Automatic Die Cleaning Device with Reusable Fluid

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Solution Overview

Problem

Manual cleaning of forged wheel hub dies is labor-intensive, time-consuming, and inefficient, with oil-based graphite lubricant being difficult to remove due to high viscosity and strong adhesion, leading to waste and environmental hazards from unused cleaning fluids.

Innovation Solution

An automatic die cleaning device equipped with a robot, a cleaning fluid cyclic-spraying system, and a die overturning mechanism, which uses reusable cleaning fluid collected and filtered for continuous recycling, reducing labor and environmental impact.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If manual cleaning is used, then labor flexibility is maintained, but cleaning efficiency is low and labor intensity is high

Engineering Contradiction:

Improvecleaning efficiencyVSAvoidlabor intensity

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The die cleaning device enables self-service cleaning through automated robotic manipulation and high-pressure spraying systems, eliminating the need for manual labor while maintaining continuous operation capability

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Manual mechanical cleaning operations are replaced by an automated robotic system with programmable motion control, high-pressure fluid delivery, and automated die handling mechanisms

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If cleaning fluid is sprayed continuously, then cleaning effectiveness is improved, but cleaning fluid waste increases

Engineering Contradiction:

Improvecleaning effectivenessVSAvoidcleaning fluid waste

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The system recovers and reuses cleaning fluid through collection devices positioned to capture runoff, filtering systems to remove contaminants, and recycling pumps to redistribute the cleaned fluid back to the spraying system

Inventive Principle:

Principle #34Discarding and recovering

Solution Approach 2:

The cleaning system incorporates feedback control through sensors that monitor cleaning effectiveness and fluid quality, adjusting spray parameters and triggering fluid recovery cycles based on real-time conditions

Inventive Principle:

Principle #23Feedback

3Strength

If high-pressure spraying is used, then cleaning power is increased, but energy consumption increases

Engineering Contradiction:

Improvecleaning powerVSAvoidenergy consumption

Core Design Contradiction:

StrengthVSUse of energy by moving object

Solution Approach 1:

The high-pressure spraying operates in periodic cycles rather than continuously, with alternating phases of high-pressure cleaning bursts and lower-pressure fluid recovery, reducing overall energy consumption while maintaining cleaning effectiveness

Inventive Principle:

Principle #19Periodic action

4Manufacturing precision

If die surfaces are cleaned manually, then equipment complexity is low, but cleaning completeness is insufficient due to uneven surfaces

Engineering Contradiction:

Improvecleaning completenessVSAvoidequipment complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The system incorporates dynamic die positioning and rotation capabilities, allowing the die to be manipulated into various orientations to access all surfaces including uneven and hard-to-reach areas, ensuring complete cleaning coverage

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The automated cleaning system integrates multiple functions including high-pressure spraying, fluid collection, filtration, die positioning, and rotation capabilities into a single multi-functional device that can handle various die geometries

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 automatic system effectively cleans die surfaces, reduces labor intensity, and enhances production efficiency by reusing cleaning fluids, resulting in a smooth and ideal cleaning effect.

Implementation Method 1

the cleaning fluid for flushing the die is collected by the cleaning fluid collection device and filtered by the cleaning fluid filtration device

Methodology Applied

Scientific EffectFiltration: Filter (physical)

Implementation Method 2

the cleaning fluid nozzle is fixed at the front end of the robot arm and moves along with the movement of the robot arm

Methodology Applied

Scientific EffectFluid spray: Fluid Spray

Data Source

PatentUS11491519B2Automatic die cleaning device with reusable cleaning fluid

Publication Date: 2022.11.08 CITIC DICASTAL CO LTD

AI summary

Disclosed is an automatic die cleaning device with reusable cleaning fluid. The automatic die cleaning device includes a robot, a cleaning fluid cyclic-spraying system and a die overturning mechanism. The automatic die cleaning device can spray the cleaning fluid to a die to clean oil stains off the surface of the wheel die, thus realizing the function of automatically cleaning the oil stains off the surface of the die; and the automatic die cleaning device also has the function of reusing the cleaning fluid, thereby saving the cleaning fluid and reducing the influence on the environment. The cleaned die surface is smooth, and the effect is ideal. The automatic die cleaning device reduces the labor intensity, meets the requirement of high-efficiency production, and improves the production efficiency.