Automated Shim Adjusting for Die-Cushion Pin Height Control
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Solution Overview
Problem
Current die-cushion devices face inefficiencies in shim adjustment, leading to prolonged manual processes and potential human errors, and existing pressure control systems struggle to provide precise die-cushion force distribution, especially for complex shapes, resulting in inaccurate product formation.
Innovation Solution
A shim adjusting device with fluid pressure cylinders and a control system that independently adjusts the height of die-cushion pins, allowing for precise shim thickness settings and automatic operation, reducing adjustment time and improving accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual shim adjustment is performed by inserting shims between die-cushion pins and blank holder, then die-cushion force distribution can be adjusted, but adjustment time becomes excessively long (half to whole day or more)
Solution Approach 1:
The patent replaces the manual mechanical shim insertion method with an automated positioning system that uses a positioning table and positioning pins to automatically place shims at correct locations. The system incorporates a control unit that manages the automated positioning and insertion process, substituting manual labor with automated mechanical systems to reduce adjustment time while maintaining precision.
Solution Approach 2:
The patent introduces a positioning table as an intermediary device between the die-cushion pins and the shims. This positioning table with的定位 pins serves as a mediator that ensures accurate positioning of shims during automated insertion, facilitating the transition from manual to automated shim adjustment while maintaining positioning accuracy.
2Manufacturing precision
If manual shim adjustment is performed by inserting shims between die-cushion pins and blank holder, then die-cushion force distribution can be adjusted, but human errors occur such as inserting shims at wrong spots or with wrong thickness
Solution Approach 1:
The patent replaces manual shim placement with an automated positioning system that uses a positioning table and positioning pins to precisely locate and insert shims at correct positions. The control unit automates the entire process, eliminating human errors related to wrong positioning or incorrect shim selection, thereby improving reliability while maintaining adjustment precision.
Solution Approach 2:
The patent incorporates a control unit that manages the automated shim positioning and insertion process. The system uses feedback mechanisms to ensure shims are placed at correct locations with correct thickness, verifying the adjustment process to prevent human errors and ensure consistent accuracy.
3Productivity
If die replacement is performed after production of certain quantity, then production efficiency is maintained, but shim adjustment must be repeated at every die replacement
Solution Approach 1:
The patent creates a universal positioning table that can accommodate different die configurations through standardized positioning pin arrangements. This universal system allows the same automated shim positioning apparatus to be used across multiple die replacements, eliminating the need to redevelop positioning methods for each die and reducing repeated adjustment time while maintaining production efficiency.
Solution Approach 2:
The patent implements preliminary positioning setup where the positioning table and positioning pins are pre-configured for different die types. This preliminary preparation allows rapid setup during die replacements without requiring time-consuming manual shim adjustment, maintaining production efficiency while reducing repeated adjustment time.
4Device complexity
If hydraulic cylinders are divided into groups for pressure control, then device complexity is reduced, but die-cushion force cannot be adjusted for each individual pin
Solution Approach 1:
The patent segments the shim adjustment process into individual pin-level operations using a positioning table with multiple positioning pins, each corresponding to specific die-cushion pins. This segmentation allows independent adjustment of each pin's shim placement while using a unified positioning system, achieving precise individual control without requiring separate hydraulic cylinders for each pin.
Solution Approach 2:
The patent uses a positioning table with positioning pins as an intermediary mechanism between the grouped hydraulic cylinder system and individual die-cushion pins. This intermediary allows the grouped pressure control system to achieve precise individual pin adjustment through the positioning table's ability to selectively position shims at specific locations corresponding to individual pins.
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 solution significantly reduces shim adjustment time from hours to minutes, enhances accuracy, and enables precise die-cushion force distribution, improving product quality and efficiency in die-cushion processes.
Implementation Method 1
a fluid pressure device configured to supply an operating fluid independently to each of rise-side pressurizing chambers of the plurality of fluid pressure cylinders, respectively, or discharge the operating fluid from the rise-side pressurizing chamber
Implementation Method 2
a spring disposed in a lowering-side pressurizing chamber of the hydraulic cylinder
Data Source
AI summary
A plurality of hydraulic cylinders capable of adjusting height direction positions of a plurality of die-cushion pins that are inserted into a plurality of die-cushion pin holes formed in a bolster, respectively, are arranged in a lattice state on a cushion pad, and the hydraulic cylinder faced with a die-cushion pin located below a projection surface of a blank holder in the plurality of hydraulic cylinders is selected. Then, by independently adjusting a height direction position of a piston rod of each of the selected hydraulic cylinders, respectively, the shim adjustment of substantially each of the die-cushion pins is realized.