Nonwoven reinforced plastic mat punch press die

Abstract

The present application relates to the technical field of stamping die, and discloses a non-woven fabric reinforced plastic pad stamping die, which comprises an upper die unit, a lower die unit and a blockage prevention system; the lower die unit comprises a lower die main body, the lower die main body is sequentially provided with a punching station and a blanking station along the feeding direction of the material belt, and the lower die main body is provided with a blanking channel which is in communication with the lower part of the punching station and the blanking station respectively; the blockage prevention system comprises a blowing execution module which is correspondingly arranged in the blanking channel, a gas supply module which is used for providing a gas source for the blowing execution module and a control module. The blockage prevention system is provided, the blowing unit and the posture sensing unit which are arranged in a high-low staggered manner work cooperatively, the accurate positioning and directional blowing of the jammed material are realized, only the downward thrust is applied from the upper part of the material, the reverse airflow is completely avoided, the success rate of breaking the jam is high, and long-time continuous unmanned production can be realized.

Description

Technical Field

[0001] This invention relates to the field of stamping die technology, and more specifically, to a stamping die for a nonwoven-reinforced plastic pad. Background Technology

[0002] Non-woven reinforced plastic gaskets are functional gaskets made with engineering plastics such as polypropylene, polyethylene, and polyamide as the matrix and composite non-woven fabric reinforcement layers. They are widely used in automotive sealing, electronic equipment vibration damping, and bathroom waterproofing. The production of these gaskets typically employs a two-station progressive stamping die. The process flow is as follows: the first station punches the inner hole of the gasket, generating punching waste; the second station blanks the outer diameter of the gasket, forming the finished gasket; the waste and finished product fall into a collection bin through corresponding blanking channels, thus achieving continuous production.

[0003] However, in actual continuous stamping operations, due to the characteristics of non-woven reinforced composite materials, such as easily exposed fiber burrs, light weight, thin walls, and susceptibility to static electricity, the stamped material is prone to jamming and clogging in the material feeding channel. Specifically, the non-woven fibers remaining at the edge of the gasket easily get caught on the inner wall of the channel, while the electrostatic adsorption effect causes the material to adhere to the hole wall, resulting in various abnormal postures such as horizontal jamming and tilting jamming, which seriously hinders the material from falling freely under gravity.

[0004] To address the aforementioned jamming and clogging issues, existing technologies have developed solutions that utilize air blowing to assist material feeding. While air blowing can alleviate clogging to some extent, it still has significant technical drawbacks in practical applications. On the one hand, existing air-blowing structures generally adopt a fixed-position, synchronous air-blowing working mode. Due to the randomness and uncertainty of the specific height of the material stuck and its blocking posture in the channel, this fixed synchronous air-blowing mode is difficult to achieve precise adaptation. When the material is stuck above some air-blowing ports while the other air-blowing ports are below the material, opening all air-blowing ports simultaneously can easily create turbulent airflows with opposing forces in a local area of ​​the material drop channel, and even create an air cushion layer under the material, thereby applying a reverse pushing force to the material, resulting in an unfavorable working condition where the more air is blown, the more stuck the material becomes. On the other hand, existing solutions lack the ability to identify the specific posture of the material stuck, and cannot distinguish between different states such as horizontal stuckness and tilted stuckness. They can only adopt a single, fixed air-blowing strategy for intervention. For materials that are tilted and stuck, due to the uneven distribution of contact stress between the material and the inner wall of the channel, the uniform air-blowing mode is often unable to effectively break the stuckness, and the actual removal effect is not ideal. Summary of the Invention

[0005] The purpose of this invention is to provide a non-woven reinforced plastic pad stamping die to solve the aforementioned technical problems.

[0006] The present invention solves the above-mentioned technical problems through the following technical solutions: This invention provides a non-woven reinforced plastic pad stamping die, comprising: an upper die unit, a lower die unit, and an anti-clogging system; The lower die unit includes a lower die body, and the lower die body is provided with a punching station and a blanking station in sequence along the material feeding direction of the strip. The bottom of the lower die body is provided with a blanking channel that is connected to the lower part of the punching station and the blanking station respectively. The anti-blocking system includes an air blowing execution module correspondingly installed in the material discharge channel, an air supply module for providing air to the air blowing execution module, and a control module; Each of the air blowing execution modules includes an attitude sensing unit and multiple air blowing units; The attitude sensing unit is used to detect the stuck attitude information of the material falling into the material feeding channel. Multiple air blowing units are distributed circumferentially along the hole wall of the material discharge channel. Each air blowing unit is arranged in a staggered manner along the material discharge direction. The air blowing direction of each air blowing unit is towards the center of the material discharge channel and has a downward tilt angle. The control module is electrically connected to the attitude sensing unit and each air blowing unit, and is configured as follows: Based on the material jamming posture information detected by the posture sensing unit, at least one target blowing unit located above the highest edge of the jammed material is identified, and only the target blowing unit is driven to perform blowing action, while the remaining blowing units located below the highest edge of the jammed material remain closed.

[0007] Preferably, each of the air blowing execution modules includes at least four air blowing units evenly distributed circumferentially along the hole wall of the material dropping channel, and the installation height of two adjacent air blowing units is different along the material dropping direction, so that the air blowing range of the air blowing execution module covers different height ranges of the material dropping channel.

[0008] Preferably, each of the air blowing units includes an air blowing nozzle and a solenoid valve for controlling the on / off state of the air blowing nozzle. The air blowing nozzle is installed in a countersunk hole type, and its air outlet is flush with the inner wall of the material discharge channel.

[0009] Preferably, the air nozzle located below the unloading station has a flat fan-shaped air outlet, while the air nozzle located below the punching station has a circular air outlet.

[0010] Preferably, each of the material discharge channels is composed of an integrated material discharge insert, the inner wall surface of which is provided with an antistatic coating; the multiple air blowing units and attitude sensing units are all embedded in the hole wall of the integrated material discharge insert.

[0011] Preferably, the attitude sensing unit includes at least four through-beam sensors, each of which is disposed in a horizontal plane corresponding to an air blowing unit at a different height position.

[0012] Preferably, the air supply module includes an air path drive unit connected to each air blowing unit, and each air path drive unit includes an electric proportional pressure reducing valve for adjusting the air blowing pressure; the control module is electrically connected to the electric proportional pressure reducing valve and is used to adjust the air blowing pressure in real time according to the type of material to be processed or the detected jamming state.

[0013] Preferably, the upper die unit includes an upper die body and a punching punch and a blanking punch corresponding to the punching station and blanking station, respectively, and the upper die body is connected to an external stamping drive mechanism.

[0014] Preferably, the control module is further configured to: activate the attitude sensing unit to detect and drive the air blowing unit to operate within the blanking window period defined after the upper die unit returns to the preset safe position, while keeping all air blowing units closed during the punching and holding pressure stage.

[0015] Preferably, the control module is further configured to: control the air blowing unit to execute different air blowing strategies based on the severity of material jamming identified by the attitude sensing unit; the air blowing strategies include at least a constant pressure continuous air blowing mode and a high-frequency pulse air blowing mode.

[0016] The beneficial effects of this invention are as follows: The anti-blocking system of this invention achieves precise positioning and directional air blowing of stuck materials through the coordinated work of air blowing units arranged at different heights and attitude sensing units. It applies downward thrust only from above the material, completely avoiding the impact of reverse airflow, resulting in a high success rate in breaking the blockage and enabling long-term continuous unmanned production. Secondly, by combining with timing control, the present invention activates air blowing only during the blanking window period after the punch returns to the safe position. During the blanking and pressure holding stage, the air blowing system is completely locked, and no airflow enters the die cutting edge area, ensuring the positioning accuracy of the strip and meeting the coaxiality requirements of high-precision sealing gaskets. In addition, the attitude sensing unit set in this invention can identify various stuck attitudes such as horizontal, tilted, and eccentric. The control module selects the corresponding air blowing unit and air blowing strategy according to the detection results, which can be adapted to the production of non-woven reinforced plastic gaskets of different thicknesses and specifications. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the overall structure of a non-woven fabric reinforced plastic pad stamping die according to the present invention; Figure 2This is a side view of a non-woven reinforced plastic pad stamping die according to the present invention; Figure 3 This is a sectional view of the side of a nonwoven reinforced plastic pad stamping die according to the present invention; Figure 4 This is the present invention. Figure 3 A magnified view of a portion of point A in the middle; Figure 5 This is a schematic diagram of the control logic of the control module in a non-woven reinforced plastic pad stamping die of the present invention; Figure 6 This is a flowchart illustrating the process of a nonwoven reinforced plastic pad stamping die according to the present invention.

[0018] In the diagram: 10. Upper die unit; 101. Upper die body; 102. Punching punch; 103. Blanking punch; 20. Lower die unit; 201. Lower die body; 202. Punching station; 203. Blanking station; 204. Blanking channel; 30. Air blowing execution module; 301. Air blowing nozzle; 302. Solenoid valve; 303. Through-beam sensor; 40. Air supply module; 50. Non-woven reinforced plastic strip. Detailed Implementation

[0019] The subject matter described herein will now be discussed with reference to exemplary embodiments. It should be understood that these embodiments are discussed only to enable those skilled in the art to better understand and implement the subject matter described herein, and changes may be made to the function and arrangement of the elements discussed without departing from the scope of this specification. Various processes or components may be omitted, substituted, or added as needed in the examples. Furthermore, features described in some examples may be combined in other examples.

[0020] Please refer to the following: Figures 1 to 6 A non-woven reinforced plastic pad stamping die includes: an upper die unit 10, a lower die unit 20, and an anti-clogging system.

[0021] The lower die unit 20 includes a lower die body 201. Along the material feeding direction of the strip, the lower die body 201 has a punching station 202 and a blanking station 203 arranged sequentially from left to right. A punching die is installed at the punching station 202, and a blanking die is installed at the blanking station 203. The bottom of the lower die body 201 has blanking channels 204 that communicate with the lower parts of the punching station 202 and the blanking station 203, respectively, for waste material blanking and finished product blanking. The two blanking channels 204 are independent of each other and are respectively connected to a waste material collection bin and a finished product collection bin.

[0022] The upper die unit 10 includes an upper die body 101, on which a punching punch 102 and a blanking punch 103, corresponding to the punching station 202 and the blanking station 203, are respectively mounted. The upper die body 101 is connected to an external stamping drive mechanism (not shown in the figure) and performs up-and-down reciprocating motion under the drive of the stamping drive mechanism.

[0023] The anti-blocking system includes an air blowing execution module 30 installed in the material discharge channel 204, an air supply module 40 for providing air to the air blowing execution module 30, and a control module.

[0024] The air blowing execution module 30 includes an attitude sensing unit and multiple air blowing units. The multiple air blowing units are distributed circumferentially along the wall of the blanking channel 204. In this embodiment, there are four air blowing units, evenly distributed at 90° angles along the circumference. These four air blowing units are arranged in a staggered manner along the blanking direction (vertically downward). Specifically, taking the lower edge of the blanking die cutting edge as the height reference 0, the installation heights of adjacent air blowing units are different, with a height difference of 15-25mm being suitable; in this embodiment, 25mm is preferred. For example, the installation heights of the four air blowing units are H1=20mm, H2=45mm, H3=70mm, and H4=95mm, respectively. The air blowing direction of each air blowing unit is towards the central axis of the blanking channel 204, and has a downward tilt angle, with a suitable tilt angle of 30°-35°; in this embodiment, 35° is preferred.

[0025] Specifically, each air blowing unit includes an air blowing nozzle 301 and a solenoid valve 302 that controls the on / off state of the air blowing nozzle 301. The air blowing nozzle 301 is installed in a countersunk hole embedded in the wall of the material discharge channel 204, with its air outlet flush with the inner surface of the hole wall and without any protruding structure to avoid scraping and jamming when the material falls. The air blowing nozzle 301 located in the finished product discharge channel 204 uses a flat fan-shaped air outlet to create a wider coverage area to fit the annular finished product gasket; the air blowing nozzle 301 located in the waste material discharge channel 204 uses a circular air outlet to generate concentrated thrust to fit small-sized circular waste materials.

[0026] The material discharge channel 204 is composed of an integrated material discharge insert, the inner diameter of which is adapted to the cutting edge size of the material discharge die. Its inner wall surface is coated with an anti-static DLC coating to reduce the risk of non-woven fabric fiber snagging and electrostatic adsorption. Multiple air blowing units and attitude sensing units are embedded within the wall of the material discharge insert.

[0027] The attitude sensing unit is used to detect the stuck posture information of the finished gasket falling into the material feeding channel 204. In this embodiment, the attitude sensing unit includes four sets of through-beam sensors 303, each set of through-beam sensors 303 is respectively set in the horizontal plane corresponding to the air blowing unit at different height positions. Among them, the optical paths of the two sets of through-beam sensors at the lower height are arranged along the X-axis direction, and the optical paths of the two sets of through-beam sensors at the higher height are arranged along the Y-axis direction, so that the optical path axes are arranged intersecting on the horizontal projection plane (X-axis direction: material feeding direction, i.e., horizontal left and right direction; Y-axis direction: perpendicular to the material feeding direction, i.e., horizontal front and back direction; Z-axis direction: vertical material falling direction, i.e., up and down direction); in this way, the optical paths of the four sets of sensors are arranged intersecting on the horizontal projection plane, which can accurately detect the spatial posture of the material in the channel.

[0028] The air supply module 40 includes a main air path and an air path drive unit connected to each blowing unit. The main air path is connected to the workshop air source and is sequentially equipped with an air filter, an oil-water separator, and a main pressure reducing valve. Each air path drive unit includes an electro-proportional pressure reducing valve for independently adjusting the blowing pressure and a one-way valve to prevent gas backflow. The control module is electrically connected to each electro-proportional pressure reducing valve and can adjust the blowing pressure of the corresponding blowing unit in real time according to the type of material to be processed or the detected jamming state.

[0029] The control module uses an industrial-grade PLC controller, which is electrically connected to the attitude sensing unit, the solenoid valves 302 of each air blowing unit, the electro-proportional pressure reducing valve, and the crankshaft angle encoder (not shown in the figure) of the stamping drive mechanism. The control module has a built-in control program configured to execute the following core control logic: (1) Timing synchronization control logic As shown in the figure, the control module obtains the real-time phase of the stamping cycle through the crankshaft angle encoder and strictly divides the action window. During the blanking and holding pressure stage (corresponding to the crankshaft angle range), the punch contacts the strip and completes the blanking. At this time, the control module keeps the solenoid valves 302 of all air blowing units closed, the air blowing system is completely locked, and there is no airflow output to ensure that the strip positioning is not disturbed. Only within the blanking window period defined after the punch returns to the preset safe position, the control module activates the attitude sensing unit to detect and drives the corresponding air blowing unit to act according to the detection result.

[0030] (2) Attitude recognition and directional blowing gating logic During the material dropping window, the attitude sensing unit continuously monitors the material. If all through-beam sensors 303 experience a "on, off, on" state change within the preset judgment time, it is determined that the material has been successfully dropped. The control module does not initiate any air blowing action and directly enters the next cycle preparation.

[0031] If a sensor at a certain height level is continuously obstructed, a jamming condition is determined. The control module identifies the highest edge height and tilt position of the jammed material based on the obstruction status and sequence of each sensor. For example, if only the sensor at height H2 is obstructed, while the sensor at height H3 (70mm) is unobstructed, the material is determined to be horizontally jammed at approximately 45mm height, with the highest edge height being 45mm. Based on this, the control module determines that the target air blowing units above the highest edge of the jammed material are the two air blowing units with installation heights of 20mm and 45mm, and sends an opening signal only to the solenoid valves 302 of these two target air blowing units to drive them to perform the air blowing action; while the remaining air blowing units below the highest edge of the jammed material (the two with installation heights of 70mm and 95mm) remain closed.

[0032] (3) Hierarchical intervention and control logic The control module is also configured to execute different air-blowing strategies based on the severity of material jamming identified by the attitude sensing unit. If the initial detection indicates mild jamming (e.g., the material is slightly tilted but not completely jammed), the control module controls the target air-blowing unit to execute a constant pressure continuous air-blowing mode at a preset reference pressure, continuously blowing air. If the jamming is resolved after one air-blowing cycle (the sensor returns to normal), then the air-blowing stops.

[0033] If the jamming is not relieved after one air blowing, it is determined to be moderate jamming. The control module automatically switches the air blowing mode to high-frequency pulse air blowing mode, for example, alternately opening and closing the solenoid valve 302 at a preset frequency, and using the vibration effect generated by the pulse airflow to help loosen the material.

[0034] If the jamming cannot be relieved after moderate intervention, it is determined to be severe jamming. The control module can execute a stepped pressure boosting purging strategy, and at the same time gradually increase the purging pressure through the electric proportional pressure reducing valve (not exceeding the safety threshold). If the jamming still exists after all strategies are executed, the control module immediately sends an emergency stop signal to the punch press control system, prohibits the feeding mechanism from operating, and issues an audible and visual alarm to prompt the operator to handle the situation.

[0035] The working process of the non-woven reinforced plastic pad stamping die of this invention for continuous stamping production is as follows: Feeding: The servo feeding mechanism precisely feeds the non-woven reinforced plastic belt 50 into the mold; Punching: The upper die unit 10 of the punch press moves downward, and the punching punch 102 cooperates with the punching die to punch out the inner hole on the strip; during the punching and holding pressure stage, all the air blowing units of the anti-blocking system remain closed, and the circular waste generated by punching enters the waste discharge channel 204.

[0036] Punching and blanking detection: After the punch returns to the safe position, it enters the blanking window period. The anti-blocking system in the scrap discharge channel 204 is activated. If scrap is detected to be stuck, directional air blowing is performed according to the above logic until the scrap falls smoothly into the scrap collection bin.

[0037] Secondary feeding: After confirming that the punching station 202 has completed the material unloading, the feeding mechanism will advance the material strip by one step and send the part of the material strip with the punched inner hole to the unloading station 203.

[0038] Blanking: The upper die unit 10 moves down again, and the blanking punch 103 cooperates with the blanking die to punch out a circular finished gasket. During the punching and holding pressure stage, the anti-blocking system remains locked.

[0039] Finished product unloading inspection: After the punch returns to the safe position, the anti-blocking system in the unloading channel 204 is activated. If the finished product gasket is detected to be stuck, directional air blowing is performed to break it until the finished product falls smoothly into the finished product collection bin.

[0040] Cycle: After confirming that there is no stuck material in the material discharge channel 204 corresponding to the punching station 202 and the blanking station 203, the control module sends a feeding permission signal to the feeding mechanism, and the mold enters the next stamping cycle to realize continuous automated production.

[0041] As can be seen from the above scheme, the present invention, through the coordinated work of the air blowing units arranged at different heights, the attitude sensing unit composed of layered through-beam sensors 303, and the intelligent control logic, accurately realizes the identification of stuck posture and directional air blowing to break it up. This solves the problem of material blockage in the material drop channel 204 caused by fiber snagging and electrostatic adsorption in the stamping production of non-woven reinforced plastic pads. At the same time, it also avoids the interference of air blowing on the positioning accuracy of the material strip, ensuring the high precision requirements of the product.

[0042] The embodiments of the present invention have been described above, but the present invention is not limited to the specific embodiments described above. The specific embodiments described above are merely illustrative and not restrictive. Those skilled in the art can make many other forms under the guidance of the present invention, all of which are within the protection scope of the present invention.

Claims

1. A stamping die for a non-woven fabric reinforced plastic pad, characterized in that, include: Upper mold unit, lower mold unit, and anti-clogging system; The lower die unit includes a lower die body, and the lower die body is provided with a punching station and a blanking station in sequence along the material feeding direction of the strip. The bottom of the lower die body is provided with a blanking channel that is connected to the lower part of the punching station and the blanking station respectively. The anti-blocking system includes an air blowing execution module correspondingly installed in the material discharge channel, an air supply module for providing air to the air blowing execution module, and a control module; Each of the air blowing execution modules includes an attitude sensing unit and multiple air blowing units; The attitude sensing unit is used to detect the stuck attitude information of the material falling into the material feeding channel. Multiple air blowing units are distributed circumferentially along the hole wall of the material discharge channel. Each air blowing unit is arranged in a staggered manner along the material discharge direction. The air blowing direction of each air blowing unit is towards the center of the material discharge channel and has a downward tilt angle. The control module is electrically connected to the attitude sensing unit and each air blowing unit, and is configured as follows: Based on the material jamming posture information detected by the posture sensing unit, at least one target blowing unit located above the highest edge of the jammed material is identified, and only the target blowing unit is driven to perform blowing action, while the remaining blowing units located below the highest edge of the jammed material remain closed.

2. The nonwoven reinforced plastic pad stamping die according to claim 1, characterized in that, Each of the air blowing execution modules includes at least four air blowing units evenly distributed circumferentially along the wall of the material dropping channel, and the installation height of two adjacent air blowing units is different along the material dropping direction, so that the air blowing range of the air blowing execution module covers different height ranges of the material dropping channel.

3. The nonwoven reinforced plastic pad stamping die according to claim 1, characterized in that, Each of the air blowing units includes an air blowing nozzle and a solenoid valve for controlling the on / off state of the air blowing nozzle. The air blowing nozzle is installed in a countersunk hole type, and its air outlet is flush with the inner wall of the material discharge channel.

4. The nonwoven reinforced plastic pad stamping die according to claim 3, characterized in that, The air nozzle located below the blanking station has a flat fan-shaped air outlet, while the air nozzle located below the punching station has a circular air outlet.

5. The nonwoven reinforced plastic pad stamping die according to claim 1, characterized in that, Each of the material discharge channels is composed of an integrated material discharge insert, the inner wall surface of which is provided with an antistatic coating; multiple air blowing units and attitude sensing units are embedded in the hole wall of the integrated material discharge insert.

6. The nonwoven reinforced plastic pad stamping die according to claim 1, characterized in that, The attitude sensing unit includes at least four sets of through-beam sensors, each set of which is disposed in a horizontal plane corresponding to the air blowing unit at different height positions.

7. The nonwoven reinforced plastic pad stamping die according to claim 1, characterized in that, The air supply module includes an air path drive unit connected to each air blowing unit, and each air path drive unit includes an electric proportional pressure reducing valve for adjusting the air blowing pressure; the control module is electrically connected to the electric proportional pressure reducing valve and is used to adjust the air blowing pressure in real time according to the type of material to be processed or the detected jamming state.

8. The nonwoven reinforced plastic pad stamping die according to claim 1, characterized in that, The upper die unit includes an upper die body and a punching punch and a blanking punch corresponding to the punching station and blanking station, respectively. The upper die body is connected to an external stamping drive mechanism.

9. The nonwoven reinforced plastic pad stamping die according to claim 1, characterized in that, The control module is also configured to: activate the attitude sensing unit to detect and drive the air blowing unit to operate within the blanking window period defined after the upper die unit returns to the preset safe position, while keeping all air blowing units closed during the punching and holding pressure stage.

10. A nonwoven reinforced plastic pad stamping die according to claim 1, characterized in that, The control module is also configured to: control the blowing unit to execute different blowing and breaking strategies based on the severity of material jamming identified by the attitude sensing unit; the blowing and breaking strategies include at least a constant pressure continuous blowing mode and a high-frequency pulse blowing mode.

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