Automated Bending Die Change for Flexible Wire Bending

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Solution Overview

Problem

The existing bending machines for bending wire, rod, or band form materials face inefficiencies due to time-consuming and resource-intensive retooling processes, leading to production interruptions, potential operator injuries, and incorrect equipment setups, especially when adapting to varying material diameters and bending radii.

Innovation Solution

A method utilizing a robot gripper arm and control device to automate the change of bending dies and guiding nozzles, allowing for flexible and remote adaptation, with the robot gripper arm performing dual functions of material removal and die/nozzle exchange without manual intervention, and incorporating autonomous logistics for efficient material handling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If manual retooling of bending dies and guiding nozzles is performed, then the bending machine can be adapted to varying material diameters and bending radii, but the retooling process becomes time-consuming and causes production interruptions

Engineering Contradiction:

Improveadaptability to varying material diameters and bending radiiVSAvoidproduction efficiency during retooling

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The system uses automated robot gripper arms to perform the retooling operation itself without requiring manual intervention. The control device manages the entire process of removing old bending dies/nozzles and installing new ones, enabling the machine to service itself and eliminating production interruptions.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Manual mechanical retooling operations are replaced by an automated robotic system controlled by a control device. The robot gripper arms execute the retooling process under automated control, substituting human operators and eliminating the time-consuming nature of manual retooling.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Adaptability or versatility

If multiple different bending dies are used to handle varying material specifications, then the bending machine can process diverse materials, but the risk of incorrect equipment setup increases leading to rejects

Engineering Contradiction:

Improvecapability to process diverse materialsVSAvoidaccuracy of equipment setup

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The control device receives information about the required bending specifications and automatically selects and installs the appropriate bending dies and guiding nozzles. This closed-loop control ensures the correct equipment is always installed, eliminating setup errors and rejects.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The automated control system manages multiple bending dies and guiding nozzles through a single unified interface. The control device coordinates the selection and installation of different tooling components based on the material specifications, providing universal control over diverse equipment.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Manufacturing precision

If manual adjustment and fitting steps are required for retooling, then the bending die can be precisely installed, but operator safety is compromised and production flow is disrupted

Engineering Contradiction:

Improveprecision of bending die installationVSAvoidoperator injury risk

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The system performs the installation and positioning of bending dies and guiding nozzles autonomously using robot gripper arms under control device management. This eliminates operator involvement in hazardous manual handling while maintaining installation precision through automated control.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Manual mechanical installation operations that pose safety risks are replaced by automated robotic manipulation. The robot gripper arms perform the precise installation tasks previously requiring human operators, eliminating injury risks while maintaining manufacturing precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Adaptability or versatility

If the bending machine is equipped with a large number of different bending dies, then various material specifications can be handled, but the retooling process becomes resource-intensive and complex

Engineering Contradiction:

Improverange of material specifications that can be processedVSAvoidcomplexity of retooling process

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The control device provides universal management for multiple bending dies and guiding nozzles through a single automated system. The robot gripper arms can handle different tooling components interchangeably, simplifying the retooling process despite the variety of available components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The complex manual retooling process involving multiple different bending dies is replaced by an automated robotic system. The control device manages the complexity of selecting and installing the correct tooling from multiple options, reducing the perceived complexity for operators.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS20230405746A1Method for automatically changing a bending die and/or at least one guiding nozzle of a machine for bending material

Publication Date: 2023.12.21 PROGRESS MASCHEN & AUTOMATION

AI summary

A method includes feeding material in wire, rod or band form to a bending head through the a guiding nozzle of a feeding device and bending the material via a bending die. The bent material is taken out of the bending machine by a robot gripper arm controlled via a control device, and the bending die and/or the guiding nozzle is removed from the bending machine by a, preferably the same, robot gripper arm. Optionally, a further bending die and/or a further guiding nozzle is arranged on the bending machine by a, preferably the same, robot gripper arm. Optionally, the material is fed to the bending head through the further guiding nozzle and/or bent via the further bending die. Optionally, the bent material is removed from the bending machine by a, preferably the same, robot gripper arm.