Adjustable Blanking Die Layout for Variable Blank Width

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Solution Overview

Problem

Existing blanking dies are limited in their ability to produce blanks of different dimensions without requiring changes to the positions of the blank cutters, which restricts their versatility in cutting multiple blanks in a single stroke.

Innovation Solution

A blanking die apparatus comprising a first and second die with movable second die on a base, allowing adjustment of the gap between them to change blank dimensions, along with an infeed assembly that imparts an arc-shape to the metal sheet for support and a matching arc-shape on the die surfaces for cutting, enabling the production of blanks of varying dimensions without repositioning the cutters.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a single blanking die cuts one blank per stroke, then manufacturing precision is maintained, but productivity is reduced

Engineering Contradiction:

Improveblanks per strokeVSAvoiddie structure complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The blanking die is divided into multiple independent cutting units (first blanking die and second blanking die) that can simultaneously cut multiple blanks from the metal strip in a single stroke. Each die unit has its own cutting edges and can operate independently, allowing production of multiple blanks without requiring complex coordinated motion mechanisms.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If blanking dies are designed for fixed dimensions, then manufacturing precision is ensured, but adaptability is reduced

Engineering Contradiction:

Improveblank dimension variationVSAvoidblank dimension accuracy

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The second blanking die is designed with movable capability along the base in the feed direction, allowing its position to be dynamically adjusted to change the dimension of blanks produced. The die can be moved to different locations and locked in place, enabling production of blanks with varying dimensions while maintaining cutting precision through the fixed cutter positions on each die unit.

Inventive Principle:

Principle #15Dynamics

3Adaptability or versatility

If the second blanking die is moved to change blank dimensions, then adaptability is improved, but device complexity increases

Engineering Contradiction:

Improveblank size adjustmentVSAvoiddie adjustment mechanism

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The base structure serves multiple functions: it provides support for both the first and second blanking dies, enables movement of the second die for dimension adjustment, and includes locking mechanisms to secure the die in various positions. This multi-functional design allows dimension adjustment without requiring separate complex adjustment mechanisms for each function.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS11583914B2Adjustable width blanking die apparatuses

Publication Date: 2023.02.21 TOYOTA MOTOR ENG & MFG NORTH AMERICA INC

AI summary

A blanking die apparatus includes a first blanking die including an upper die shoe including an upper die shoe cutting surface and a lower die shoe including a lower die shoe cutting surface. A second blanking die includes an upper die shoe including an upper die shoe cutting surface and a lower die shoe including a lower die shoe cutting surface. The second blanking die movable on a base in a feed direction to increase and decrease a dimension of a blank formed between the first blanking die and the second blanking die.