Adjustable Draw-In Block Assembly for Closed-Loop Die Control
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Solution Overview
Problem
Existing stamping processes face challenges with irregularities in parts due to inconsistent material draw-in, leading to issues like splits, waves, slip lines, and wrinkles.
Innovation Solution
An adjustable block assembly is introduced in the stamp tool assembly, comprising interlocking teeth on top and lower plates that can be adjusted to control the spacing between draw-in surfaces, allowing for tailored material draw-in.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If material draw-in is insufficient during stamping, then the stamping process is simpler, but splits or waves appear in the material
Solution Approach 1:
The patent applies parameter changes by adjusting the vertical position of the adjustable block to modify the spacing between draw-in surfaces. This changes the material draw-in parameter during stamping, allowing optimization of both process simplicity and surface quality by preventing splits and waves through controlled material flow
Solution Approach 2:
The patent implements dynamics by making the block position adjustable rather than fixed. The block can be repositioned vertically to adapt spacing between draw-in surfaces, enabling dynamic optimization of material draw-in for different stamping conditions and preventing defects like waves and splits
2Ease of operation
If material draw-in is excessive during stamping, then the material flow is easier, but slip lines and wrinkles appear
Solution Approach 1:
The patent applies parameter changes by adjusting the block position to control the spacing between draw-in surfaces. This modifies the material draw-in parameter to prevent excessive flow that causes slip lines and wrinkles, optimizing surface quality while maintaining adequate material flow
Solution Approach 2:
The patent implements dynamics through the adjustable block that can be repositioned to adapt material draw-in levels. This allows dynamic control of material flow to prevent wrinkles and slip lines while maintaining ease of operation for different stamping scenarios
3Device complexity
If the spacing between draw-in surfaces is not adjustable, then the device structure is simpler, but material draw-in inconsistencies persist
Solution Approach 1:
The patent implements dynamics by transforming the fixed block structure into an adjustable one. The block can be repositioned vertically along the stamping tool to change spacing between draw-in surfaces, enabling adaptation to different material and part requirements while maintaining structural simplicity through a straightforward adjustment mechanism
Solution Approach 2:
The patent applies segmentation by dividing the block assembly into separable components that can be independently adjusted. The adjustable block with teeth and corresponding slots allows discrete positioning adjustments, enabling precise control of draw-in spacing while keeping the overall device structure relatively simple
4Ease of manufacture
If the block position is fixed, then the manufacturing process is simpler, but part quality varies throughout production cycle
Solution Approach 1:
The patent implements dynamics by enabling the block position to be adjusted during the production cycle. This allows optimization of part quality consistency by adapting the spacing between draw-in surfaces to compensate for material variations, while maintaining relatively simple manufacturing processes through an easy adjustment mechanism
Data Source
AI summary
A stamp tool assembly is provided that includes a forming cavity for shaping a blank into a formed part. The stamp tool assembly includes adjustable block assembly for modifying the amount of material draw-in from subsequently stamped blanks. A draw-in sensor measures the amount of material from the blanks that is not drawn-into the forming cavity during each stroke. Based on the readings from the draw-in sensor, the adjustable block assembly is expanded or reduced. The adjustable block assembly includes a pair of opposing inclined plates having interlocking teeth such that movement of one plate with respect to the other plate changes a vertical extension of the adjustable block assembly. The adjustable block assembly sets the spacing between two opposing draw-in surfaces, which, in turn, changes the amount of draw-in. Multiple adjustable block assemblies and draw-in sensors may be used in conjunction and controlled via a controlling system.