Automatic Bending Die Changeover for Flexible Wire Bending
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Solution Overview
Problem
Existing bending machines for wire, rod, or strip-shaped materials face inefficiencies due to the time and resource-intensive process of changing bending dies and guide nozzles for varying material diameters and bending radii, leading to production delays, manual handling risks, and potential incorrect assembly, which results in rejects and reduced productivity.
Innovation Solution
A method and arrangement utilizing a robot gripper arm and control device to automatically change bending dies and guide nozzles, allowing for fully automated or semi-automated operation, enabling flexible adaptation to different materials and bending configurations without manual intervention, and incorporating a locking mechanism for secure die placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual changing of bending dies and guide nozzles is used, then the bending machine can be adapted to different materials, but the process is time-consuming and reduces productivity
Solution Approach 1:
The system enables automatic self-changing of bending dies and guide nozzles through the robot gripper arm, which autonomously removes and installs tooling components based on control device instructions, eliminating the need for manual intervention and significantly reducing changeover time
Solution Approach 2:
The control device stores predefined information about different bending dies and guide nozzles, including their positions and installation parameters. Before a changeover is needed, the system has already prepared the necessary data and can quickly execute the change by retrieving the pre-stored information, reducing actual changeover time
2Adaptability or versatility
If multiple bending dies are available for different materials, then the machine can handle various configurations, but the risk of incorrect loading increases
Solution Approach 1:
The control device receives feedback from sensors and the robot gripper arm about the current state of the bending machine and the tooling components being installed. This feedback loop allows the system to verify correct installation and detect errors, ensuring reliable assembly even when handling multiple different bending dies
Solution Approach 2:
The control device maintains digital copies or records of each bending die and guide nozzle's correct installation parameters and positions. The robot gripper arm uses this information to precisely locate and install the correct component, eliminating human error in selecting and installing the right tooling for each material configuration
3Ease of operation
If manual adjustment and assembly steps are required, then flexibility is maintained, but operator safety is compromised
Solution Approach 1:
The patent replaces manual mechanical operations with an automated robot gripper arm system controlled by a control device. The robot performs all dangerous manual tasks including removing and installing bending dies and guide nozzles, eliminating operator exposure to moving parts and heavy components while maintaining full operational flexibility through programmable control
Solution Approach 2:
The robot gripper arm acts as an intermediary between the operator and the bending die components. Instead of operators directly handling heavy and potentially dangerous tooling components, the robot serves as a safe intermediary that performs the hazardous manipulation while the operator remains protected and in control through the control device
4Ease of manufacture
If production shutdowns occur for manual assembly changes, then component installation can be performed, but manufacturing efficiency decreases
Solution Approach 1:
The automated robot gripper arm system enables continuous operation of the bending machine. While one bending die is being used, the robot can prepare the next die for installation, and changeovers can be performed quickly without stopping production for extended periods. The system maintains continuous useful action by minimizing idle time during tooling changes
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3a~3b
AI summary
Method for automatically changing at least one bending die (1) and/or at least one guide nozzle (2) of a bending machine (3) for wire, rod, or strip-shaped material (4), wherein the following process steps, to be carried out in particular in chronological order, are performed: - wire, rod, or strip-shaped material (4) is fed to at least one bending head (5) through the at least one guide nozzle (2) of at least one feeding device (21) and bent over the at least one bending die (1), - the bent material (4) is removed from the bending machine (3) by a robot gripper arm (7) controlled by at least one control device (6), - the at least one bending die (1) and/or the at least one guide nozzle (2) is removed from the bending machine (3) by a robot gripper arm (7), preferably the same, - optionally, at least one further bending die (1) and/or at least one further guide nozzle (2) is removed by a robot gripper arm (7),preferably the same robot gripper arm (7) is arranged on the bending machine (3) - optionally, wire-, rod- or strip-shaped material (4) is fed to the at least one bending head (5) through the at least one further guide nozzle (2) and/or bent over the at least one further bending die (1), - optionally, the bent material (4) is removed from the bending machine (3) by a, preferably the same, robot gripper arm (7). The invention also relates to a bending machine and a bending die.