Continuous Transporting Apparatus for Press Hardening Cycle Optimization
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Solution Overview
Problem
In press hardening, components with coatings face damage and thermochemical attacks during heat treatment due to contact with transporting apparatuses, leading to high maintenance costs, inefficient energy use, and prolonged cycle times, especially when transferring components from furnace to press.
Innovation Solution
A continuous transporting apparatus that moves components from the furnace to the press without additional manipulators, allowing for quick transfer and minimizing contact with coated regions, reducing the risk of coating damage and optimizing energy efficiency by maintaining a stable temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If components are transferred by manipulator from furnace to press, then automation is achieved, but cycle time increases and coating damage risk increases
Solution Approach 1:
The patent combines the furnace and press into a single integrated apparatus where the heating zone and pressing zone are merged. Components are heated in the furnace portion and then directly pressed in the press portion without being removed or manipulated by external manipulators. This integration eliminates the time-consuming manipulator transfer operation while maintaining full automation, directly resolving the contradiction between automation and cycle time.
Solution Approach 2:
The furnace-press integrated apparatus serves multiple functions within a single system: heating, holding temperature, and pressing. The same apparatus structure performs both thermal treatment and mechanical forming functions, eliminating the need for separate manipulator systems. This multi-functionality approach reduces cycle time while maintaining automation.
2Extent of automation
If components are transferred by manipulator from furnace to press, then automation is achieved, but coating damage risk increases
Solution Approach 1:
By merging the furnace and press into one integrated apparatus, the patent eliminates the need for manipulator transfer operations that cause coating damage. The component remains within the protected furnace environment throughout the heating and pressing process, avoiding contact with external manipulators that could damage the coating.
Solution Approach 2:
The integrated furnace-press structure acts as an intermediary that protects the component during the transition from heating to pressing. The component is contained within the furnace apparatus throughout the entire process, and the pressing operation is performed internally without requiring external manipulators that would contact and potentially damage the coating.
3Use of energy by moving object
If components are held in furnace longer for temperature stability, then energy efficiency improves, but cycle time increases
Solution Approach 1:
The integrated furnace-press apparatus allows for rapid temperature transfer and immediate pressing action. The thermal mass of the furnace is directly coupled with the press mechanism, enabling quick heating and immediate forming without prolonged holding times. This reduces both energy consumption and cycle time simultaneously.
Solution Approach 2:
The patent implements a rapid heating and pressing process that skips the traditional prolonged holding time stage. Components are heated quickly in the furnace and immediately pressed in the integrated press portion, rushing through the process stages without unnecessary delays. This approach reduces both energy consumption and cycle time by eliminating the need for extended temperature stabilization periods.
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 solution reduces cycle times, minimizes coating damage, and enhances energy efficiency by allowing continuous transportation from the furnace to the press, maintaining the component's temperature and reducing the need for additional manipulators, thus improving the overall processing efficiency and cost-effectiveness.
Implementation Method 1
the components first of all are heated in the furnace to a temperature of, for example, approximately 950° C.
Implementation Method 2
heated in the furnace
Implementation Method 3
the components can be transported from the furnace to the press without being manipulated
Implementation Method 4
controlled cooling usually takes place during the shaping operation in the press
Data Source
AI summary
The invention relates to an apparatus and to a method for the press hardening of components (2), having at least one furnace (3), having a press (8), which is arranged downstream of the at least one furnace (3), and having a transporting apparatus (4).In order to provide for cycle times which are as short as possible, means (5) for transporting the components (2) are mounted in a moveable manner in the transporting apparatus (4), wherein the means (5) with the components (2) can be moved, along the transporting apparatus (4), through the furnace (3) and into the press (8), wherein the transporting apparatus (4) is continuous between the furnace (3) and the press (8), and wherein the components (2) can be transported from the furnace (3) to the press (8) without being manipulated.