Direct-Drive Notching Press for Flexible Single-Notching Control
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Solution Overview
Problem
Notching presses used for producing rotor and stator sheets for electric motors and generators face inefficiencies in small-batch production due to high costs associated with compound dies, leading to the need for multiple punching processes with a single notching punch, known as single notching.
Innovation Solution
A direct drive system for notching presses is introduced, featuring a frame with a stand and headpiece, a plunger coupled to the headpiece, and an optional indexing head for rotating the workpiece, driven by an electric machine with a drive shaft and connecting rod, allowing for flexible motion control and reduced constructive space requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a traditional mechanical drive system with flywheel and coupling/brake combination is used, then the punching process can be performed, but the device complexity and constructive space requirements increase
Solution Approach 1:
The patent removes the flywheel and coupling/brake combination from the drive system, retaining only the essential electric motor and drive shaft components. This extraction of non-essential elements reduces both constructive space requirements and device complexity while maintaining the core punching function.
Solution Approach 2:
The patent replaces the traditional mechanical drive system (flywheel, coupling, brake combination) with an electrical direct drive system using an electric motor. This substitution eliminates complex mechanical transmission elements and reduces the overall complexity of the drive train while achieving the same punching function.
2Device complexity
If a direct drive system is implemented, then device complexity is reduced, but control flexibility for pendular stroke may be limited
Solution Approach 1:
The patent employs a programmable controller that can dynamically adjust the motion profile of the drive shaft, enabling flexible control of the plunger's pendular stroke. The system can adapt motion parameters such as stroke length, speed, and timing based on different processing requirements, maintaining high versatility despite the simplified mechanical structure.
Solution Approach 2:
The patent utilizes variable frequency drives and programmable logic to change operational parameters of the electric motor, allowing the system to achieve different motion characteristics including pendular stroke patterns. By modifying electrical control parameters rather than mechanical components, the system maintains adaptability while reducing structural complexity.
3Adaptability or versatility
If multiple punching processes are used for single notching, then production flexibility is improved, but productivity decreases
Solution Approach 1:
The patent designs a universal direct drive system that can perform multiple punching operations and different stroke patterns through programmable control. The single drive mechanism is capable of executing various notching patterns and multi-stage punching processes, providing both production flexibility and high productivity without requiring separate specialized equipment for each operation type.
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 direct drive system enables efficient and flexible control of the plunger's motion, reducing the need for additional axes and flywheels, optimizing the punching process, and extending tool life by minimizing impact velocity and eliminating the requirement for complex drive train maintenance.
Implementation Method 1
an electrical direct drive, The direct drive may comprise an electric machine, a drive shaft drivable by the electric machine
Implementation Method 2
a drive shaft drivable by the electric machine and comprising eccentric, and a connecting rod coupled to the eccentric and coupleable to the plunger
Data Source
AI summary
The present invention relates to a drive device for driving an apparatus (100) for notching, wherein the apparatus (100) for notching comprises a frame with a stand (104) and a headpiece (106), a plunger (114) coupled to the headpiece (106) and movable along a punching axis (116) oriented along a y axis, and optionally an indexing head (120) for receiving a workpiece (102) to be machined. The drive device comprises an electrical direct drive (118) for driving the plunger (114).