Automated Die Locking Arms for Thermal Expansion Compensation
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Solution Overview
Problem
Isothermal forging dies experience breakage or movement due to thermal expansion, which is not effectively addressed by existing manual bolt-tightening methods, leading to inefficiencies and safety concerns.
Innovation Solution
A die locking device with adjustable actuators and hinges that monitor and control the force exerted on the die stack, allowing for real-time adjustment to compensate for thermal expansion, preventing die movement and breakage while automating the locking process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If bolts are manually tightened to prevent die movement, then die stability is improved, but thermal expansion causes bolts to break
Solution Approach 1:
The locking system transitions from static manual bolt tightening to dynamic automated locking arms that can adjust their clamping force. The locking arms are actuated by hydraulic or pneumatic cylinders, allowing the system to dynamically adapt to thermal expansion while maintaining secure die positioning throughout the heating and forging process.
Solution Approach 2:
The patent replaces the mechanical bolt-tightening system with an automated actuated locking system. Instead of relying on manual mechanical fasteners that cannot accommodate thermal changes, the system uses actuated locking arms with controlled force application, eliminating the bolt breakage problem while maintaining die stability.
2Strength
If bolts are insufficiently tightened to prevent breakage, then bolt strength is preserved, but dies move relative to each other during forging
Solution Approach 1:
The system incorporates sensors that monitor die position, alignment, and thermal expansion in real-time. This feedback is fed to the control system, which automatically adjusts the actuation force applied to the locking arms, ensuring optimal clamping force is maintained throughout the forging process without causing bolt failure or die movement.
Solution Approach 2:
The locking system is self-regulating through automated control. The system monitors its own performance and automatically adjusts locking forces without external intervention, maintaining optimal die security while adapting to thermal conditions during the forging process.
3Device complexity
If manual bolt tightening is used, then device complexity is reduced, but productivity decreases due to slower die changes
Solution Approach 1:
The patent replaces manual mechanical bolt operations with automated actuated locking mechanisms. This substitution increases initial system complexity but dramatically improves productivity by enabling rapid die changes without requiring manual disassembly and reassembly of multiple bolts, reducing die change time significantly.
Solution Approach 2:
The locking arms are designed to automatically engage and lock dies in position as they are placed in the press, eliminating the need for subsequent manual bolt tightening. The preliminary automated locking action prepares the system for immediate operation, reducing overall die change time.
4Object-affected harmful factors
If complete cooling is required for die changes, then die safety is improved, but loss of time increases
Solution Approach 1:
The automated actuated locking system replaces manual bolt operations, allowing die changes to be performed safely and rapidly without requiring complete cooling cycles. The automated system can quickly release and reposition dies, reducing the time dies must remain in the press and thereby reducing thermal exposure risks while maintaining safety through controlled operation.
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 ensures the dies are securely held during forging, preventing breakage and movement, reduces manual labor, and allows for faster die changes without complete cooling, enhancing safety and process efficiency.
Implementation Method 1
a plurality of actuators, each of the plurality of actuators affixed to a first end of one of a plurality of locking arms
Implementation Method 2
As die stack is heated the die stack experiences thermal expansion
Data Source
AI summary
A die locking device including a press having a top end, a bottom end and a plurality of channels disposed around a perimeter of the press. The device also includes a plurality of actuators, each of the plurality of actuators affixed to a first end of one of a plurality of locking arms that are each at least partially disposed in one of the plurality of channels. The device also includes a plurality of locking clips, each affixed to a second end of each of the plurality of locking arms and each affixed to one of a plurality of hinges. The plurality of hinges is configured to receive and secure a die stack to the top end of the press.