Die Lip Gap Adjustment via Hydraulic Actuation
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Solution Overview
Problem
Existing die adjustment mechanisms fail to provide quick, accurate, and repeatable adjustment of the gap between lips of adjacent die bodies, especially for wide dies, and struggle to maintain uniformity across the die width.
Innovation Solution
A die adjustment system using linear moving members, ball bearings, and a sliding member, where the sliding member abuts ball bearings and linear moving members, allowing for single-point adjustment of the flexible lip, enabling precise and repeatable gap control between die bodies with minimal force and low manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional link mechanisms are used to adjust die lips, then the structure is simple, but the adjustment is slow and lacks precision
Solution Approach 1:
The patent replaces traditional mechanical link mechanisms with a hydraulic actuation system. Hydraulic cylinders provide precise control of the flexible lip position through fluid pressure, enabling accurate gap adjustment without complex mechanical linkages. This substitution achieves high precision while simplifying the overall adjustment mechanism.
Solution Approach 2:
The patent uses hydraulic pressure as a controllable parameter to adjust the lip gap. By varying the hydraulic pressure, the system can precisely control the position of the flexible lip, enabling repeatable and accurate gap adjustments. This parameter-based control replaces manual mechanical adjustment with automated fluid-powered actuation.
2Reliability
If adjustment mechanisms are added to improve gap control, then precision improves, but the number of parts and complexity increases
Solution Approach 1:
The hydraulic actuation system serves multiple functions: it adjusts the lip gap, maintains the gap under pressure, and provides repeatable positioning. This single hydraulic system replaces what would otherwise require multiple separate mechanical adjustment mechanisms, achieving high reliability without proportionally increasing complexity.
Solution Approach 2:
The hydraulic system maintains continuous pressure on the flexible lip to hold the gap setting without requiring additional locking mechanisms or adjustment devices. The hydraulic pressure itself serves the dual purpose of both adjusting and maintaining the gap position, eliminating the need for separate holding devices.
3Productivity
If manual adjustment methods are used, then the device is simple, but adjustment time and labor increase
Solution Approach 1:
The patent employs hydraulic cylinders to actuate the flexible lip adjustment. Hydraulic systems provide high force multiplication, allowing rapid adjustment of the lip gap with minimal input force. The fluid power system can quickly move the lip to the desired position and hold it there, significantly improving adjustment speed and productivity.
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 allows for swift, accurate, and repeatable adjustment of the lip gap, maintaining uniformity across wide dies with minimal force required, enhancing the precision and efficiency of extrusion processes by providing a separate cross-web gauge adjustment mechanism and controlling machine-direction orientation.
Implementation Method 1
the sliding member, within or upon the main body portion, may abut a plurality of ball bearings and the ball bearings may abut the linear moving members
Data Source
AI summary
The invention comprises a die apparatus including a flexible lip for adjusting a gap between the flexible lip and a second lip. The apparatus includes linear moving members that are adjusted through operative communication with gradients on a slide bar. Ball bearings may be in operative communication with the gradients of the slide bar. Movement of the slide bar causes the ball bearings to move linearly, which, in turn, cause the linear moving members to move in a similar linear direction. The moving members operatively communicate with the lip. As a result, the dimensions of the gap may be changed by moving the slide bar in a first direction.