Hybrid switching structure for wide-range profile boundary change and switching method thereof

Abstract

The invention relates to the technical field of mold switching, and discloses a mixed switching structure for wide-range profile boundary change, which comprises a pneumatic switching device mounted on an upper mold, a cover plate type switching device mounted on a lower mold, and a manual switching device, on-line switching of large-range profile boundary changes is achieved in the PC punching procedure, the PD shaping procedure and the PE finishing procedure. The invention further discloses a switching method of the hybrid switching structure for the wide-range profile boundary change. According to the hybrid switching structure for wide-range profile boundary change and the switching method thereof, three modes of pneumatic switching, cover plate type switching and online manual switching are comprehensively applied, quality reduction in the switching process caused by a traditional manual switching structure is avoided, the switching efficiency is effectively improved, and the labor cost is reduced.

Description

Technical Field

[0001] This invention relates to the field of mold switching technology, and specifically to a hybrid switching structure and switching method for large-scale surface boundary changes. Background Technology

[0002] In current automobile manufacturing, to accommodate the need for co-production of gasoline-powered and electric vehicles, the same vehicle platform often requires the production of various derivative products with fuel tank holes, charging holes, or no holes, using the same set of molds. Traditional switching methods are mainly limited to whether or not small holes are available on the same profile, and usually involve manually disassembling and assembling punches or inserts.

[0003] However, when dealing with large-scale surface boundary changes such as fuel tank openings and charging ports, traditional methods have significant drawbacks: 1. The switching process relies on manual operation and takes a long time (approximately 20 minutes per session). 2. Repeated disassembly and reassembly cause the positioning pin holes to become rough and loose, leading to misalignment of the inserts; 3. Large areas of voids on the lower model surface lack support due to the absence of holes, causing the part surface to collapse and resulting in a rework rate as high as 20%. 4. The shaping and finishing processes are difficult to automate, which seriously affects production efficiency and product quality consistency. Summary of the Invention

[0004] The purpose of this invention is to address the shortcomings of the aforementioned technologies by providing a hybrid switching structure and switching method for large-scale surface boundary changes. This invention integrates pneumatic switching, cover plate switching, and online manual switching, avoiding the quality degradation of the switching process caused by traditional manual switching structures, effectively improving switching efficiency, and reducing labor costs.

[0005] To achieve the above objectives, the present invention designs a hybrid switching structure for large-scale surface boundary changes, comprising a pneumatic switching device mounted on the upper die, a cover plate-type switching device mounted on the lower die, and a manual switching device. This structure enables online switching for large-scale surface boundary changes during the PC punching process, PD shaping process, and PE finishing process. The pneumatic switching device is applied to the upper die pre-punching punch in the PC punching process, the upper die shaping punch in the PD shaping process, and the upper die finishing punch in the PE finishing process. It controls the retraction or extension state of the upper die pre-punching punch, the upper die shaping punch, and the upper die finishing punch to achieve the switching between the state with holes and without holes. The cover plate switching device is applied to the lower mold shaping insert in the PD shaping process. Taking the perforated lower mold shaping insert as a reference, a detachable non-perforated cover plate is installed on top of it. The switching between the perforated and non-perforated states is achieved by installing or removing the non-perforated cover plate. The online manual switching device is used for the pre-punching insert of the lower die and the skylight insert of the upper die in the PC punching process, the skylight insert of the upper die in the PD shaping process, and the skylight insert of the upper die and the fine-finishing insert of the lower die in the PE finishing process. The switching is achieved by manually installing or removing the corresponding insert.

[0006] Preferably, the pneumatic switching device is equipped with a pneumatic switching fixing plate. The up and down movement of the pneumatic switching fixing plate controls the retraction or extension state of the upper die pre-punching punch, the upper die shaping punch, and the upper die finishing punch, thereby realizing the switching between the state with holes and the state without holes.

[0007] A switching method for a hybrid switching structure with a wide range of surface boundary changes, when switching between perforated and non-perforated states: In the PC punching process, the upper die pre-punching punch is switched between retracted and extended states by a pneumatic switching device. The upper die sunroof insert moves up and down with the pneumatic switching device, while the lower die pre-punching insert does not switch. In the PD shaping process, the upper mold shaping punch is switched between retracted and extended states by a pneumatic switching device. The lower mold shaping insert is switched between having holes and not having holes by installing or removing the holeless cover plate. The upper mold sunroof insert is switched by an online manual switching device. In the PE finishing process, the upper die finishing punch is switched between retracted and extended states by a pneumatic switching device, and the lower die finishing insert and the upper die skylight insert are switched by an online manual switching device.

[0008] Preferably, in the PC punching process, the pre-punched hole does not cross the feature edge line, the surrounding process surface is greater than 120mm, and the hole diameter does not exceed 220mm.

[0009] Preferably, in the PC punching process, for the lower die pre-punching insert, different lower die pre-punching inserts are provided for pre-punching holes of different diameters. The installation space remains unchanged, and they share screw holes and grouped pin holes. When switching between the state with holes and the state without holes, the state with holes is directly saved. When switching between different hole diameters, the lower die pre-punching insert is switched by an online manual switching device.

[0010] Preferably, in the PC punching process, for the upper die sunroof insert, different upper die sunroof inserts are provided for pre-punching holes of different diameters. The installation space remains unchanged, and they share screw holes and grouped pin holes. At the same time, they are designed to avoid large holes. The lower die pre-punching insert has the fixing screw holes and positioning pin holes designed inside the cutting edge. When switching between the state with holes and without holes, the upper die sunroof insert moves up and down with the pneumatic switching device. When switching between different hole diameters, the upper die sunroof insert is switched by an online manual switching device.

[0011] Preferably, in the PD shaping process, for the lower die shaping insert, different lower die shaping inserts are provided for pre-punched holes of different diameters. The installation space remains unchanged, and they share screw holes and grouped pin holes. When switching between the hole-containing and hole-free states, the hole-containing lower die shaping insert is retained, and the hole-free cover plate is installed and removed to achieve the switching between the hole-containing and hole-free states. When switching between different hole diameters, the lower die shaping insert is switched by an online manual switching device.

[0012] Preferably, in the PD shaping process, for the upper mold sunroof insert, different upper mold sunroof inserts are provided for pre-punched holes of different diameters. The installation space remains unchanged, and they share screw holes and grouped pin holes. At the same time, they are designed to avoid large holes. The lower mold shaping insert has the fixing screw holes and positioning pin holes designed inside the cutting edge. When switching between the state with holes and without holes, the upper mold sunroof insert moves up and down with the pneumatic switching device. When switching between different hole diameters, the upper mold sunroof insert is switched by an online manual switching device.

[0013] Preferably, in the PE finishing process, for the lower die finishing insert, different lower die finishing inserts are provided for pre-punched holes of different diameters. The installation space remains unchanged, and they share screw holes and grouped pin holes. When switching between the hole-containing and hole-free states, the hole-containing lower die finishing insert is retained, and the hole-free cover plate is installed and removed to achieve the switching between the hole-containing and hole-free states. When switching between different hole diameters, the lower die finishing insert is switched by an online manual switching device.

[0014] Preferably, in the PE finishing process, for the upper mold sunroof insert, different upper mold sunroof inserts are provided for pre-punched holes of different diameters, with the installation space remaining unchanged, sharing screw holes and grouped pin holes, while avoiding large holes in the design. The lower mold finishing insert has the fixing screw holes and positioning pin holes designed inside the cutting edge. When switching between the state with holes and without holes, the upper mold sunroof insert is switched by an online manual switching device. When switching between different hole diameters, the upper mold sunroof insert is switched by an online manual switching device.

[0015] Compared with the prior art, the present invention has the following advantages: 1. It solves the problem that traditional switching can only switch between having holes and not having holes under the same surface, and realizes online switching of molds in the later process for the production of a wide range of products with different surface variations; 2. By adopting a hybrid switching method for products with a wide range of surface changes, the switchable range is expanded and the mold development cost is reduced; 3. Reduce the decline in the appearance quality of parts caused by switching, reduce the rework rate of defective products, and reduce rework costs; 4. Reduced switching time and improved work efficiency. Detailed Implementation

[0016] The technical solution of the present invention will be clearly and completely described below with reference to specific embodiments. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0017] When producing different types of products for traditional side panel parts, the upper die for punching small holes can be pneumatically switched, while other parts are switched manually. The lower die often uses manual switching of inserts. Repeated manual operations inevitably lead to roughening, loosening, and misalignment of the positioning pin holes. Misalignment is the main cause of quality defects.

[0018] This embodiment presents a hybrid switching structure for large-scale surface boundary changes, including a pneumatic switching device mounted on the upper die, a cover plate-type switching device mounted on the lower die, and a manual switching device. It enables online switching for large-scale surface boundary changes during PC punching, PD shaping, and PE finishing processes. The pneumatic switching device is applied to the upper die pre-punching punch in the PC punching process, the upper die shaping punch in the PD shaping process, and the upper die finishing punch in the PE finishing process. It controls the retraction or extension state of the upper die pre-punching punch, the upper die shaping punch, and the upper die finishing punch to achieve the switching between the state with holes and without holes. The cover plate switching device is applied to the lower mold shaping insert in the PD shaping process. Taking the perforated lower mold shaping insert as a reference, a detachable non-perforated cover plate is installed on top of it. The switching between the perforated and non-perforated states is achieved by installing or removing the non-perforated cover plate. The online manual switching device is used for the pre-punching insert of the lower die and the skylight insert of the upper die in the PC punching process, the skylight insert of the upper die in the PD shaping process, and the skylight insert of the upper die and the fine-finishing insert of the lower die in the PE finishing process. The switching is achieved by manually installing or removing the corresponding insert.

[0019] The pneumatic switching device is equipped with a pneumatic switching fixing plate. The up and down movement of the pneumatic switching fixing plate controls the retraction or extension of the upper die pre-punching punch, upper die shaping punch and upper die finishing punch, so as to realize the switching between the state with holes and the state without holes.

[0020] This embodiment is used for switching between perforated and non-perforated states in a hybrid switching structure with a large range of surface boundary changes: In the PC punching process, the upper die pre-punching punch is switched between retracted and extended states by a pneumatic switching device. The upper die sunroof insert moves up and down with the pneumatic switching device, while the lower die pre-punching insert does not switch. In the PD shaping process, the upper mold shaping punch is switched between retracted and extended states by a pneumatic switching device. The lower mold shaping insert is switched between having holes and not having holes by installing or removing the holeless cover plate. The upper mold sunroof insert is switched by an online manual switching device. In the PE finishing process, the upper die finishing punch is switched between retracted and extended states by a pneumatic switching device, and the lower die finishing insert and the upper die skylight insert are switched by an online manual switching device.

[0021] This embodiment reduces manual switching operations by using a pneumatic switching + cover plate switching design, thereby reducing the occurrence of roughening, loosening, and misalignment of the positioning pin holes.

[0022] Specifically, in this embodiment, during the PC punching process, for features such as oil tank holes / charging holes with or without flanges, and side panels and fenders without holes, the pre-punching holes do not cross the feature ridge line, the surrounding process surface is greater than 120mm, and the hole diameter does not exceed 220mm.

[0023] In the PC punching process, the upper die is pneumatically switched, and the lower die is in the punching state. This embodiment involves the application of a set of side panel trimming and punching dies for oil tank holes and charging holes, which are divided into those with holes and those without holes, corresponding to designs with the same pre-punched hole diameter and those with different hole diameters.

[0024] For the lower die pre-punching insert, different lower die pre-punching inserts are provided for pre-punching holes of different diameters. The installation space remains unchanged. They share screw holes and grouped pin holes. When switching between the state with holes and the state without holes, the state with holes is directly saved. When switching between different hole diameters, the lower die needs to discharge waste material, so the lower die pre-punching insert is switched through an online manual switching device.

[0025] For the upper mold sunroof insert, different upper mold sunroof inserts are provided for pre-punched holes of different diameters. The installation space remains unchanged, and they share screw holes and grouped pin holes. At the same time, they are designed to avoid large holes. The lower mold pre-punched hole insert has the fixing screw holes and positioning pin holes designed inside the cutting edge. This can facilitate online switching and shorten the switching time. When switching between the state with holes and without holes, the upper mold sunroof insert moves up and down with the pneumatic switching device. When switching between different hole diameters, the upper mold sunroof insert is switched through the online manual switching device.

[0026] In the PD shaping process, there are oil tank hole / no hole, charging hole / no hole, and oil tank hole / charging hole / no hole. The surface with holes is different from the PC punching process, while the surface without holes is the same as the PC punching process. A hybrid switching method is adopted to solve the problem of large-scale surface boundary changes and reduce switching operations in one mold to achieve the production of different products.

[0027] The shaping of the fuel tank hole and charging hole causes a downward slope to the non-perforated surface. The upper mold shaping insert can only be used for one product, ensuring no interference occurs during the movement of the upper and lower molds. Manual removal or pneumatic lifting of the upper mold shaping insert will not affect the production of non-perforated products. However, the large open area of ​​the lower mold shaping insert will cause the surface to collapse and reduce quality when producing non-perforated products. The lower mold uses shared screws for switching between two different surface inserts, and the use of different groups of locating pin holes involves frequent switching operations. When the non-perforated surface insert is installed above the perforated surface, only the non-perforated cover plate needs to be installed to indicate no perforation, and removing the cover plate indicates perforation, making the operation clear and preventing quality degradation.

[0028] Specifically, for the lower die shaping insert, different lower die shaping inserts are provided for pre-punched holes of different diameters. The installation space remains unchanged, and they share screw holes and grouped pin holes. When switching between the hole-containing and hole-free states, the hole-containing lower die shaping insert is retained, and the hole-free cover plate is installed and removed to achieve the switching between the hole-containing and hole-free states. When switching between different hole diameters, the lower die shaping insert is switched through an online manual switching device because the shaping boundary of the lower die is different.

[0029] For the upper mold sunroof insert, different upper mold sunroof inserts are provided for pre-punched holes of different diameters. The installation space remains unchanged, and they share screw holes and grouped pin holes. At the same time, they are designed to avoid large holes. The lower mold shaping insert has the fixing screw holes and positioning pin holes designed inside the cutting edge. When switching between the hole-containing and hole-free states, the upper mold sunroof insert moves up and down with the pneumatic switching device. The stroke of the pneumatic fixing plate is considered based on the shaping amount (generally 10~15mm) + 10mm. When switching between different hole diameters, the upper mold cannot exist at the same time. The upper mold sunroof insert is switched by an online manual switching device.

[0030] In the PE finishing process, issues arise involving fuel tank holes / no holes, charging holes / no holes, and fuel tank holes / charging holes / no holes. After molding, the boundaries of holes are finished to ensure dimensional tolerances. A hybrid switching method is used to produce different products. Fuel tank holes and charging holes are shaped and then finished. The upper mold finishing insert can only be used for one product. The upper mold sunroof insert has a significantly different profile for holes and no holes, ensuring no interference during the movement of the upper and lower molds. Manual removal or pneumatic lifting of the upper mold finishing insert will not affect the production of holes-free products; however, the upper mold sunroof insert must be switched manually. However, large openings in the lower mold finishing insert can cause the profile to collapse and degrade quality when producing holes-free products. The switching between the two different profile inserts in the lower mold can be achieved using the same method as the PD shaping process.

[0031] Specifically, for the lower die finishing insert, different lower die finishing inserts are provided for pre-punched holes of different diameters. The installation space remains unchanged, and they share screw holes and grouped pin holes. When switching between the hole-containing and hole-free states, the hole-containing lower die finishing insert is retained, and the hole-free cover plate is installed and removed to achieve the switching between the hole-containing and hole-free states. When switching between different hole diameters, the lower die finishing insert is switched by an online manual switching device.

[0032] For the upper mold sunroof insert, different upper mold sunroof inserts are provided for pre-punched holes of different diameters. The installation space remains unchanged, and they share screw holes and grouped pin holes. At the same time, they are designed to avoid large holes. The lower mold finishing insert has the fixing screw holes and positioning pin holes designed inside the cutting edge. This allows for convenient online switching. Whether it is manual or pneumatic switching, the switching time is shortened. When switching between the state with holes and without holes, the upper mold sunroof insert is switched through the online manual switching device. When switching between different hole diameters, the upper mold sunroof insert is switched through the online manual switching device.

[0033] This invention innovates upon traditional manual switching technology for producing various parts, and after multiple rounds of field testing and refinement, proposes a hybrid switching structure and method for handling large-scale surface boundary changes. This solves the problems of poor part quality, excessive rework, and even part scrapping caused by switching on parts with large surface boundary changes, such as fuel tank holes and charging holes, as well as low switching efficiency. It also addresses the limitations of traditional switching methods, which only allow switching between parts with and without holes on the same surface. This invention expands the switchable range, employing a hybrid switching method for products with large surface changes, effectively reducing part rework costs, as shown in the table below: It should be noted that the above description of the technical solutions is exemplary, and this specification may be embodied in different forms and should not be construed as limiting it to the technical solutions set forth herein. Rather, providing these descriptions will ensure that the disclosure of this invention is thorough and complete, and will fully convey the scope of this specification to those skilled in the art. Furthermore, the technical solutions of this invention are defined only by the scope of the claims. Features of various embodiments of this invention may be combined or spliced ​​together in part or in whole, and may be implemented in various different configurations as will be fully understood by those skilled in the art. Embodiments of this invention may be implemented independently of each other or may be implemented together in an interdependent relationship.

[0034] For those skilled in the art, several simple deductions or substitutions can be made without departing from the concept of the present invention, and the above structures should all be considered to fall within the protection scope of the present invention.

Claims

1. A hybrid switching structure for large-scale surface boundary changes, characterized in that: This includes a pneumatic switching device mounted on the upper die, a cover plate-type switching device mounted on the lower die, and a manual switching device, enabling online switching of large-scale surface boundary changes in the PC punching process, PD shaping process, and PE finishing process. The pneumatic switching device is applied to the upper die pre-punching punch in the PC punching process, the upper die shaping punch in the PD shaping process, and the upper die finishing punch in the PE finishing process. It controls the retraction or extension state of the upper die pre-punching punch, the upper die shaping punch, and the upper die finishing punch to achieve the switching between the state with holes and without holes. The cover plate switching device is applied to the lower mold shaping insert in the PD shaping process. Taking the perforated lower mold shaping insert as a reference, a detachable non-perforated cover plate is installed on top of it. The switching between the perforated and non-perforated states is achieved by installing or removing the non-perforated cover plate. The online manual switching device is used for the pre-punching insert of the lower die and the skylight insert of the upper die in the PC punching process, the skylight insert of the upper die in the PD shaping process, and the skylight insert of the upper die and the fine-finishing insert of the lower die in the PE finishing process. The switching is achieved by manually installing or removing the corresponding insert.

2. The hybrid switching structure for large-scale surface boundary changes as described in claim 1, characterized in that: The pneumatic switching device is equipped with a pneumatic switching fixing plate. The up and down movement of the pneumatic switching fixing plate controls the retraction or extension of the upper die pre-punching punch, upper die shaping punch and upper die finishing punch, so as to realize the switching between the state with holes and the state without holes.

3. A switching method for a hybrid switching structure with a large range of surface boundary changes as described in claim 1, characterized in that: When switching between the state with and without holes: In the PC punching process, the upper die pre-punching punch is switched between retracted and extended states by a pneumatic switching device. The upper die sunroof insert moves up and down with the pneumatic switching device, while the lower die pre-punching insert does not switch. In the PD shaping process, the upper mold shaping punch is switched between retracted and extended states by a pneumatic switching device. The lower mold shaping insert is switched between having holes and not having holes by installing or removing the holeless cover plate. The upper mold sunroof insert is switched by an online manual switching device. In the PE finishing process, the upper die finishing punch is switched between retracted and extended states by a pneumatic switching device, and the lower die finishing insert and the upper die skylight insert are switched by an online manual switching device.

4. The switching method for a hybrid switching structure with a large range of surface boundary changes as described in claim 3, characterized in that: In the PC punching process, the pre-punched hole does not cross the feature edge line, the surrounding process surface is greater than 120mm, and the hole diameter does not exceed 220mm.

5. The switching method for a hybrid switching structure with a large range of surface boundary changes as described in claim 3, characterized in that: In the PC punching process, for the lower die pre-punching insert, different lower die pre-punching inserts are provided for pre-punching holes of different diameters. The installation space remains unchanged, and they share screw holes and grouped pin holes. When switching between the state with holes and the state without holes, the state with holes is directly saved. When switching between different hole diameters, the lower die pre-punching insert is switched through an online manual switching device.

6. The switching method for a hybrid switching structure with a large range of surface boundary changes as described in claim 3, characterized in that: In the PC punching process, for the upper die sunroof insert, different upper die sunroof inserts are provided for pre-punching holes of different diameters. The installation space remains unchanged, and they share screw holes and grouped pin holes. At the same time, they are designed to avoid large holes. The lower die pre-punching insert has the fixing screw holes and positioning pin holes designed inside the cutting edge. When switching between the state with holes and without holes, the upper die sunroof insert moves up and down with the pneumatic switching device. When switching between different hole diameters, the upper die sunroof insert is switched by an online manual switching device.

7. The switching method for a hybrid switching structure with a large range of surface boundary changes as described in claim 3, characterized in that: In the PD shaping process, for the lower die shaping insert, different lower die shaping inserts are provided for pre-punched holes of different diameters. The installation space remains unchanged, and they share screw holes and grouped pin holes. When switching between the hole-containing and hole-free states, the hole-containing lower die shaping insert is retained, and the hole-free cover plate is installed and removed to achieve the switching between the hole-containing and hole-free states. When switching between different hole diameters, the lower die shaping insert is switched by an online manual switching device.

8. The switching method for a hybrid switching structure with a large range of surface boundary changes as described in claim 3, characterized in that: In the PD shaping process, for the upper mold sunroof insert, different upper mold sunroof inserts are provided for pre-punched holes of different diameters. The installation space remains unchanged, and they share screw holes and grouped pin holes. At the same time, they are designed to avoid large holes. The lower mold shaping insert has the fixing screw holes and positioning pin holes designed inside the cutting edge. When switching between the state with holes and without holes, the upper mold sunroof insert moves up and down with the pneumatic switching device. When switching between different hole diameters, the upper mold sunroof insert is switched by an online manual switching device.

9. The switching method for a hybrid switching structure with a large range of surface boundary changes as described in claim 3, characterized in that: In the PE finishing process, for the finishing insert of the lower mold, different finishing inserts are provided for pre-punched holes of different diameters. The installation space remains unchanged, and they share screw holes and grouped pin holes. When switching between the state with holes and the state without holes, the lower mold finishing insert with holes is retained, and the cover plate without holes is installed and removed to achieve the switching between the state with holes and the state without holes. When switching between different hole diameters, the finishing insert of the lower mold is switched by an online manual switching device.

10. The switching method for a hybrid switching structure with a large range of surface boundary changes as described in claim 3, characterized in that: In the PE finishing process, for the upper mold sunroof insert, different upper mold sunroof inserts are provided for pre-punched holes of different diameters. The installation space remains unchanged, and they share screw holes and grouped pin holes. At the same time, they are designed to avoid large holes. The lower mold finishing insert has the fixing screw holes and positioning pin holes designed inside the cutting edge. When switching between the state with holes and without holes, the upper mold sunroof insert is switched by an online manual switching device. When switching between different hole diameters, the upper mold sunroof insert is switched by an online manual switching device.

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