Automated DIN Rail Shear System for Custom Lengths
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Solution Overview
Problem
Manual cutting of DIN rail blanks to customized lengths in electrical control panels is time-consuming and labor-intensive, requiring individual measurement and handling, which can be improved by automating the process.
Innovation Solution
An automated system comprising a shear die assembly, servo motor, hydraulic actuator, DIN rail advancer, and cassette that allows for the controlled and programmed cutting of multiple DIN rail blanks to varying lengths without manual intervention, using a shear die assembly with a die plate and actuator to shear the rail, and a cassette with slots to hold and rotate the blanks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual cutting methods are used for DIN rail blanks, then flexibility in cutting individual pieces is maintained, but labor time and operational complexity increase significantly
Solution Approach 1:
The system feeds DIN rail blanks automatically from a magazine without manual intervention. The programmable controller autonomously controls the feeding, positioning, and cutting operations, allowing the system to serve itself rather than requiring continuous human operation.
Solution Approach 2:
Multiple DIN rail blanks are pre-loaded into the magazine in advance. The programmable controller pre-programs the cutting sequence and lengths based on production requirements, so that when production starts, the system can operate automatically without repeated manual setup.
2Manufacturing precision
If individual measurement and handling of each DIN rail blank is performed, then precise cutting lengths are achieved, but time consumption and labor requirements increase
Solution Approach 1:
The system replaces manual measurement and positioning with automated programmable control. The controller precisely positions each blank for cutting based on pre-programmed dimensions, eliminating the need for manual measurement while maintaining or improving precision through digital control.
Solution Approach 2:
The programmable controller stores the cutting parameters and sequence as a program. This digital copy of the cutting instructions is repeatedly executed for each blank, ensuring consistent precision without requiring repeated manual measurement and calculation.
3Productivity
If programmable interfaces are used to automate cutting, then productivity improves, but manual input and handling of blanks are still required
Solution Approach 1:
The magazine serves multiple functions: it stores multiple blanks, automatically feeds them one by one, and positions them for cutting. This multi-functional design eliminates the need for separate manual loading and positioning operations, allowing the system to handle all blank preparation automatically.
Solution Approach 2:
The system feeds and positions blanks automatically without human intervention. The programmable controller manages the entire sequence from blank selection to positioning and cutting, allowing the system to operate autonomously once started.
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 enables efficient and automated cutting of DIN rail blanks to precise lengths, reducing labor and time, and allowing for high-volume production of customized lengths without manual handling, thereby improving productivity and reducing waste.
Implementation Method 1
The actuator may be a hydraulic actuator that is paired with the shear die assembly to drive the shear plate of the shear die assembly to the shearing position
Implementation Method 2
The shear plate may be spring biased to return to an open position when not shearing a rail
Data Source
AI summary
An apparatus is described that is suitable for automated manufacture of electrical control panel DIN rails. The apparatus is directed to an automated assembly that shears multiple DIN rail blanks at varying lengths without a need to manually feed DIN rail blanks through a cutter. The apparatus is particularly well suited for use in an automated assembly of electrical control panels that require customized lengths of significant quantities of DIN rail.