阅读说明：本技术 用于金属成形和/或切割的方法和设备 (Method and apparatus for metal forming and/or cutting ) 是由 埃里卡·亨里克森 乔恩·涅米宁 于 2019-09-26 设计创作，主要内容包括：本发明提供了一种借助于工具(4)和驱动单元(1)进行材料成形和/或切割的方法,该方法包括移动驱动单元(1)以向工具(4)提供动能,以使工具(4)撞击工件材料(W),以使工件材料(W)成形和/或切割工件材料(W),其中,在工具(4)撞击工件材料(W)之前,将工具(4)与驱动单元(1)可操作地分离。(The invention provides a method of material shaping and/or cutting by means of a tool (4) and a drive unit (1), the method comprising moving the drive unit (1) to provide kinetic energy to the tool (4) to cause the tool (4) to impact a workpiece material (W) to shape and/or cut the workpiece material (W), wherein the tool (4) is operatively separated from the drive unit (1) before the tool (4) impacts the workpiece material (W).)

1. A method of material forming and/or cutting by means of a tool (4) and a drive unit (1), the method comprising moving the drive unit (1) to provide kinetic energy to the tool (4) to cause the tool (4) to impact a workpiece material (W) to form and/or cut the workpiece material (W), characterized in that the tool (4) is operatively separated from the drive unit (1) before the tool (4) impacts the workpiece material (W).

2. Method according to claim 1, wherein moving the drive unit comprises accelerating the drive unit, and the tool (4) is in contact with the drive unit (1) during at least a major part of the acceleration of the drive unit (1).

3. Method according to any one of claims 1 to 2, wherein the drive unit (1) is decelerated to separate the tool (4) from the drive unit (1) before the tool (4) impacts the workpiece material (W).

4. A method according to claim 3, comprising guiding the tool (4) towards the workpiece material (W) after the tool (4) is separated from the drive unit (1).

5. A method according to any one of claims 3 to 4, wherein the drive unit (1) is decelerated so that the tool (4) is no longer in contact with the drive unit (1) again until after the tool (4) has impacted the workpiece material (W).

6. Method according to any of claims 3-5, wherein moving the drive unit comprises accelerating the drive unit and the drive unit is a plunger (1) arranged to be driven by a hydraulic system (11, 12, 13, 16, 17, 18) comprising a first chamber (17) for hydraulically biasing the plunger (1) towards the workpiece material (W), wherein for acceleration of the plunger (1) the hydraulic system is controlled to direct hydraulic fluid towards the first chamber (17), wherein for deceleration of the plunger (1) the hydraulic system is controlled to reduce the transport of hydraulic fluid towards the first chamber (17), but high enough to avoid cavitation of the hydraulic fluid.

7. A method according to any of claims 3-6, wherein moving the drive unit comprises accelerating the drive unit, and the drive unit is a plunger (1) arranged to be driven by a hydraulic system (11, 12, 13, 16, 17, 18), the method comprising, for deceleration, allowing a portion (14) of the plunger to enter a brake chamber (15), thereby allowing hydraulic fluid to be trapped in the brake chamber, whereby an increase in pressure in the trapped fluid decelerates the plunger (1).

8. A method according to any of the preceding claims, wherein the tool (4) is positioned at a distance of at least 3mm from the workpiece material (W), preferably at a distance of at least 5mm from the workpiece material (W), most preferably at a distance of at least 8mm from the workpiece material (W), before providing kinetic energy to the tool (4) by the movement of the drive unit (1).

9. The method according to any of the preceding claims, wherein moving the drive unit comprises accelerating the drive unit, and the drive unit is an upwardly accelerating plunger (1).

10. Method according to claim 9, wherein during at least a major part of the acceleration the tool (4) is in contact with the plunger (1), the contact being provided by the tool (4) resting on the plunger (1).

11. The method according to any one of claims 9 to 10, comprising dropping the tool (4) back onto the plunger (1) after the tool (4) impacts the workpiece material (W).

12. The method of claim 11, comprising attenuating the fall of the tool (4) as it approaches the plunger (1).

13. The method according to any one of claims 1 to 8, wherein moving the drive unit comprises accelerating the drive unit, and the drive unit is a plunger (1) moving downwards.

14. A method according to any of the preceding claims, wherein the method steps form part of a workpiece material impact process, wherein the drive unit is a plunger (1) arranged to be driven by a hydraulic system (11, 12, 13, 16, 17, 18) comprising a first chamber (17) for hydraulically biasing the plunger (1) towards the workpiece material (W), and a valve arrangement (11, 12) for controlling the pressure in the first chamber, the method comprising: receiving signals indicative of one or more of plunger position, plunger velocity, plunger acceleration, tool position, tool velocity, tool acceleration, pressure (pA) in the first chamber (17), one or more response times of the valve arrangement, ambient temperature and temperature of the hydraulic system oil, the method further comprising storing at least some of the signals received during impact of at least one workpiece material (W), and/or storing data provided as a result of processing at least some of the signals received during impact of at least one workpiece material (W), and adjusting control of the valve arrangement (11, 12) for further impact procedures based at least in part on the stored signals and/or the stored data.

15. The method according to claim 1, wherein the tool (4) is stationary before providing kinetic energy to the tool (4) by the movement of the drive unit (1), and moving the drive unit (1) to provide kinetic energy to the tool (4) comprises striking the stationary tool (4) with the drive unit (1).

16. The method according to claim 1, wherein the drive unit is a rotary unit comprising a protrusion fixed to a rotor, which protrusion is rotated by rotation of the rotor to provide kinetic energy to the tool (4).

17. An apparatus for material forming and/or cutting by means of a tool (4) and a drive unit (1), the apparatus being arranged to move the drive unit (1) to provide kinetic energy to the tool (4) to cause the tool (4) to impact a workpiece material (W) to form or cut the workpiece material (W), characterized in that the apparatus is arranged such that the tool (4) is operatively separated from the drive unit (1) before the tool (4) impacts the workpiece material (W).

18. The device according to claim 17, wherein moving the drive unit comprises accelerating the drive unit, the device being arranged to be in contact with the drive unit (1) during at least a major part of the acceleration of the drive unit (1).

19. An apparatus according to claims 17 to 18, wherein the apparatus is arranged to decelerate the drive unit (1) before the tool (4) hits the workpiece material (W) to separate the tool (4) from the drive unit (1).

20. An apparatus according to claim 19, wherein a guiding device (3) is arranged to guide the tool (4) towards the workpiece material (W) after the tool (4) has been separated from the drive unit (1).

21. An apparatus according to any one of claims 19-20, wherein moving the drive unit comprises accelerating the drive unit, and the drive unit (1) is a plunger arranged to be driven by a hydraulic system (11, 12, 13, 16, 17, 18), the apparatus being arranged to allow a portion (14) of the plunger (1) to enter a brake chamber (15) for deceleration, so that hydraulic fluid is trapped in the brake chamber.

22. An apparatus according to any of claims 17 to 21, wherein moving the drive unit comprises accelerating the drive unit, and the drive unit (1) is a plunger, the apparatus being arranged to provide an upward acceleration to the plunger (1).

23. Apparatus according to claim 22, comprising a damping device (8) arranged to damp the fall of the tool (4) as the tool (4) approaches the plunger (1).

24. An apparatus according to any one of claims 17-23, wherein the tool (4) is arranged to be stationary before providing kinetic energy to the tool (4) by means of the movement of the drive unit (1), and the apparatus is arranged to move the drive unit (1) to provide kinetic energy to the tool (4) and to strike the stationary tool (4) with the drive unit (1).

25. Apparatus according to claim 24, wherein the drive unit is a rotary unit comprising a protrusion fixed to a rotor, the protrusion being arranged to be rotated by rotation of the rotor to provide kinetic energy to the tool (4).

26. A method of high speed forming and/or cutting by means of a tool (4) and a drive unit (1), the method comprising accelerating the drive unit (1) to provide kinetic energy to the tool (4) to cause the tool (4) to impact a workpiece material (W) to form and/or cut the workpiece material (W), characterized in that the tool (4) is in contact with the drive unit (1) during at least a major part of the acceleration of the drive unit (1).

27. Method according to claim 26, wherein the drive unit (1) is decelerated to separate the tool (4) from the drive unit (1) before the tool (4) impacts the workpiece material (W).

28. A method according to claim 27, comprising guiding the tool (4) towards the workpiece material (W) after the tool (4) is separated from the drive unit (1).

29. A method according to any one of claims 27 to 28, wherein the drive unit (1) is decelerated so that the tool (4) is no longer in contact with the drive unit (1) again until after the tool (4) has impacted the workpiece material (W).

30. A method according to any one of claims 27-29, wherein the drive unit (1) is arranged to be driven by a hydraulic system (11, 12, 13, 16, 17, 18) comprising a first chamber (17) for hydraulically biasing the drive unit (1) towards the workpiece material (W), wherein for deceleration of the drive unit (1) the hydraulic system is controlled such that the transport of hydraulic fluid towards the first chamber (17) is reduced, but sufficiently high that cavitation of the hydraulic fluid is avoided.

31. A method according to any of claims 27-30, wherein the drive unit (1) is arranged to be driven by a hydraulic system (11, 12, 13, 16, 17, 18), the method comprising, for deceleration, allowing a part (14) of the drive unit to enter a brake chamber (15), thereby allowing hydraulic fluid to be trapped in the brake chamber, whereby an increase in pressure in the trapped fluid decelerates the drive unit (1).

32. A method according to any one of claims 26 to 31, wherein the drive unit (1) is accelerated upwards.

33. Method according to claim 32, wherein the contact of the tool (4) with the drive unit (1) is provided by the tool (4) resting on the drive unit (1) during at least a major part of the acceleration.

34. Method according to any one of claims 32 to 33, comprising dropping the tool (4) back onto the drive unit (1) after the tool (4) has hit the workpiece material (W).

35. A method according to claim 34, comprising damping the fall of the tool (4) as the tool (4) approaches the drive unit (1).

36. A method according to any one of claims 26 to 35, wherein the method steps form part of a workpiece material impact process, wherein the drive unit (1) is arranged to be driven by a hydraulic system (11, 12, 13, 16, 17, 18) comprising a first chamber (17) for hydraulically biasing the drive unit (1) towards the workpiece material (W), and a valve arrangement (11, 12) for controlling the pressure in the first chamber, the method comprising: receiving signals indicative of one or more of drive unit position, drive unit speed, drive unit acceleration, tool position, tool speed, tool acceleration, pressure (pA) in the first chamber (17), one or more response times of the valve arrangement, ambient temperature and temperature of hydraulic system oil, the method further comprising storing at least some of the signals received during impact of at least one workpiece material (W), and/or storing data provided as a result of processing at least some of the signals received during impact of at least one workpiece material (W), and adjusting control of the valve arrangement (11, 12) for further impact procedures based at least in part on the stored signals and/or the stored data.

37. A computer program comprising program code means for performing the steps of any one of claims 1 to 16 or 26 to 36 when said program is run on a computer.

38. A computer readable medium carrying out a computer program comprising program code means for performing the steps of any of claims 1 to 16 or 26 to 36 when said program product is run on a computer.

39. A control unit configured to perform the steps of the method according to any one of claims 1 to 16 or 26 to 36.

40. An apparatus for high speed forming and/or cutting by means of a tool (4) and a drive unit (1), the apparatus being arranged to accelerate the drive unit (1) to provide kinetic energy to the tool (4) to cause the tool (4) to impact a workpiece material (W) to form and/or cut the workpiece material (W), characterized in that the apparatus is arranged such that the tool (4) is in contact with the drive unit (1) during at least a major part of the acceleration of the drive unit (1).

41. An apparatus according to claim 40, wherein the apparatus is arranged to decelerate the drive unit (1) before the tool (4) impacts the workpiece material (W) to separate the tool (4) from the drive unit (1).

42. An apparatus as claimed in claim 41, wherein a guide device (3) is arranged to guide the tool (4) towards the workpiece material (W) after the tool (4) has been separated from the drive unit (1).

43. Apparatus according to any of claims 41 to 42, wherein the drive unit is a plunger (1) arranged to be driven by a hydraulic system (11, 12, 13, 16, 17, 18), the apparatus being arranged to allow a portion (14) of the plunger (1) to enter a brake chamber (15) for deceleration, thereby allowing hydraulic fluid to be trapped in the brake chamber.

44. Apparatus according to any of claims 40 to 43, wherein the apparatus is arranged to provide an upward acceleration to the drive unit (1).

45. Apparatus according to claim 44, comprising damping means (8) arranged to damp the fall of the tool (4) when the tool (4) approaches the drive unit (1).

46. Apparatus according to any one of claims 17 to 25 or 40 to 45, comprising a control unit according to claim 39.

Technical Field

The present invention relates to a method for forming and/or cutting a material. The invention also relates to a computer program, a computer-readable medium, a control unit and an apparatus for forming and/or cutting of material.

Background

The present invention is advantageously used for high speed forming (HVF) and/or cutting, but according to other embodiments of the invention, may be used for forming and/or cutting of materials involving other speeds than HVF. HVF is also referred to herein as high-speed material forming. HVF of metals is also known as high-speed metal forming. High speed cutting or high speed cutting may also be referred to as high speed crosscutting or high speed crosscutting.

In conventional metal forming operations, force is applied to the metal to be worked by using a simple hammer blow or power press; the heavy tools used move at a relatively low speed. Conventional techniques include methods such as forging, extrusion, drawing, and stamping. In conventional metal cutting operations, there are many techniques available for cutting metal, including machining techniques such as turning, milling, drilling, grinding, sawing. Among other techniques are welding/combustion techniques such as laser combustion, oxy-fuel combustion, and plasma.

HVF involves imparting high kinetic energy to the tool by imparting a high velocity to the tool before it impacts the workpiece. HVF includes methods such as hydroforming, for example, with the aid of an electric motor, explosive forming, electro-hydraulic forming, and electromagnetic forming. In these forming processes, a large amount of energy is applied to the workpiece in a very short time interval. The velocity of the HVF may generally be at least 1m/s, preferably at least 3m/s, preferably at least 5 m/s. For example, the velocity of the HVF may be 1-20m/s, preferably 3-15m/s, preferably 5-15 m/s. HVF may be considered as a process that derives material forming forces from kinetic energy, whereas in conventional material forming, material forming forces are derived from pressure, e.g., hydraulic pressure.

Similarly, as in HVF, high speed cutting involves imparting high kinetic energy to the cutting tool by imparting a higher velocity to it before it strikes and cuts the workpiece. The speed of the high speed cutting may generally be at least 1m/s, preferably at least 3m/s, preferably at least 5 m/s. For example, the speed of the high speed cutting may be 1 to 20m/s, preferably 3 to 15m/s, preferably 5 to 15 m/s.

One advantage of HVF is that many metals tend to deform more easily under very rapid loading. The strain distribution is more uniform in a single pass of the HVF compared to conventional forming techniques. This results in a tendency to produce complex shapes without inducing unnecessary strain in the material. This allows complex parts to be formed with tight tolerances, as well as forming alloys that may not be formed by conventional metal forming processes. For example, HVF may be used in the manufacture of metal flow plates used in fuel cells. Such manufacture requires small tolerances.

One advantage of high-speed cutting is that a more efficient and simpler method in terms of production engineering can be used to obtain a higher measurement accuracy. Furthermore, the time between impacts of the cutting tool can be made very short, resulting in high productivity.

Another advantage of HVF and high speed cutting is that although the kinetic energy of the tool is linearly proportional to the mass of the tool, it is squared against the speed of the tool, and therefore, a much lighter weight tool can be used in HVF compared to conventional metal forming.

It is known that in HVF and high speed cutting, a plunger is driven from a starting position by hydraulic pressure in a first chamber in order to transfer high kinetic energy by impact to a tool which in turn machines a workpiece material, for example a workpiece. In order to avoid excessive deformation of the tool upon impact from the plunger, the tool must have a relatively high stiffness and thus a relatively high mass. As a result, the system for driving the plunger needs to exhibit a high capacity. Furthermore, due to the high kinetic energy, the plunger may hit the tool more than once. This may occur if the workpiece material bounces due to deformation upon impact of the tool, and as a result the workpiece material in turn impacts the tool, thereby pushing the tool towards and again into contact with the plunger. This is an undesirable action. The plunger should only hit the tool once, otherwise the forming and/or cutting of the workpiece may result in impaired properties of the final product, such as weakness and unevenness, and even production failures.

It is also desirable to improve the control of the energy provided to the workpiece material in HVF and high speed cutting. Improved energy control can improve the properties of the process in the workpiece material. This may further extend the applicability of HVF and high speed cutting, for example, to tolerances that are even smaller than those achievable with current HVF and high speed cutting processes. It is also desirable to find an alternative to using a plunger as the drive unit. Another desire is to eliminate the risk of the plunger hitting/impacting the tool more than once for each forming and/or cutting of the product.

Disclosure of Invention

It is an object of the present invention to improve the control of the energy supplied to the workpiece material in the forming and/or cutting of the material, preferably in high speed forming and high speed cutting. It is another object of the present invention to reduce the plunger drive system capacity requirements in material forming and/or cutting, preferably in high speed forming and cutting. A further object is to be able to provide workpiece materials with smaller tolerances, which are achieved by current material shaping and/or cutting processes, and preferably at current high speed and/or cutting processes. A further object is to prevent the plunger from hitting/striking the tool more than once each time the product is formed and/or cut.

These objects are achieved by a method according to claim 1. These objects are therefore achieved by a method of material shaping and/or cutting by means of a tool and a drive unit, the method comprising moving the drive unit to provide kinetic energy to the tool to cause the tool to impact a workpiece material to shape and/or cut said workpiece material, wherein the tool is operatively separated from the drive unit prior to the tool impacting the workpiece material. Since the tool is operatively separated from the drive unit, the risk of bounce-back is reduced or prevented. This improves the properties of the final product, avoids weakening and unevenness problems and reduces the risk of production failures. The method is advantageously used for high speed forming and/or cutting. However, the method may also be used for other types of material forming and/or cutting.

The operably separating the tool from the drive unit may include separating the tool from the drive unit.

When moving the drive unit comprises accelerating the drive unit, the tool may be in contact with the drive unit and may provide kinetic energy to the tool during at least a major part of the acceleration of the drive unit. The tool and the drive unit may start accelerating at the same time. However, in some embodiments, the tool may not be in contact with the drive unit during an initial phase of acceleration of the drive unit. Alternatively, the drive unit may be in contact with the tool after the initial stage, the tool remaining in contact with the drive unit during the remainder of the acceleration. For example, the tool may start its acceleration before the drive unit reaches 50%, preferably 20%, more preferably 10% of its maximum speed. In embodiments where the drive unit contacts the tool after the drive unit has started accelerating, the drive unit and/or the tool may be provided with a damper for bringing the drive unit into contact with the tool.

In some embodiments, wherein moving the drive unit comprises accelerating the drive unit, the drive unit being a plunger arranged to be driven by the hydraulic system. The plunger may be movably arranged in the cylinder housing. The cylinder housing may be mounted to the frame. The hydraulic system may include a first chamber for biasing the plunger toward the workpiece. The hydraulic system may include a second chamber for biasing the plunger away from the workpiece. The first and second chambers may be formed by the cylinder housing and the plunger. As described in detail below, the second chamber may be provided with the system pressure of the hydraulic system throughout the impact process. In alternative embodiments, the plunger may be arranged to be driven in some alternative manner, for example by explosives, by electromagnetism or by pneumatics.

The energy of the tool may be adjusted by adjusting the speed and/or mass of the tool. It should be understood that the second tool may be present on the opposite side of the workpiece material. The workpiece material may be a workpiece, such as a solid material, e.g. a material in sheet form, e.g. in metal form. Alternatively, the workpiece material may be some other form of material, such as a powder form.

The acceleration and speed of the drive unit can be controlled with high accuracy. However, as mentioned above, the process of striking the tool by the drive unit does not fully control the speed of the tool and therefore the kinetic energy of the tool. The invention allows for improved control of the acceleration and speed of the tool by bringing the tool into contact with the drive unit during at least a major part of the acceleration of the drive unit. The present invention thus provides improved control over the kinetic energy of the tool and hence the energy imparted to the workpiece material.

Embodiments of the present invention provide for accelerating the drive unit and the tool with the same simultaneous acceleration. The acceleration of the tool is therefore considerably slower in relation to the movement obtained by the process performed by the drive unit as described above. Therefore, there is no need to consider the risk of excessive deformation of the tool due to the impact of the drive unit. Thus, the tool may have a reduced stiffness and thus a reduced mass. In addition, in the case where the drive unit is a plunger, the mass of the drive unit may be reduced compared to the plunger during impact of the tool by the plunger. As a result, the capacity of the system for driving the plunger may be reduced.

The tool is operatively decoupled from the drive unit. The tool is arranged to be operatively separated from the drive unit during impact of workpiece material involving movement of the drive unit. The tool is arranged to be operatively separated from the drive unit before the tool impacts the workpiece material. For example, where moving the drive unit includes accelerating the drive unit, the drive unit may be an upwardly accelerating plunger. The tool may be arranged to rest on top of the plunger without any fastening element securing the tool to the plunger. Thus, the following illustrative advantageous embodiments are achieved.

Preferably, the drive unit is decelerated before the tool impacts the workpiece material to separate the tool from the drive unit before the tool impacts the workpiece material. The drive unit can therefore continue towards the workpiece material by means of inertia.

Preferably, the method comprises directing the tool towards the workpiece material after the tool has been separated from the drive unit. In some embodiments, the path of the tool may be controlled by a guide device. In some examples, the guide device includes a plurality of pins secured to the tool. However, alternatives are possible. For example, a frame surrounding the tool or a path of the tool may be arranged to guide the tool. Thus, one or more guide means fixed to the tool may be arranged to engage with the frame as the tool moves along the frame. Guidance of the tool allows the tool to be accurately positioned on the workpiece material.

The tool may be positioned at a distance of at least 3mm from the workpiece material before kinetic energy is provided to the tool by the movement of the drive unit. Preferably, the tool is at a distance of at least 5mm from the workpiece material. Most preferably, the tool is at a distance of at least 8mm from the workpiece material. Preferred positioning of the tool relative to the workpiece material may be provided in embodiments in which the tool is in contact with the plunger during at least a major portion of the acceleration of the plunger, and in embodiments exemplified below in which the tool is stationary before kinetic energy is provided to the tool by movement of the drive unit, and moving the drive unit to provide kinetic energy to the tool comprises impacting the stationary tool with the drive unit.

The drive unit decelerates so that the tool is no longer in contact with the plunger until after the tool impacts the workpiece material. When the tool is in contact with the workpiece material, the drive unit does not reach a position of contact with the tool. Thus, the energy imparted to the workpiece material for shaping the workpiece material is provided by the tool without any involvement of the drive unit. Thus, the operative separation or uncoupling may render the drive unit non-existent when the tool impacts the workpiece material. Thus, problems of the known system, such as the risk of the drive unit repeating one or more impacts, are eliminated.

As suggested, the plunger may be arranged to be driven by a hydraulic system comprising a first chamber for hydraulically biasing the plunger towards the workpiece material. The method may comprise, for acceleration of the plunger, controlling the hydraulic system to move hydraulic fluid to the first chamber, wherein, for deceleration of the plunger, the hydraulic system is controlled to reduce the delivery of hydraulic fluid towards the first chamber but high enough to avoid cavitation of the hydraulic fluid. Thus, cavitation of the fluid, which may be harmful to the process, may be effectively avoided.

Preferably, where the plunger is arranged to be driven by a hydraulic system, the method comprises: to decelerate, a portion of the plunger is allowed to enter the brake chamber and thereby allow hydraulic fluid to be trapped in the brake chamber, whereby an increase in pressure in the trapped fluid decelerates the plunger. For example, the portion of the plunger may be a waist. Thus, where the plunger is arranged to be driven by a hydraulic system, the plunger may be provided with a waist, the method comprising: for deceleration, the waist is allowed to enter the brake chamber, allowing hydraulic fluid to be trapped in the brake chamber, whereby an increase in pressure in the trapped fluid decelerates the plunger. As suggested above, where a second chamber is provided for biasing the plunger away from the workpiece material, the detent chamber may be formed at an end of the second chamber in a direction towards the workpiece material.

Preferably, moving the drive unit comprises accelerating the drive unit, which is an upwardly accelerating plunger. Thus, the tool will also accelerate upwards.

Thus, said contact of the tool with the plunger may be provided by the tool being placed on the plunger during at least a major part of the acceleration. Thus, the tool can be held by the plunger by gravity and acceleration. This simplifies the arrangement of the impact process. However, it should be noted that alternatively, the plunger and tool may be accelerated in another direction, such as downward or sideways.

In some embodiments, the tool is stationary and moving the drive unit to provide kinetic energy to the tool comprises impacting the stationary tool with the drive unit. The tool may be stationary at a distance above the plunger before the plunger strikes the tool.

In the event that the plunger is accelerated upwardly, the method may include allowing the tool to fall back onto the plunger after the tool impacts the workpiece material. Preferably, the fall of the tool is attenuated as it approaches the plunger. For this purpose, damping means may be provided, as shown in the following example. This may reduce impact when the tool is in contact with the plunger, which may reduce wear.

The above-described method steps may form part of a workpiece material impact process. Where the plunger is arranged to be driven by a hydraulic system comprising a first chamber for hydraulically biasing the plunger towards the workpiece material and a valve arrangement for controlling the pressure in the first chamber, the method may comprise receiving signals indicative of one or more of plunger position, plunger speed, plunger acceleration, tool position, tool speed, tool acceleration, pressure in the first chamber, one or more response times of the valve arrangement, ambient temperature and temperature of the hydraulic system oil. The method may further comprise storing at least some of the signals received during the impact of the at least one workpiece material, and/or storing data provided as a result of processing at least some of the signals received during the impact of the at least one workpiece material, and adjusting the control of the valve arrangement for further impact procedures based at least in part on the stored signals and/or the stored data. During a further impact, the control of the valve device can also be adjusted partly on the basis of the current sensor signal. Thus, the timing of valve actuation during impact can be accurate in view of conditions such as temperature and aging of the device.

According to an embodiment of the invention, the drive unit is a rotary unit comprising a protrusion fixed to the rotor, which protrusion is rotated by rotation of the rotor to provide kinetic energy to the tool.

The object is also achieved by a device according to any of claims 17 to 25. The invention therefore also provides an apparatus for forming and/or cutting material by means of a tool and a drive unit, the apparatus being arranged to move the drive unit to provide kinetic energy to the tool to cause the tool to impact a workpiece material to form or cut the workpiece material, wherein the apparatus is arranged such that the tool is operatively separated from the drive unit prior to the tool impacting the workpiece material. Where moving the drive unit comprises accelerating the drive unit, the apparatus may be arranged such that the tool is in contact with the drive unit during at least a major part of the acceleration of the drive unit. The advantages of such a device can be understood from the above description of the method according to the invention. In some embodiments, the tool is operably separated or decoupled from the drive unit. The tool may be arranged to be operatively separated or detached from the drive unit during workpiece material impact involving acceleration of the drive unit. The tool is arranged to be operatively separated or detached from the drive unit before the tool impacts the workpiece material.

Preferably, the apparatus is arranged to decelerate the drive unit to separate the tool from the drive unit before the tool impacts the workpiece material. Preferably, the guiding means is arranged to guide the tool towards the workpiece material after the tool has been separated from the drive unit. Preferably, the tool is arranged to be stationary before providing kinetic energy to the tool by movement of the drive unit, and the apparatus is arranged to move the drive unit to provide kinetic energy to the tool and to strike the stationary tool with the drive unit. Preferably, when moving the drive unit comprises accelerating the drive unit, the drive unit being a plunger arranged to be driven by the hydraulic system, the apparatus is arranged to allow a portion of the plunger to enter the brake chamber to decelerate it so that hydraulic fluid is trapped in the brake chamber. The portion of the plunger may be a waist. Thus, the plunger may be arranged to be driven by the hydraulic system, wherein the plunger is provided with a waist, the device being arranged to allow the waist to enter the brake chamber to decelerate it, thereby allowing hydraulic fluid to be trapped in the brake chamber.

These objects are also achieved by a method according to claim 26. These objects are therefore achieved by a method for high speed forming and/or cutting by means of a tool and a drive unit, the method comprising accelerating the drive unit to provide kinetic energy to the tool to cause the tool to impact a workpiece material to form and/or cut the workpiece material, wherein the tool is in contact with the drive unit during at least a major part of the acceleration of the drive unit.

By bringing the tool into contact with the drive unit during at least a major part of the acceleration of the drive unit, kinetic energy can be provided to the tool. Preferably, the tool is in contact with the drive unit during the entire acceleration of the drive unit. Thus, the tool and the drive unit may start accelerating at the same time. However, as suggested, in some embodiments, the tool may not be in contact with the drive unit during an initial phase of drive unit acceleration. Alternatively, the drive unit may be in contact with the tool after an initial stage, the tool remaining in contact with the drive unit during the remainder of the acceleration. As suggested, for example, the tool may start its acceleration before the drive unit reaches 50%, preferably 20%, more preferably 10% of its maximum speed. In embodiments where the drive unit contacts the tool after the drive unit has started accelerating, the drive unit and/or the tool may be provided with a damper for bringing the drive unit into contact with the tool.

The drive unit may be a plunger. In some embodiments, the drive unit is arranged to be driven by a hydraulic system. As suggested, the drive unit may be movably arranged in the cylinder housing. The cylinder housing may be mounted to the frame. The hydraulic system may include a first chamber for biasing the drive unit toward the workpiece. The hydraulic system may include a second chamber for biasing the drive unit away from the workpiece. The first and second chambers may be formed by the cylinder housing and the drive unit. As described in detail below, the second chamber may be provided with the system pressure of the hydraulic system throughout the impact process. In alternative embodiments, the drive unit may be arranged to be driven in some alternative manner, for example by explosives, by electromagnetism or by pneumatics.

As suggested, the energy of the tool may be adjusted by adjusting the speed and/or mass of the tool. It should be understood that the second tool may be present on the opposite side of the workpiece material. The workpiece material may be a workpiece, such as a solid material, e.g. a material in sheet form, e.g. in metal form. Alternatively, the workpiece material may be some other form of material, such as a powder form.

As suggested, the acceleration and speed of the drive unit can be controlled with high accuracy. However, as mentioned above, the process of striking the tool by the drive unit does not fully control the speed of the tool and therefore the kinetic energy of the tool. Embodiments of the invention allow improved control of the acceleration and speed of the tool by bringing the tool into contact with the drive unit during at least a major part of the acceleration of the drive unit. Thus, embodiments of the present invention provide improved control over the kinetic energy of the tool and hence the energy imparted to the workpiece material.

As suggested, embodiments of the present invention provide for accelerating the drive unit and the tool with the same simultaneous acceleration. The acceleration of the tool is therefore considerably slower in relation to that obtained by the process performed by the drive unit as described above. Therefore, there is no need to consider the risk of excessive deformation of the tool due to the impact of the drive unit. Thus, the tool may have a reduced stiffness and thus a reduced mass. In addition, the mass of the drive unit may be reduced compared to the drive unit during striking of the tool by the drive unit. As a result, the capacity of a system for driving the drive unit may be reduced.

In some embodiments, the tool may be separate from the drive unit. The tool may be arranged to be separated from the drive unit during workpiece material impact involving acceleration of the drive unit. The tool may be arranged to be separated from the drive unit before the tool impacts the workpiece material. For example, in case the drive unit is accelerated upwards, the tool may be arranged to rest on top of the drive unit without any fastening elements securing the tool to the drive unit. Thus, the following illustrative advantageous embodiments are achieved. However, in some embodiments, the tool may be secured to the drive unit during impact of the workpiece material. Thus, the tool may be secured to the drive unit by one or more releasable fastening elements, e.g. comprising bolts or the like. In such an embodiment, the tool may be secured to the drive unit when the tool impacts the workpiece material.

Preferably, as suggested, the drive unit is decelerated before the tool impacts the workpiece material to separate the tool from the drive unit before the tool impacts the workpiece material. The drive unit can therefore continue towards the workpiece material by means of inertia.

Preferably, as suggested, the method comprises directing the tool towards the workpiece material after the tool has been separated from the drive unit. In some embodiments, the path of the tool may be controlled by a guide device. In some examples, the guide device includes a plurality of pins secured to the tool. However, alternatives are possible. For example, a frame surrounding the tool or a path of the tool may be arranged to guide the tool. Thus, one or more guide means fixed to the tool may be arranged to engage with the frame as the tool moves along the frame. Guidance of the tool allows the tool to be accurately positioned on the workpiece material.

Preferably, as suggested, the drive unit is decelerated so that the tool is no longer in contact with the drive unit until after the tool impacts the workpiece material. Preferably, the drive unit does not reach a position of contact with the tool when the tool is in contact with the workpiece material. Thus, the energy imparted to the workpiece material for shaping the workpiece material is provided by the tool without any involvement of the drive unit. Thus, the separation may be such that the drive unit is not present when the tool impacts the workpiece material. Thus, problems of the known system, such as the risk of the drive unit repeating one or more impacts, are eliminated.

As suggested, the drive unit may be arranged to be driven by a hydraulic system comprising a first chamber for hydraulically biasing the drive unit towards the workpiece material. The method may comprise, for acceleration of the drive unit, controlling the hydraulic system to move hydraulic fluid to the first chamber, wherein, for deceleration of the drive unit, the hydraulic system is controlled to reduce the delivery of hydraulic fluid towards the first chamber but high enough to avoid cavitation of the hydraulic fluid. Thus, cavitation of the fluid, which may be harmful to the process, may be effectively avoided.

Preferably, as suggested, in case the drive unit is arranged to be driven by a hydraulic system, the method comprises: for deceleration, a portion of the drive unit is allowed to enter the brake chamber and thereby allow hydraulic fluid to be trapped in the brake chamber, whereby an increase in pressure in the trapped fluid decelerates the drive unit. As suggested, the portion of the drive unit may be a waist, for example. Thus, in case the drive unit is arranged to be driven by a hydraulic system, the drive unit may be provided with a waist, the method comprising: for deceleration, the waist is allowed to enter the brake chamber, allowing hydraulic fluid to be trapped in the brake chamber, whereby an increase in pressure in the trapped fluid decelerates the drive unit. As suggested above, in case a second chamber for biasing the drive unit away from the workpiece material is provided, the brake chamber may be formed at an end of the second chamber in a direction towards the workpiece material.

Preferably, the drive unit accelerates upwards. Thus, as suggested, the tool is also accelerated upward. Thus, said contact of the tool with the drive unit may be provided by the tool placed on the drive unit during at least a major part of the acceleration. Thus, the tool can be held by the drive unit by gravity and acceleration. This simplifies the arrangement of the impact process. It should be noted, however, that alternatively the drive unit and the tool may be accelerated in another direction, for example downwards or sideways.

As suggested, where the drive unit is accelerated upwardly, the method may include allowing the tool to fall back onto the drive unit after the tool impacts the workpiece material. Preferably, the fall of the tool is damped as it approaches the drive unit. For this purpose, damping means may be provided, as shown in the following example. This may reduce the impact when the tool is in contact with the drive unit, which may reduce wear.

As suggested, the above-described method steps may form part of a workpiece material impact process. Where the drive unit is arranged to be driven by a hydraulic system comprising a first chamber for hydraulically biasing the drive unit towards the workpiece material and a valve arrangement for controlling the pressure in the first chamber, the method may comprise receiving signals indicative of one or more of drive unit position, drive unit speed, drive unit acceleration, tool position, tool speed, tool acceleration, pressure in the first chamber, one or more response times of the valve arrangement, ambient temperature and temperature of the hydraulic system oil. The method may further comprise storing at least some of the signals received during the impact of the at least one workpiece material, and/or storing data provided as a result of processing at least some of the signals received during the impact of the at least one workpiece material, and adjusting the control of the valve arrangement for further impact procedures based at least in part on the stored signals and/or the stored data. During a further impact, the control of the valve device can also be adjusted partly on the basis of the current sensor signal. Thus, the timing of valve actuation during impact can be accurate in view of conditions such as temperature and aging of the device.

The object is also achieved by a computer program according to claim 37, a computer readable medium according to claim 38 or a control unit according to claim 39. The control unit may be provided as a single physical unit or as a plurality of units arranged to communicate with each other.

It should be noted that although in some embodiments the method may be controlled by the control unit, in other embodiments the method may be controlled mechanically. For example, the method may include hydraulically pressurizing the first chamber to bias the drive unit toward the workpiece material. The method may further comprise, in order to decelerate the drive unit before the tool impacts the workpiece material, allowing a portion of the drive unit to enter the brake chamber and thereby allowing hydraulic fluid to be trapped in the brake chamber, whereby an increase in pressure in the trapped fluid decelerates the drive unit. In such an embodiment, the step of controlling the hydraulic system may be omitted to reduce the delivery of hydraulic fluid towards the first chamber.

The object is also achieved by a device according to any of claims 40 to 46. Embodiments of the invention therefore also provide an apparatus for high speed forming and/or cutting by means of a tool and a drive unit, the apparatus being arranged to accelerate the drive unit to provide kinetic energy to the tool to cause the tool to impact a workpiece material to form and/or cut said workpiece material, wherein the apparatus is arranged such that the tool is in contact with the drive unit during at least a major portion of the acceleration of the drive unit. The advantages of such a device can be understood from the above description of an embodiment of the method according to the invention. In some embodiments, the tool may be separate from the drive unit. The tool may be arranged to be separated from the drive unit during workpiece material impact involving acceleration of the drive unit. The tool may be arranged to be separated from the drive unit before the tool impacts the workpiece material. As suggested, the drive unit may be a plunger.

Preferably, as suggested, the apparatus is arranged to decelerate the drive unit to separate the tool from the drive unit before the tool impacts the workpiece material. Preferably, the guiding means is arranged to guide the tool towards the workpiece material after the tool has been separated from the drive unit. Preferably the drive unit is arranged to be driven by the hydraulic system, the apparatus being arranged to allow a portion of the drive unit to enter the brake chamber to decelerate it so that hydraulic fluid is trapped in the brake chamber. The portion of the drive unit may be a waist. Thus, the drive unit may be arranged to be driven by a hydraulic system, wherein the drive unit is provided with a waist, the arrangement being arranged to allow the waist to enter the brake chamber to decelerate it, thereby allowing hydraulic fluid to be trapped in the brake chamber.

One aspect of the invention provides a method of material forming and/or cutting by means of a tool and a drive unit, the method comprising operating the drive unit to provide kinetic energy to the tool to cause the tool to impact a workpiece material to form and/or cut said workpiece material, wherein the tool is operatively separated from the drive unit prior to the tool impacting the workpiece material. The drive unit may be arranged to electromagnetically drive the tool. The drive unit may comprise an electromagnetic spool arranged to provide a magnetic field to drive the tool. Operatively decoupling the tool from the drive unit may include controlling, for example, switching off the electromagnetic spool to eliminate the electromagnetic field. In other embodiments, the operation driving unit may include a movement driving unit, as described above.

The invention also provides a method of material forming and/or cutting by means of a tool and a plunger, the method comprising accelerating the plunger to provide kinetic energy to the tool to cause the tool to impact a workpiece material to form or cut the workpiece material, wherein the method steps form part of a workpiece material impact process, wherein the plunger is arranged to be driven by a hydraulic system comprising a first chamber for hydraulically biasing the plunger towards the workpiece material, and a valve arrangement for controlling the pressure in the first chamber, the method comprising receiving signals indicative of one or more of plunger position, plunger speed, plunger acceleration, tool position, tool speed, tool acceleration, pressure in the first chamber, one or more response times of the valve arrangement, ambient temperature and temperature of hydraulic system oil, the method further comprising storing at least some of the signals received during at least one workpiece material impact process And/or storing data provided as a result of at least some of the signals received during the impact of the at least one workpiece material, and adjusting the control of the valve arrangement for further impact processes based at least in part on the stored signals and/or stored data.

Further advantages and advantageous features of the invention are disclosed in the following description and in the dependent claims.

Drawings

Embodiments of the invention will now be described with reference to the accompanying drawings, in which:

figure 1 shows an apparatus for high speed material forming and/or cutting according to an embodiment of the present invention,

figure 2 is a flow chart depicting steps in the impact process of the apparatus of figure 1,

FIG. 3 shows an apparatus for high speed material forming and/or cutting, according to another embodiment of the present invention, an

FIG. 4 illustrates an apparatus for high speed material forming and/or cutting according to yet another embodiment of the present invention.

Detailed Description

FIG. 1 illustrates an apparatus for high speed material forming and/or cutting according to an embodiment of the present invention. The device comprises a frame 7. The frame is supported by a plurality of support means 10. The anvil 6 is fixed to the frame. In this embodiment, the anvil 6 is fixed on top of the frame 7.

A tool, referred to herein as a holding tool 5, is mounted to the anvil. The fixing tool 5 is mounted on the underside of the anvil 6. The movable tool 4 is located below the stationary tool 5, as described in more detail below. The tools 4, 5 have complementary surfaces facing each other. The workpiece W is removably mounted to the fixing tool 5. The workpiece W may be mounted to the fixture 5 in any suitable manner, for example, by clamping or by vacuum. The workpiece W may be of various types, such as a piece of sheet metal. The movable tool 4 is also referred to herein as the first tool. The fixing means 5 is also referred to herein as second means. It should be noted that in some embodiments, the second tool 5 may also be movable.

In the embodiment shown in fig. 1, the drive assembly comprising the cylinder housing 2 is mounted to the frame 7. Furthermore, the drive assembly comprises a drive unit, hereinafter referred to as plunger 1, arranged in the cylinder housing 2. The plunger 1 is elongate and, as will be understood from the following description, has a varying width along its longitudinal axis. Preferably, any cross-section of the plunger is circular. The plunger 1 is arranged to move towards and away from the fixing means 5, as described in more detail below.

The tool may be placed at a distance of at least 5mm from the tool material W before providing kinetic energy to the tool 4 by moving or accelerating the drive unit to impact the tool. Preferably, the tool is at a distance of at least 8mm from the workpiece material W. Most preferably, the tool is at a distance of at least 12mm from the workpiece material W.

The plunger 1 is arranged to be driven by a hydraulic system. The hydraulic system comprises a first chamber 17 for biasing the plunger towards the workpiece and a second chamber 18 for biasing the plunger away from the workpiece. The first and second chambers are formed by the cylinder housing 2 and the plunger 1. In this example, the workpiece is located above the plunger. Thus, in this example, the first chamber 17 is located below the second chamber 18.

The hydraulic system includes a hydraulic pump 16, the hydraulic pump 16 being used to increase the pressure of the hydraulic fluid in the system to a pressure referred to herein as the system pressure pS. The hydraulic system further comprises a check valve 161 downstream of the hydraulic pump 16. The second chamber 18 is permanently connected to the system pressure pS. The hydraulic accumulator 13 is arranged to store hydraulic fluid at system pressure. As will be understood from the following description, the accumulator 13 is provided to achieve a rapid pressure increase in the first chamber with plunger acceleration.

The hydraulic system further comprises a valve arrangement. The valve arrangement comprises a first valve 11 and a second valve 12. The first valve 11 is connected to the first chamber 17 as well as to the second chamber 18. Furthermore, the second valve 12 is connected to the first chamber 17 as well as to the second chamber 18. The valve means may be controlled by an electronic control unit CU. The valves 11, 12 are arranged to take positions so as to provide the steps described below. It should be noted here that the valve means 11, 12 may be in a position where there is no communication between the first chamber 17 and the second chamber 18. The valve may be provided with a drain for end bushing leakage.

At the opposite ends, the cylinder housing and the plunger form axial slide bearings 21, 22. Thus, one of the bearings 21 defines the first chamber 17 and is referred to herein as the first chamber bearing 21. The other of the bearings 22 defines the second chamber 18 and is referred to herein as the second chamber bearing 22. On each of the first bearing 21 and the second bearing 22, a discharge conduit 9 is provided. Between the first chamber 17 and the second chamber 18, an intermediate axial slide bearing 23 is formed by the cylinder housing and the plunger. The bearings 21, 22, 23 allow axial movement of the plunger 1 relative to the cylinder housing 2.

The three bearings 21, 22, 23 are all circular, seen in a direction parallel to the direction of movement of the plunger. Also, the bearings have mutually different diameters. More generally, the bearings have areas different from each other. In other words, circles formed by the circular shape of the bearing have areas different from each other. As a result, the effective area of the plunger 1 in the first and second chambers is different. In this example, the area a23 of the intermediate bearing 23 is greater than the area a22 of the second bearing 22. Further, the area a22 of the second bearing 22 is larger than the area a21 of the first bearing 21. Thus, in order for the plunger 1 to be in the rest position, a balance is made between the system pressure pS in the second chamber and the regulated pressure pA in the first chamber, which must be such that

pA*(A23-A21)＝pS*(A23-A22)+mp*g

Where mp is the mass of the plunger and g is the acceleration of gravity.

Referring also to fig. 2, fig. 2 depicts steps in the impacting process of the apparatus of fig. 1, including the impacting of the movable tool 4 against the workpiece W and the stationary tool 5.

Before the impact, the movable tool 4 rests S1 on top of the plunger 1. In addition, the movable tool 4 is at a distance from the fixed tool 5 before the impact. Thus, the plunger 1 and the movable tool 4 are in a position S1 referred to herein as the respective starting positions.

In this example, the first valve 11 is a four-way, three-position valve. Prior to impact, the first valve 11 is closed. Also, prior to impact, the second chamber 18 is subjected to the system pressure pS. At the same time, the second valve 12 is used to control the regulated pressure pA in the first chamber 17 to keep the plunger 1 in a fixed position, as described above. The second valve 12 is preferably a proportional valve. It will be appreciated that in order to keep the plunger 1 stationary, the regulated pressure pA of the first chamber 17 may be lower than the system pressure pS. Thus, the plunger can be held in its starting position.

The acceleration of the plunger 1 is influenced by adjusting the starting position of the plunger 1 and the system pressure pS.

The workpiece W is fixed S2 at the fixed tool 5 before being impacted by the movable tool 4. It will be appreciated that in the starting position, the movable tool 4 is at a distance from the workpiece W.

When the impact starts, the first valve 11 and the second valve 12 move to respective positions in which the respective ports P having the system pressure pS are connected with the respective ports a connected to the first chamber 17. Also in the first valve 11, in said position, the port B with the system pressure pS is connected to the port T, which is connected to the first chamber 17. As a result, the plunger 1 will be accelerated S3 toward the workpiece W by the movable tool 4. Thus, hydraulic fluid will flow from the second chamber 18 and the accumulator 13 to the first chamber 17. At the same time, second chamber 18 is provided with system pressure pS. The force F to move the plunger can be expressed as

F＝pS*(A22-A21)-mp*g

As described above, where a21 and a22 are the areas of the first bearing 21 and the second bearing 22, respectively.

During acceleration, the movable tool 4 remains resting on the plunger 1. Thus, the plunger and the movable tool are accelerated at the same simultaneous acceleration.

Subsequently, the plunger 1 decelerates S4 or brakes. The plunger deceleration is started before the movable tool 4 reaches the workpiece W. For plunger deceleration, the first valve 11 moves to the closed position. In addition, for deceleration of the plunger, the second valve 12 is controlled to reduce the delivery of hydraulic fluid towards the first chamber 17. Thus, the second valve 12 is controlled such that the delivery of hydraulic fluid towards the first chamber 17 is relatively low. However, said control of the second valve 12 is such that the delivery of hydraulic fluid towards the first chamber 17 is sufficiently high to avoid cavitation of the hydraulic fluid.

During deceleration, the second chamber 18 remains connected to the system pressure pS. The plunger 1 is provided with a waist 14, which waist 14 is arranged to enter the brake chamber 15 at the end of the second chamber 18. In this example, the brake chamber 15 is formed at an upper end of the second chamber 18. Thus, for deceleration of the plunger, the waist 14 enters the brake chamber 15. This traps hydraulic fluid in the brake chamber and the increased pressure in the trapped fluid will act to brake the plunger 1. Thus, the plunger speed may be reduced to zero.

When the plunger deceleration starts, the movable tool 4 is separated from the plunger 1S 5. The movable tool continues by its inertia S5 towards the workpiece W. In an embodiment of the invention, the speed of the movable tool 4 at this stage may be, for example, between 1-20 m/s. At this stage, the speed of the movable tool 4 may be, for example, higher than 10m/s, or even higher than 12 m/s. The speed of the movable tool 4 may be selected. The speed of the movable tool 4 may be selected to optimize the impact process.

The path of the movable tool 4 is controlled S5 by the guiding means 3. In this example, the guiding means comprise a plurality of pins fixed to the movable tool 4. Pins extend from the movable tool and through corresponding openings in the frame 7.

Subsequently, the movable tool collides with the workpiece S6, and the kinetic energy of the movable tool 4 shapes the workpiece W between the movable tool 4 and the fixed tool 5.

When the forming of the workpiece is completed, the movable tool 4 will spring back. It will be appreciated that when the forming of the workpiece is completed, the movable tool 4 will drop S7 towards the plunger 1. Thus, the movable tool will be guided by the guiding means 3.

In order to brake the return movement of the movable tool 4, a damping device 8 is provided when it approaches the plunger 1. In this example, the damping means comprises a damper mounted to the plunger 1. The damper is mounted on the top end of the plunger. The damper may be of any suitable type, for example hydraulic or pneumatic. Alternatively or additionally, the damper may comprise a resilient element, such as a leaf spring. In some embodiments, the damping device may comprise a damper mounted on the movable tool. In a further embodiment, the damping means may comprise a damper mounted on the frame 7. The damping means will effectively brake S8 the return movement of the movable tool. The damping means may also prevent the movable tool from bouncing at the end of its return movement. The movable tool 4 can thus be brought back to rest on the plunger in a controlled manner.

When the plunger 1 has stopped, the first valve 11 is closed. Thus, the second chamber is still subject to the system pressure pS. At the same time, the second valve 12 is used to control the regulated pressure pA in the first chamber 17 in order to move the plunger 1S 9 back to its starting position, whereby a subsequent plunger acceleration can be started.

In some embodiments, the tool contacts the plunger after the workpiece is formed and before the plunger is moved back to its starting position S9. However, in other embodiments, the plunger 1 may be moved back S9 to its starting position after the workpiece is formed and before the tool contacts the plunger. In further embodiments, the plunger 1 may be moved towards a portion of its starting position after the workpiece is formed and before the tool contacts the plunger.

The control unit CU is arranged to receive signals from one or more sensors (not shown). Thus, the signal received by the control unit CU may be indicative of one or more of the plunger position, the plunger speed, the plunger acceleration, the movable tool position, the movable tool speed, the movable tool acceleration, the adjusted pressure pA, one or more response times of the valve arrangement 11, 12 and the ambient temperature.

The control unit CU is arranged to register and/or process signals received during at least one impact procedure, preferably signals received during a plurality of impact procedures, more preferably signals received during each impact procedure. The processed or unprocessed signals are stored to form historical crash process data.

The control unit CU is further arranged to adjust the control of the valve arrangement 11, 12 during or during an impact process based on historical data and current sensor signals. Thus, the timing of valve actuation during impact can be accurate in view of conditions such as temperature and aging of the device.

It is to be understood that the invention is not limited to the embodiments described above and shown in the drawings; on the contrary, the skilled person will recognise that many variations and modifications are possible within the scope of the appended claims.

FIG. 3 illustrates an apparatus for high speed material forming and/or cutting according to another embodiment of the present invention. The same reference numerals are used for corresponding features shown and described with reference to fig. 1.

A tool, referred to herein as a securing tool (not shown), may be mounted to the anvil 6. The fastening means may be mounted on the underside of the anvil 6. Below the stationary tool is a movable tool 4, which will be described in more detail below. The tools have complementary surfaces facing each other. The workpiece W is detachably mounted on the fixing tool. The workpiece W may be mounted to the fixture in any suitable manner, for example, by clamping or by vacuum. The workpiece W may be of various types, such as a piece of sheet metal. The movable tool 4 is also referred to herein as the first tool. The securing means is also referred to herein as a second means. It should be noted that in some embodiments, the second tool may also be movable.

The drive assembly including the cylinder housing 2 is mounted to a frame (not shown). Furthermore, the drive assembly comprises a drive unit, hereinafter referred to as plunger 1, arranged in the cylinder housing 2. The plunger 1 is elongate and, as will be understood from the following description, has a varying width along its longitudinal axis. Preferably, any cross-section of the plunger is circular. The plunger 1 is arranged to move towards and away from a fixing tool, as described in more detail below.

The tool may be placed at a distance of at least 3mm from the tool material W before providing kinetic energy to the tool 4 by moving or accelerating the drive unit to impact the tool. Preferably, the tool is at a distance of at least 5mm from the workpiece material W. Most preferably, the tool is at a distance of at least 8mm from the workpiece material W.

The plunger 1 is arranged to be driven by a hydraulic system. Similar to the embodiment described with reference to fig. 1, the hydraulic system includes a first chamber for biasing the plunger toward the workpiece and a second chamber for biasing the plunger away from the workpiece. The first and second chambers are formed by the cylinder housing 2 and the plunger 1.

The hydraulic system described above with reference to the embodiment shown in fig. 1 may be applied to the drive unit shown in fig. 3.

When the movable plunger is driven towards the workpiece W, the plunger strikes the tool 4.

Similar to the embodiment in fig. 1, during deceleration the second chamber remains connected to the system pressure. The plunger 1 is provided with a waist 14, which waist 14 is arranged to enter a brake chamber 15 at the end of the second chamber. Thus, for deceleration of the plunger, the waist 14 enters the brake chamber 15. This traps hydraulic fluid in the brake chamber and the increased pressure in the trapped fluid will act to brake the plunger 1. Thus, the plunger speed may be reduced to zero.

When the plunger 1 hits the tool 4, the tool 4 may be separated from the plunger 1. The impact may be used to decelerate the plunger 1. When the plunger deceleration starts, the movable tool 4 is separated from the plunger 1. The movable tool continues to move toward the workpiece W by its inertia.

Similar to the embodiment in fig. 1, the path of the movable tool 4 is controlled by a guiding device. The guiding means may comprise a plurality of pins fixed to the movable tool 4. Pins extend from the movable tool and through corresponding openings in the frame.

In the embodiment shown in fig. 3, the guiding means for controlling the path of the movable tool 4 are not shown. In the embodiment shown in fig. 3, the tool 4 is arranged stationary, preferably controlled by the aforementioned guiding means, before the tool 4 is provided with kinetic energy by the movement of the drive unit 1. The apparatus is arranged to move the drive unit 1 to provide kinetic energy to the tool 4 by impacting the stationary tool 4 with the drive unit 1.

FIG. 4 illustrates an apparatus for high speed material forming and/or cutting according to yet another embodiment of the present invention. The same reference numerals are used for corresponding features shown and described with reference to fig. 1 and 3. A tool, referred to herein as a securing tool (not shown), may be mounted to the anvil 6. The fastening means may be mounted on the underside of the anvil 6. Below the stationary tool is a movable tool 4, which will be described in more detail below. The tools have complementary surfaces facing each other. The workpiece W is detachably mounted on the fixing tool. The workpiece W may be mounted to the fixture in any suitable manner, for example, by clamping or by vacuum. The workpiece W may be of various types, such as a piece of sheet metal. The movable tool 4 is also referred to herein as the first tool. The securing means is also referred to herein as a second means. It should be noted that in some embodiments, the second tool may also be movable.

In the embodiment of fig. 4, the drive unit is a rotary unit 1, the rotary unit 1 comprising a protrusion 101 fixed to a rotor 102. The projection 101 is rotated by the rotation of the rotor to provide kinetic energy to the tool 4. In this way, the projection will repeatedly strike the tool 4 for each revolution.

In the embodiment shown in fig. 4, the guiding means for controlling the path of the movable tool 4 are not shown, but guiding means similar to those of fig. 1 may be used. In the embodiment shown in fig. 4, the tool 4 is arranged stationary, preferably controlled by the aforementioned guiding means, before the tool 4 is provided with kinetic energy by the movement of the rotary unit 1. The apparatus is arranged to provide kinetic energy to the tool 4 by moving the rotary unit 1 by striking the tool 4 with projections protruding from the periphery of the rotary unit 1. When the rotation unit comprising the projections fixed to the rotor continues its rotation, the movable tool 4 is separated from the projections of the rotor. The movable tool 4 continues by its inertia towards the workpiece W. Thus, the tool 4 will be operatively separated from the rotary unit 1 before the tool 4 hits the workpiece material W. When the projection is in a position ready to strike the tool again for the next revolution of the rotor, the tool 4 is brought back to the fixed position, preferably controlled by the aforementioned guide means. For each revolution the protrusions will repeatedly hit the tool 4 until the rotating unit stops in a controlled manner.