Adjustable Shearing Carriage for Precise Rod Section Positioning
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Solution Overview
Problem
Existing forming machines with shearing devices cannot adjust the position of sheared bar sections optimally at forming stations without stopping the machine, leading to inefficiencies and increased downtimes due to non-uniform geometry and center of mass issues.
Innovation Solution
Incorporating a shearing device with adjustable stroke and direction for the shearing carriage, enabled by a control unit, allowing for real-time adjustment of the shearing carriage's movement during operation, which includes a hydraulic cylinder and pivot mechanism for precise positioning of the sheared bar sections at the forming station.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If adjusting plates and adjusting screws are used to adjust the positioning of the sheared bar section, then the positioning precision is improved, but the machine stoppage time increases
Solution Approach 1:
The patent transforms the static adjustment mechanism into a dynamic one by enabling adjustment during machine operation. The shearing carriage can be repositioned along the bar material while the machine is running, allowing positioning adjustments without complete machine stoppage. This dynamic adjustment capability resolves the contradiction by maintaining positioning precision while minimizing production downtime.
Solution Approach 2:
The patent implements preliminary positioning actions by allowing the shearing carriage to be adjusted to optimal positions before shearing operations begin. The system can pre-position the carriage based on the center of mass location and desired volume distribution, then execute shearing operations without interruption. This preliminary adjustment capability enables precise positioning while avoiding prolonged machine stoppages.
2Device complexity
If the shearing carriage position is fixed, then the device complexity is reduced, but the adaptability to different bar section geometries deteriorates
Solution Approach 1:
The patent introduces dynamic adjustability to the shearing carriage system, enabling it to adapt to different bar section geometries and center of mass locations. The carriage can be repositioned along the bar material during operation, providing flexibility without requiring complex reconfiguration mechanisms. This dynamic capability maintains relatively simple device architecture while significantly improving adaptability.
Solution Approach 2:
The patent creates a universal shearing carriage system that can handle various bar section geometries and positioning requirements through a single adjustable mechanism. The carriage is designed to accommodate different center of mass locations and volume distribution requirements by allowing positional adjustments during operation. This multi-functional capability eliminates the need for multiple specialized devices, maintaining simplicity while enhancing versatility.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables optimal positioning of sheared bar sections at forming stations without machine stoppages, significantly reducing downtime and improving efficiency by allowing for continuous operation and precise adjustment of the shearing carriage's stroke and direction.
Implementation Method 1
The shearing carriage is designed to be movable forwards and backwards by a variable-stroke shearing carriage drive, in particular by a hydraulic cylinder
Data Source
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AI summary
A forming machine (100) has a forming station (91) and a shearing device (1) for shearing off a section of rod (W) from a rod material and feeding the sheared-off section of rod (W) to the forming station (91). The shearing device (1) comprises a shearing carriage (2), which can be moved forwards and backwards, and a shearing cutter (30), which is fastened on the shearing carriage (2). With the shearing cutter (30), the section of rod (W) can be sheared off from the rod material in a forward movement of the shearing carriage (2) and can be fed to the forming station (91). The shearing device (1) comprises means for adjusting the stroke and the direction of the forward movement of the shearing carriage (2). This allows optimum positioning of the sheared-off section of rod (W) at the forming station (91). The invention also relates to a method for shearing off a section of rod.