a PUS (b) leg

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Fig. 3

Spatial nonoverconstrained press architectures with (a) 3dof, (b) 4dof, (c) 5dof, and (d) 6dof

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Fig. 4

Biaxial servo press prototype: (a) CAD (computer aided design) section front view and (b) CAD overall layout

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Fig. 5

Biaxial servo press prototype: (a) global view and (b) 2dof actuation mechanism (top view, cover removed)

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Fig. 6

Reference press cycle of the prototype

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Fig. 7

Lumped parameter model of each servo axis

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Fig. 8

Mechanical power provided by each axis of the press prototype during the reference cycle, for different values of the gearbox transmission ratio

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Fig. 9

Motor torque against motor speed during the press cycle: (1) acceleration during downward positioning, (2) deceleration during downward positioning, (3) pressing operation, (4) ram breaking, (5) acceleration during upward positioning, and (6) deceleration during upward positioning

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Fig. 10

Total mechanical power exchanged by the press prototype during the reference cycle

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Fig. 11

Hydraulic circuit

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Fig. 12

Power comparison between the servo press and its hydraulic equivalent

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