Cast Component Straightening and Cooling Machine
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Solution Overview
Problem
The existing methods for producing aluminum die-cast components in automobile construction are time-consuming and inefficient, particularly in the straightening process, which often requires manual handling and additional heat treatment steps that can lead to distortion and failure to meet precision specifications.
Innovation Solution
A machine and method that integrate cooling and straightening processes for cast components, allowing for simultaneous hot-state straightening and cooling using a parts shower with pressure cylinders and adjustable supports, enabling precise alignment and deformation without the need for separate heat treatment steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If cast components are straightened using traditional embossing tools after cooling, then the components can be straightened, but the process is time-consuming and requires additional heat treatment steps
Solution Approach 1:
The patent combines the cooling process and straightening process into a single integrated operation. The cast component is cooled by spraying cooling liquid while simultaneously being straightened by embossing tools, eliminating the need for separate cooling and straightening steps, and removing the requirement for additional heat treatment that was needed in traditional processes
Solution Approach 2:
The straightening process is performed while the cast component is still hot and pliable, before it fully cools down. This preliminary straightening takes advantage of the material's increased ductility at elevated temperatures, making the straightening more effective and reducing the need for subsequent corrective operations
2Manufacturing precision
If additional heat treatment steps are performed to correct distortion, then precision specifications can be met, but the process becomes more complex and time-consuming
Solution Approach 1:
The patent merges cooling, straightening, and heat treatment functions into a single integrated process step. The embossing tools straighten the component while cooling liquid is applied, and the residual heat from the die-casting process provides the necessary thermal energy, eliminating the need for separate heat treatment equipment and process steps
Solution Approach 2:
The cast component's own residual heat from the die-casting process is utilized for the straightening operation, without requiring external heating. The process uses the heat already present in the component, making it self-sufficient and reducing process complexity
3Ease of operation
If manual straightening is performed, then flexibility is maintained, but productivity decreases and time loss increases
Solution Approach 1:
The patent replaces manual mechanical straightening operations with an automated system where embossing tools are actuated by hydraulic or pneumatic cylinders. This mechanical automation maintains the flexibility and control of manual operations while dramatically increasing productivity and reducing cycle time
Solution Approach 2:
The system allows for adjustable embossing force and duration parameters, enabling operators to optimize the straightening process for different component types and distortion levels. This parameter adjustability maintains operational flexibility while achieving automated high-speed processing
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
This integrated approach reduces the time and effort required for straightening, ensures high-precision components are achieved without additional heat treatment, and allows for preventive overbending to counteract potential distortions, thereby improving the efficiency and accuracy of the die-casting process.
Implementation Method 1
the cast component being immediately exposed to a cooling liquid in a parts shower
Implementation Method 2
the cast component is subjected to a straightening process while it is still hot before the cooling liquid is applied to the cast component
Implementation Method 3
means for holding the cast component and straightening pressure cylinders with straightening dies installed are that press the cast component against supports
Data Source
Figure 1a~1b
Figure 2
Figure 3
AI summary
A machine for cooling and straightening cast components (10) made of cast material is proposed, consisting of a structure for holding the cast components (10) and a holder for supplying cooling liquids. The machine has means (12, 22) for holding the cast component (10) and incorporates straightening pressure cylinders (24) with straightening punches (23) that press the cast component (10) against supports (14). A method for straightening a cast component after removal from the mold is also described.