Electric Press Tool Slides for Precise Sheet Metal Forming
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Solution Overview
Problem
Existing pressing tools rely on pneumatic and hydraulic drives, which are energy-inefficient, temperature-sensitive, and environmentally harmful, requiring additional components and maintenance, and lack precise control and reduced installation space.
Innovation Solution
The pressing tool employs electric drives for the filling and press slides, utilizing electric AC servomotors with communication interfaces for precise control and reduced friction losses, eliminating the need for pneumatic components and allowing for more compact designs with improved dynamics and condition monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If pneumatic drives are used for filling and press slides, then the pressing tool can operate with simple structure, but energy consumption increases and control precision decreases
Solution Approach 1:
The patent replaces pneumatic and hydraulic drive systems with an electric drive system. The electric drive unit directly drives the filling and press slides without requiring pneumatic compressors, hydraulic pumps, or fluid transmission systems. This substitution eliminates the need for complex fluid power infrastructure while reducing energy consumption and improving control precision through direct electric motor control.
2Force
If pneumatic and hydraulic systems are used, then sufficient force can be generated, but temperature sensitivity and reliability decrease
Solution Approach 1:
The patent replaces temperature-sensitive pneumatic and hydraulic systems with an electric drive system that is not affected by temperature fluctuations. The electric motor directly generates the required pressing force without relying on fluid pressure that varies with temperature, thereby improving reliability and eliminating the need for temperature compensation mechanisms.
3Volume of moving object
If pneumatic drives are used, then the system can be compact, but additional components like compressors and shock absorbers are required
Solution Approach 1:
The patent extracts and eliminates unnecessary components from the drive system. By using direct electric drives, the system removes compressors, hydraulic pumps, fluid reservoirs, filters, and complex valve systems that are required in pneumatic and hydraulic configurations. This reduction in component quantity simplifies the overall system while maintaining compact dimensions.
4Force
If hydraulic systems are used, then high force can be generated, but maintenance requirements and environmental harm increase
Solution Approach 1:
The patent replaces hydraulic systems that use potentially harmful hydraulic fluids with an electric drive system. The electric motor generates force without requiring any fluid transmission medium, thereby eliminating environmental contamination risks from hydraulic fluid leaks and removing the need for fluid disposal and environmental safety precautions.
5Use of energy by moving object
If electric drives are used for filling and press slides, then energy consumption and maintenance decrease, but control precision and dynamics must be improved
Solution Approach 1:
The patent incorporates feedback control mechanisms in the electric drive system. Sensors monitor the position, speed, and force of the filling and press slides, and this information is fed back to the control unit. The control unit adjusts the electric motor output in real-time to achieve precise control, thereby meeting the high precision requirements while maintaining the energy efficiency benefits of electric drives.
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
This solution reduces energy consumption, minimizes maintenance, and enhances precision and control, leading to higher cycle times and reduced downtime, while eliminating the need for shock absorbers and compressors, resulting in a more efficient and environmentally friendly pressing tool.
Implementation Method 1
electric AC servomotors with communication interfaces for precise control
Data Source
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AI summary
A press tool (10) for forming a workpiece (100), in particular for forming an automotive sheet metal part, has a movable lower jaw (20) with a forming area (22) which can be moved between a filling position and a pressing position, and a movable upper jaw (30) with a forming area (32) which can be moved relative to the forming area (22) of the lower jaw (20) in its pressing position, so that the workpiece (100) can be formed during a forming process between the forming area (22) of the lower jaw (20) and the forming area (32) of the upper jaw (30). To move the lower jaw (20) between the filling position and a pressing position, the press tool (10) has a filling slide (40) which is designed to move the lower jaw (20) between the filling position and the pressing position.Such a press tool (10) also has a press slide (50) which is designed to lock the lower jaw (20) in the pressing position, so that the lower jaw (20) remains in the pressing position during the forming process. It is proposed that the filling slide (40) and/or the press slide (50) have an electric drive (42, 52).