Fastener Hot Upsetting Layout With Automated Heating and Transfer
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Solution Overview
Problem
Existing hot upsetting forming apparatuses face inefficiencies due to complex layouts, high human intervention, and safety risks in machining small fasteners, particularly in handling and heating processes, which result in increased costs and reduced productivity.
Innovation Solution
The apparatus incorporates a heating assembly with manipulators and a vibratory inline feeder for automated handling, measurement devices for precise positioning and temperature control, and a hot upsetting assembly with manipulators for lubrication and efficient transfer of fasteners, optimizing layout and reducing manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual handling of fasteners is used, then operational flexibility is maintained, but productivity decreases and labor costs increase
Solution Approach 1:
The automation system is divided into distinct functional modules: vibratory feeder for material supply, heating device for thermal processing, manipulator for positioning, and pressing device for forming. Each module operates independently but coordinates through the control system, resolving the complexity issue by making the system modular and maintainable while achieving high productivity
Solution Approach 2:
The manipulator serves multiple functions: picking fasteners from the feeder, positioning them on the heating device, transferring heated fasteners to the pressing device, and removing finished products. This multi-functionality reduces the number of separate components needed, managing system complexity while maximizing productivity
2Manufacturing precision
If high heating temperature is applied, then fastener forming quality improves, but safety risks increase
Solution Approach 1:
The system uses automated manipulators and heating devices that operate without human intervention during the high-temperature process. The fasteners are heated and formed automatically, eliminating the need for operators to handle hot materials directly, thus maintaining forming quality while eliminating safety risks associated with manual high-temperature operations
Solution Approach 2:
The heating device and manipulator act as intermediaries between the operator and the hot fasteners. These automated components handle the high-temperature materials, protecting human operators from direct exposure to harmful heat while ensuring precise thermal processing for quality forming
3Productivity
If batch machining of fasteners is performed, then production volume increases, but handling difficulty and costs increase
Solution Approach 1:
The vibratory feeder continuously supplies fasteners to the manipulator, which continuously transfers them to the heating device and pressing device. This continuous automated flow eliminates the need for manual batch handling, maintaining high production volume while significantly reducing handling difficulty and operational complexity
Solution Approach 2:
Manual mechanical handling is replaced with an automated electromechanical system comprising vibratory feeders, programmable manipulators, and controlled heating/pressing devices. This substitution handles large batch volumes automatically, reducing the physical handling burden on operators while maintaining high productivity
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 configuration enhances machining efficiency by automating the handling and heating processes, reduces space occupation, and ensures precise control over fastener placement and temperature, thereby improving productivity and safety.
Implementation Method 1
a heating device, provided with a heating station for heating a workpiece
Implementation Method 2
a lubricant spraying mechanism, configured to spray a lubricant to reduce friction between a workpiece and a die
Data Source
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AI summary
The present invention relates to the technical field of hot upsetting forming apparatuses and discloses an apparatus for hot upsetting forming of a fastener, the apparatus comprising a heating assembly and a hot upsetting assembly, wherein the heating assembly comprises at least a first frame, and a first manipulator, a second manipulator and a heating device that are fixed to the first frame, wherein the first manipulator is configured to transfer a workpiece from a vibratory inline feeder with a magazine to the heating device, and the second manipulator is configured to transfer the workpiece from the heating device to a hot upsetting station of the hot upsetting assembly; the hot upsetting assembly comprises at least a hot upsetting machine, and a third manipulator and a fourth manipulator that are fixed to the hot upsetting machine; and the third manipulator is configured to spray a lubricant on a workpiece to be machined, and the fourth manipulator is configured to transfer the workpiece from the hot upsetting machine to the workbin. The apparatus for hot upsetting forming of a fastener according to the present invention has a rational layout and high production efficiency.