Automatic Loading Unit for Bending Pin Bars
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Solution Overview
Problem
Manual intervention in replacing bending pins supporting bars in automated systems for forming three-dimensional lattice-like structures from electro-welded metal grids is time-consuming, risky, and disrupts continuous production, requiring frequent calibration and complete bar replacement.
Innovation Solution
An automatic loading unit with a multiple-station magazine that moves longitudinally and coaxially with the bending machine, using automatic grippers to extract and insert bending pins supporting bars with specific geometric characteristics, eliminating the need for manual intervention and enabling quick replacement of bars with different radii of curvature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual operators replace bending pins supporting bars, then the operation can be performed with simple equipment, but the production is interrupted for long periods and operators are exposed to high accident risk
Solution Approach 1:
The system performs automatic bar replacement without human intervention. The extraction device automatically removes used bars from the bending unit and places them in the magazine, while the insertion device automatically loads new bars from the magazine to the bending unit, enabling the system to service itself
Solution Approach 2:
Manual mechanical operations by operators are replaced with an automated mechanical system comprising extraction devices, insertion devices, and a magazine system controlled by computerized management systems, eliminating human exposure to hazard zones
2Device complexity
If bending pins supporting bars are replaced manually, then the equipment complexity is low, but the replacement time is considerable and production is disrupted
Solution Approach 1:
Multiple bending pins supporting bars with different geometric characteristics are pre-loaded into the magazine in advance. When a bar needs replacement, the system can immediately extract a new bar from the magazine without waiting for preparation, significantly reducing replacement time
Solution Approach 2:
The automated extraction and insertion devices perform bar replacements without human intervention, operating continuously to minimize downtime while maintaining relatively simple equipment through systematic automation
3Ease of operation
If the magazine is positioned laterally to the bending machine, then the bar extraction and insertion is facilitated, but the space occupation lateral to the production line increases
Solution Approach 1:
The magazine is designed to move longitudinally along the production line rather than being fixed laterally. This dynamic positioning allows the magazine to occupy minimal lateral space while maintaining ease of bar extraction and insertion through automated longitudinal movement to the bending unit
Solution Approach 2:
The magazine positioning is changed from a lateral static arrangement to a longitudinal dynamic arrangement. By moving the magazine along the longitudinal axis of the production line, the system reduces lateral space occupation while maintaining operational effectiveness through automated positioning
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 automatic loading unit reduces setup times, minimizes the risk of accidents, and ensures continuous production by automating the replacement of bending pins supporting bars, allowing for the efficient formation of three-dimensional lattice-like frames with varying radii of curvature without manual operator intervention.
Implementation Method 1
automatic grippers to extract and insert bending pins supporting bars
Data Source
Figure 1~9
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AI summary
An automatic loading unit (3) for bending pin supporting bars (7), which serves an automatic machine for bending electro-welded metal grids, and/or an automatic system for forming three-dimensional lattice-like frames derived from electro- welded steel grids. The automatic loading unit is provided with a magazine (9), which is horizontal or of another type, with a plurality of side-by-side stations which accommodate various bending pin supporting bars (7) having different geometric characteristics. The loading unit is arranged coaxially with the working axis of the bending machine. It can move automatically, arranging one bar at a time proximate to said machine and the upper carriage (6) provided with an adapted grip clamp so as to move it longitudinally and inserting it in the bending machine. The reverse operation likewise occurs automatically. Replacement or loading of the bar (7) on the bending machine occurs fully automatically without the direct manual intervention of the operators thereon.