Carrier Positioning Unit With Self-Holding Clamp for Low-Heat Transfer
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Solution Overview
Problem
Positioning units in transfer systems face high load and energy consumption issues with electrical actuators during the holding phase, leading to overheating and potential failure, which compromises reliability and safety.
Innovation Solution
A positioning unit with electric drive mechanisms, such as linear or rotary motors, that only applies force when engaging the workpiece carrier and can be de-energized during the holding phase, utilizing mechanical devices like cams, levers, and springs to maintain clamping force without continuous energy input, enhancing reliability and reducing installation effort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an electric actuator is used to actuate the positioning section during the holding phase, then the positioning force can be maintained reliably, but the energy consumption and heat generation increase significantly
Solution Approach 1:
The electric actuator is activated only during the transition phase when the positioning section needs to engage with the carrier, and switched off during the holding phase. This periodic operation pattern eliminates continuous energy consumption while maintaining positioning reliability through precise timing of actuation cycles.
Solution Approach 2:
The positioning section is designed to maintain its clamped position through mechanical self-holding characteristics, such as friction between the positioning section and carrier, or through the geometry of the clamping mechanism itself. This allows the system to hold position without continuous external energy input, eliminating the need for continuous actuator engagement.
2Reliability
If an electric actuator applies continuous holding force, then the carrier remains securely positioned, but the actuator overheats and may fail
Solution Approach 1:
The actuator operates in short, periodic pulses only when needed for engagement and disengagement, remaining inactive during the holding phase. This eliminates continuous heat generation while maintaining positioning security through precisely timed actuation cycles that ensure the carrier remains clamped.
Solution Approach 2:
The positioning mechanism is designed with self-holding characteristics where the mechanical geometry or friction between components maintains the clamped position without continuous actuator force. This eliminates heat generation from continuous actuator operation while preserving positioning security through inherent mechanical stability.
3Use of energy by stationary object
If pneumatic actuators are used for positioning, then the holding phase can be maintained with less energy, but the installation and maintenance effort increases
Solution Approach 1:
The patent replaces pneumatic actuators with electric actuators that operate only during transition phases. This substitution eliminates the need for complex pneumatic infrastructure (compressors, hoses, regulators) while using simpler electric motors that require minimal maintenance, thereby reducing installation complexity while maintaining energy efficiency.
Solution Approach 2:
The positioning system is designed to maintain holding force through mechanical self-holding characteristics rather than continuous pneumatic or electric pressure. This eliminates the need for continuous energy input from any actuator type, achieving energy efficiency without requiring complex pneumatic system infrastructure.
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 solution reduces energy consumption and heat generation, increases reliability, and provides a fail-safe mechanism by allowing the drive to be switched off during the holding phase, thus preventing overheating and improving the overall performance of the transfer system.
Implementation Method 1
The drive is in particular electric
Implementation Method 2
a tensioning device, in particular a compression spring
Implementation Method 3
the workpiece carrier is stopped at the stations by a positioning unit... bringing the positioning section into contact with the workpiece carrier
Data Source
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AI summary
A positioning unit for positioning a carrier on a transfer system is disclosed, comprising positioning sections with which the carrier can be brought into a tensioned system for positioning, and a first of which can be actuated into the tensioned system by a drive, in particular an electric one, of the positioning unit. A transfer system is also disclosed.