Cold Forming Tool Slide Control for Precise Profile Setup
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Solution Overview
Problem
Existing cold forming machines face challenges in achieving high productivity with low waste and ensuring high-quality profile formation on workpieces.
Innovation Solution
A cold forming machine with two tool pairs and at least three independently movable tool slides, each equipped with a controllable drive unit, allows for precise adjustment of tool pairs to produce profiles with reduced pitch errors and vibration transmission, using a control unit to synchronize and adjust the tool slides for optimal deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple tool pairs are used to increase productivity, then production output increases, but machine complexity and setup time increase
Solution Approach 1:
The machine is divided into multiple independent tool pairs (first tool pair with first and second cold forming racks, second tool pair with third and fourth cold forming racks), each capable of independent operation. This segmentation allows parallel processing of multiple workpieces while maintaining manageable complexity through modular architecture.
Solution Approach 2:
Multiple tool pairs are integrated into a single machine platform that shares common structural elements and control systems. Each tool pair can process different workpiece types or profiles, providing multi-functionality that increases productivity without proportionally increasing overall machine complexity.
2Manufacturing precision
If tool slides are independently adjustable to improve precision, then profile quality improves, but adjustment time and operational complexity increase
Solution Approach 1:
The tool slides are equipped with controllable drive units that enable precise positioning and adjustment of cold forming racks before the actual forming operation begins. This preliminary adjustment ensures optimal profile quality is achieved through pre-positioning rather than trial-and-error during production.
Solution Approach 2:
The control unit coordinates the positioning of multiple tool slides based on programmed parameters, providing automated feedback control that reduces manual adjustment time while maintaining high precision in profile formation.
3Productivity
If cold forming racks are moved at high speed to increase productivity, then output increases, but vibration and pitch errors increase
Solution Approach 1:
The cold forming racks are designed with controllable drive units that enable dynamic speed adjustment during operation. The system can operate at high speeds for productivity while incorporating vibration damping and speed synchronization features that minimize pitch errors and maintain manufacturing precision even during rapid movement.
4Productivity
If multiple tool pairs operate simultaneously to increase productivity, then production volume increases, but vibration transmission between tools increases
Solution Approach 1:
Each tool pair is mounted on separate, independently movable tool slides that are not mechanically coupled to one another. This physical segmentation isolates vibration sources, allowing multiple tool pairs to operate simultaneously at high production volumes without vibration transmission between tools degrading quality.
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 machine achieves high productivity with reduced setup times and improved quality by minimizing pitch errors and vibration-induced drawbacks, enabling efficient production of profiles on multiple workpieces simultaneously.
Implementation Method 1
a controllable drive unit for each tool slide of the at least three tool slides that is configured to move an assigned tool slide of the at least three tool slides in the longitudinal direction
Implementation Method 2
cold forming machine for cold forming of a workpiece in order to create a profile on a workpiece outer surface
Implementation Method 3
the one first cold forming rack moves opposite to the one second cold forming rack in the longitudinal direction in order to thereby deform the workpiece between the one first cold forming rack and the one second cold forming rack
Implementation Method 4
a control unit that is configured to control the controllable drive unit of at least two of the at least three tool slides in a manner so that the one first cold forming rack and the one second cold forming rack of each of the two tool pairs take an individually adjustable reference position relative to one another
Data Source
AI summary
The present disclosure refers to a cold forming machine having two tool pairs that include a first cold forming rack and a second cold forming rack for cold forming of a workpiece respectively. The cold forming racks are movable parallel to a longitudinal direction during deformation. Each cold forming rack is attached to an assigned tool slide. Each tool slide can be moved and positioned in a longitudinal direction by means of an assigned drive unit. The drive unit is controllable by means of a control unit. The control slides can be individually positioned and moved in the longitudinal direction. Cold forming machine comprises at least three individually movable tool slides. For setup of cold forming machine, the tool slides and the cold forming racks of each tool pair attached thereon can be brought into a defined reference position in order to obtain the desired geometry of the profile on the deformed workpiece during the following deformation. The reference position can be corrected optionally during a series production of multiple workpieces of the same type, if this is necessary due to external influences, such as thermal influences, tool variations from a desired tool shape or tool wear.