Clutched Dual-Motor Press Drive for High-Speed and High-Force Forming
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Solution Overview
Problem
Large press machines face productivity issues due to the inability to simultaneously achieve high-speed and high-torque movements, leading to inefficiencies and problems associated with hydraulic actuators, such as temperature dependency and mechanical complexity, including issues with crankshafts and flywheels.
Innovation Solution
A press machine design utilizing two motors and male-female thread mechanisms to achieve high-force and high-speed linear movements independently, allowing for efficient part formation without the drawbacks of hydraulic systems, by using a belt system to couple the motors and actuator sprockets for controlled movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a motor is chosen to deliver high torque for forming the part, then the force capability is improved, but the rotational speed and vertical speed of the moving tool are limited
Solution Approach 1:
The press machine is divided into two independent drive systems: a high-torque motor system for delivering forming force and a high-speed motor system for advancing and retracting the moving tool. Each motor system operates independently to optimize its specific function, resolving the contradiction between force capability and speed.
Solution Approach 2:
The actuator system is designed to accept input from either motor system depending on the operational phase. The actuator can be driven by the high-torque motor during forming operations or by the high-speed motor during advancement and retraction, making it a multi-functional component that adapts to different performance requirements.
2Force
If hydraulic actuators are used to deliver high forces with acceptable speed, then the force and speed requirements are met, but temperature dependency and fluid leakage problems occur
Solution Approach 1:
The patent replaces the hydraulic actuator system with a mechanical actuator driven by motor systems. This substitution eliminates the need for hydraulic fluid, pumps, valves, and filters, thereby removing the sources of temperature dependency and fluid leakage while maintaining the capability to deliver high forces through the high-torque motor system.
3Force
If crankshafts with flywheels are used in large presses, then high forces can be delivered, but mechanical complexity and maintenance requirements increase
Solution Approach 1:
The patent replaces the complex crankshaft-flywheel mechanism with a direct-drive motor system. The high-torque motor delivers force directly to the actuator through a simplified transmission system, eliminating the need for crankshafts, flywheels, connecting rods, and associated lubrication systems, thereby reducing mechanical complexity and maintenance requirements while maintaining high force capability.
4Device complexity
If a single motor is used to drive the press, then the system is simpler, but it cannot simultaneously achieve high-speed advancement and high-torque forming
Solution Approach 1:
The drive system is segmented into two specialized motor systems: one optimized for high-speed operation to advance and retract the moving tool, and another optimized for high-torque operation to deliver forming force. This segmentation allows each motor to operate in its optimal performance range, achieving simultaneous high-speed and high-torque capability that a single motor cannot provide.
Solution Approach 2:
The system dynamically switches between the two motor systems based on the operational phase. The control system activates the high-speed motor during advancement and retraction phases, and switches to the high-torque motor during the forming phase, optimizing performance throughout the complete operational cycle.
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 design enhances productivity by enabling high-force and high-speed operations simultaneously, reducing the complexity and maintenance challenges associated with hydraulic systems, while maintaining control and precision in large press operations.
Implementation Method 1
The linear motion of the moving tool is typically created by a motor that rotates a male-and-female screw mechanism that directly or indirectly couples the moving tool to the output shaft of the motor
Data Source
AI summary
A press machine comprises a moveable press ram, an actuator, a first motor system, a second motor system, and a belt system. The moveable press ram holds a tool that forms a part. The actuator linearly moves the moveable press ram by use of a male-female thread mechanism. The actuator includes an actuator sprocket coupled to the male-female thread mechanism. The first motor system produces a high-force linear movement condition to the press ram, and includes a clutch coupled to a first motor and a first motor sprocket coupled to the clutch. The second motor system produces a high-speed linear movement condition to the press ram. The belt system couples the actuator sprocket, the first motor sprocket, and the second motor sprocket. The clutch allows the first motor to partially or fully disengage from rotational movement of the first sprocket when the belt is being driven by the second motor.