Research Press

Abstract

A method of simulating loading of an area on a workpiece in a production line type process. Also, a simulation press having a main body and an actuator attached thereto. The actuator is substantially aligned with the main body. A first plate is coupled to the main body and a second plate is coupled to the actuator. Both plates are adapted to engage a workpiece so as to simulate various modes of deformation of an area or areas on the workpiece when the second plate is moved relative to the first plate. The simulation press further includes a drive controller for controlling operation of the actuator. The drive controller additionally responds to feedback from at least one feedback sensor included with the simulation press.

1 . A method of simulating loading of an area on a workpiece in a production line type process comprising the steps:
 providing a workpiece comprising at least one layer;   providing a first plate having a first surface, the first plate being operably coupled to a base;   providing a second plate having a second surface, the second plate being operably coupled to an armature of an actuator, the actuator being further coupled to the base such that the direction of movement of the armature of the actuator is substantially axially aligned with a longitudinal axis of symmetry of the base and generally lies in the same plane as the base; and   moving one of the first and second plates relative to the other of the first and second plates such that the first and second surfaces compress a point site on the workpiece so as to simulate compression loading of a point site on a workpiece in a production line type process.   
     
     
         2 . The method of simulating loading of an area on a workpiece in a production line type process as set forth in  claim 1 , further including active gap control comprising providing one or more sensors comprising at least one of:
 at least one sensor for measuring the gap between the first plate and the second plate;   at least one sensor for measuring the load of at least one of the first and second plates; and   at least one sensor for measuring the inertial force of at least one of the first and second plates;   wherein the one or more sensors provide feedback for determining accurate gap measurement of a gap between the first and second plates.   
     
     
         3 . The method of simulating loading of an area on a workpiece in a production line type process as set forth in  claim 1 , wherein the first surface of the first plate comprises one of a substantially planar surface for simulating an anvil roll and at least one protuberance for simulating a production line type process and the second surface of the second plate comprises one of a substantially planar surface for simulating an anvil roll and at least one protuberance for simulating a production line type process. 
     
     
         4 . The method of simulating loading of an area on a workpiece in a production line type process as set forth in  claim 1 , further comprising:
 determining a motion trajectory profile for one of the first and second plates based on a desired loading gap profile between the first and second plates;   generally measuring an actual gap profile between the first and second plates during loading;   determining a second motion trajectory profile based on the desired loading gap profile and the actual gap profile.   
     
     
         5 . The method of simulating loading of an area on a workpiece in a production line type process as set forth in  claim 4 , wherein determining the second motion trajectory profile comprises determining a motion trajectory profile error based on the desired loading gap profile and the actual gap profile and the motion trajectory profile error is the difference of the desired loading gap profile and the actual gap profile. 
     
     
         6 . The method of simulating loading of an area on a workpiece in a production line type process as set forth in  claim 5 , wherein the second motion trajectory profile is determined based on at least a portion of the total value of the profile error.