Automated Forging Line Control for Hot Material Handling

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Traditional forging and pressing production relies heavily on manual labor, is labor-intensive, and lacks efficient automation, leading to inaccuracies, safety risks, and high operational costs due to the need for human judgment and manual handling of high-temperature materials.

Innovation Solution

A control platform integrates a hot melt device, forging device, and delivering device to automate the forging and pressing process, monitoring and controlling temperature, pressure, and material handling, reducing manual intervention and enhancing safety and efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If manual labor is used for heating and forging operations, then operational flexibility is maintained, but labor intensity and safety risks increase significantly

Engineering Contradiction:

Improveoperational flexibilityVSAvoidlabor intensity

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The system enables automated self-service through the control platform that coordinates heating, forging, and delivering devices to operate autonomously without manual intervention, reducing labor intensity while maintaining operational continuity

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Manual mechanical operations are replaced by automated control systems that coordinate multiple devices through a centralized platform, substituting human labor with automated mechanical and control systems

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If manual handling of high-temperature materials is performed, then operational control is maintained, but safety risks and health hazards increase

Engineering Contradiction:

Improveoperational controlVSAvoidsafety risks

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The control platform acts as an intermediary between operational commands and device execution, enabling remote control without direct human contact with high-temperature materials, thus maintaining operational control while eliminating safety risks

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

Manual handling operations are replaced by automated delivering devices controlled through a centralized platform, substituting human interaction with automated mechanical systems that can safely handle high-temperature materials

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Adaptability or versatility

If multiple separate devices are used for heating and forging, then functional flexibility is maintained, but coordination efficiency and productivity decrease

Engineering Contradiction:

Improvefunctional flexibilityVSAvoidcoordination efficiency

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

Multiple separate devices (heating device, forging device, delivering device) are merged into an integrated system coordinated by a centralized control platform, maintaining functional flexibility while significantly improving coordination efficiency and overall productivity

Inventive Principle:

Principle #5Merging (Combining)

4Productivity

If automated control is implemented, then productivity and safety are improved, but system complexity increases

Engineering Contradiction:

Improveproduction efficiencyVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The control platform provides universal control capabilities across multiple devices through a single integrated system, enabling automated coordination of heating, forging, and delivering operations while managing system complexity through standardized interfaces

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

The system enables automated, high-efficiency production by accurately controlling operational variables, minimizing human exposure to high temperatures, and reducing waste, thereby improving production quality and safety while lowering costs.

Implementation Method 1

a hot melt device, heating at least a material (100) so that the material is heated to a proper temperature

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

a forging device, adapted for pressing the heated material based on the control of the control platform so as for forming the material through forging and pressing

Methodology Applied

Scientific EffectCompression: Compression

Data Source

PatentUS12491557B2Forging and pressing production system and management method therefor

Publication Date: 2025.12.09 NINGBO TEXOON BRASSWORKS CO LTD

AI summary

A forging and pressing production systems enables at least one material to be formed by hot melt and forging and pressing by itself without human operation, thereby completing the mass production of the material. Operating factors such as the pressure, temperature and mold required for formation are taken into account, and the identification requirements for the material are reduced, thereby realizing large-scale production.