Electric Press Core Pin Position Control
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Solution Overview
Problem
Hydraulically driven toggle-lever presses face challenges in precise control of core pin position and movement, leading to inconsistencies in metal piece deformations and increased resource waste due to inaccuracies and wear on molds, especially when producing multiple holes or surface deformations simultaneously.
Innovation Solution
An electrically driven press system with a movable ram and adjustable bearing allows precise control of core pin position and speed, enabling accurate deformation and extended mold life through closed-loop lubrication and independent core pin adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If hydraulically driven toggle-lever presses are used to deform metal pieces, then sufficient deformation power can be achieved, but precise control of core pin position and movement is lost
Solution Approach 1:
The press system is divided into independent controlled units with separate electric motors for each core pin, allowing individual precise control of position and movement while maintaining overall system power capability
Solution Approach 2:
The hydraulic drive system is replaced with an electrically driven system featuring electric motors, gearboxes, and ball screw mechanisms that provide both sufficient power and precise positional control through electronic feedback systems
2Adaptability or versatility
If manual adjustment of connecting rod hinging points is performed, then travel adjustment is possible, but adjustment time increases and precision is limited to discrete positions
Solution Approach 1:
The system transitions from static discrete adjustment positions to dynamic continuous adjustment capability through electrically controlled mechanisms that can be programmed for any travel distance and speed profile
Solution Approach 2:
The connecting rod hinging point positions are replaced with electrically adjustable mechanisms that allow continuous variation of travel parameters through electronic control rather than manual mechanical adjustment
3Power
If hydraulic oil thermodynamic characteristics are used for power transmission, then power can be transmitted, but variations over time cause errors in component displacement
Solution Approach 1:
The hydraulic power transmission system is replaced with an electric drive system using electric motors and mechanical power transmission elements that do not suffer from fluid thermodynamic variations, providing consistent and repeatable displacement
Solution Approach 2:
The electrically driven system incorporates feedback control mechanisms that monitor and adjust motor position and speed in real-time, compensating for any variations and ensuring repeatable displacement accuracy
4Productivity
If several toggle arrangements with respective core pins are used, then multiple holes or surface deformations can be made simultaneously, but device complexity and bulk increase remarkably
Solution Approach 1:
A single electric drive system with multiple independently controlled motors serves multiple core pins, providing universal control capability that reduces overall system complexity compared to separate hydraulic systems for each pin
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 achieves high accuracy and repeatability in metal piece deformation, extends mold service life, and reduces resource waste by enabling precise control of core pin position and speed, ensuring consistent product quality across multiple cycles.
Implementation Method 1
the second movement element is electrically driven
Implementation Method 2
The core pin is arranged on a ram movable along a first axis, and such a ram is connected through a connecting rod to a movement element reciprocating at least axially along a second axis incident to the first axis
Implementation Method 3
at least one deforming core pin, or punch, that can be reversibly and at least partially inserted into the mould to deform the metal piece
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Press (1) for deforming at least one metal piece initially having the shape of a billet or similar semifinished product, comprising at least one mould (3) for the metal piece and at least one deforming core pin (2) that can be reversibly, and at least partially, inserted into the mould (3) to plastically deform the metal piece. The core pin (2) is arranged on a ram (4) movable along a first axis (A1), and is connected through a connecting rod (6) to a movement element (5) reciprocating at least axially along a second axis (A2) incident to the first axis (A1). The movement element (5) is electrically driven.