Automated Die Cleaning Robot for Non-Planar Press Surfaces
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Solution Overview
Problem
Current methods for cleaning die surfaces in press machines are inefficient, leading to productivity losses and safety risks due to manual operation, as they require shutting down machines and can relocate contaminants, making it difficult to remove foreign debris effectively.
Innovation Solution
An automated die cleaning system with a brush-equipped robot that can maneuver in three dimensions to target and remove foreign debris from non-planar die surfaces based on defect locations identified by a workpiece inspection system, reducing downtime and operator risk.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual cleaning method is used, then operator can remove contaminants, but productivity decreases due to machine shutdown and cleaning time
Solution Approach 1:
The system uses an inspection system to automatically detect defects and triggers the cleaning machine to autonomously clean the die surface without human intervention. The control system automatically coordinates between defect detection and cleaning execution, enabling the system to service itself.
Solution Approach 2:
The manual mechanical cleaning process is replaced with an automated cleaning machine that uses a brush or blade actuated by a robotic arm or linear actuator. This substitution eliminates the need for operator intervention and machine shutdown while maintaining effective contaminant removal.
2Reliability
If operator enters press machine space to clean, then contaminant can be removed, but safety risk increases due to potential injury
Solution Approach 1:
The automated system performs cleaning operations without human entry into the press machine space. The inspection system and cleaning machine work autonomously, eliminating exposure to safety hazards while maintaining cleaning effectiveness.
Solution Approach 2:
The manual cleaning operation is replaced with an automated robotic or actuated cleaning mechanism that operates within the press machine space, eliminating operator exposure to harmful environments while performing the necessary cleaning function.
3Ease of manufacture
If wiping with lint-free towel is used, then cleaning can be performed, but contaminant may be relocated rather than removed
Solution Approach 1:
The wiping action with a towel is replaced with a brush or blade mechanism that physically scrapes or lifts contaminants from the die surface. This mechanical substitution ensures contaminants are removed rather than merely relocated, while the automated positioning ensures precise targeting of affected areas.
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 system enhances productivity by minimizing downtime and reducing the risk of injury by automating the cleaning process, ensuring effective removal of contaminants directly from their source on the die surfaces.
Implementation Method 1
a die cleaning machine having a brush configured to remove foreign debris from at least one of the upper die surface and the lower die surface during a cleaning operation
Data Source
AI summary
A stamping system includes a press machine having installed an upper die with an upper die surface and a lower die with a lower die surface. The upper die surface and the lower die surface each have a non-planar geometry. The press machine presses a workpiece between the upper die surface and the lower die surface during a pressing operation. A die cleaning machine is provided having a brush configured to remove foreign debris from at least one of the upper die surface and the lower die surface during a cleaning operation, wherein the die cleaning machine is configured to maneuver the brush in various orientations relative to the press machine to clean the non-planar upper die surface or the non-planar lower die surface.