Fine Blanking Head with V-Shaped Piston for Foreign Body Detection
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Solution Overview
Problem
Existing solutions for preventing tool breakage during fine blanking and forming in presses are either complex, costly, or inefficient in detecting foreign bodies and compensating kinetic energy, often requiring separate hydraulic systems or additional sensors.
Innovation Solution
A device with a fine blanking head featuring a V-shaped projection piston and touch piston, connected to a hydraulic system with adjustable pressure rooms, allows for detection of foreign bodies and absorption of kinetic energy through differential pressures, triggering an immediate stop of the press via a sensor signal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing protection devices with detectable gaps and sensors are used, then tool protection is provided, but the device complexity increases and foreign bodies in the tool cannot be detected
Solution Approach 1:
The patent combines the foreign body detection function and tool protection function into a single integrated system using the existing hydraulic pressure medium. The pressure medium serves dual purposes: driving the pistons and detecting foreign bodies through pressure changes, eliminating the need for separate detection systems and reducing overall device complexity.
Solution Approach 2:
The hydraulic pressure medium is given multiple functions: it acts as both the driving force for the quick-elevating pistons and the detection medium for foreign bodies. This multi-functionality reduces the number of separate systems needed and simplifies the overall device architecture.
2Reliability
If separate hydraulic systems with compressed air are used for tool protection, then detection capability is improved, but construction effort and circuitry complexity increase considerably
Solution Approach 1:
The existing hydraulic system is made multi-functional by using the pressure medium for both actuation and detection purposes. This eliminates the need for separate hydraulic systems with compressed air, significantly reducing circuitry complexity while maintaining detection capability.
Solution Approach 2:
The hydraulic system serves itself by using its own pressure medium for detection purposes. The same fluid that drives the system also provides detection information through pressure changes, eliminating the need for external detection systems and reducing overall system complexity.
3Measurement precision
If optical sensors or ultrasonic sensors are used for detecting foreign bodies, then detection accuracy is improved, but device complexity and cost increase
Solution Approach 1:
The patent uses hydraulic pressure changes to detect foreign bodies instead of optical or ultrasonic sensors. The pressure medium transmits force changes caused by foreign bodies directly to the pistons, providing accurate detection through simple pressure sensing that leverages the existing hydraulic infrastructure.
Solution Approach 2:
The hydraulic system detects foreign bodies using its own pressure medium, eliminating the need for separate optical or ultrasonic detection systems. The pressure changes in the hydraulic fluid directly indicate the presence of foreign bodies, providing accurate detection with minimal additional complexity.
4Reliability
If touch pistons and differential pressure systems are added, then foreign body detection is improved, but the quantity of parts increases
Solution Approach 1:
The patent merges the foreign body detection function with the existing piston and pressure chamber structure. The touch piston and differential pressure system are integrated into the existing hydraulic actuation mechanism, allowing detection without adding significant numbers of separate parts.
Solution Approach 2:
The pressure chambers and pistons are given dual functionality: they serve both as actuation mechanisms for the blanking press and as detection elements for foreign bodies. This multi-functionality allows improved detection capability without proportionally increasing the quantity of parts.
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 solution effectively prevents tool breakage by detecting foreign bodies and compensating kinetic energy with a simpler, cost-effective design that integrates with the existing hydraulic system, ensuring immediate press stoppage and reducing construction and circuitry complexity.
Implementation Method 1
a hydraulic system with adjustable pressure rooms, allows for detection of foreign bodies and absorption of kinetic energy through differential pressures
Implementation Method 2
A sensor is provided to a gap between the touch table and main plate that in case of a change of the detection distance transmits a signal to the computer to immediately stop the press
Data Source
AI summary
A device and method are provided for preventing a tool from breaking during fine blanking and/or forming in a press. The device includes a fine blanking head positioned above a ram that carries out a stroke movement. The fine blanking head includes, among other things, a main cylinder retaining a V-shaped projection piston, a touch piston, several V-shaped projection pins, a main plate covering the main cylinder and a touch table to which the tool can be connected. Pressure provided by a hydraulic system is introduced to the device in distinct regions. Gaps between certain device components are maintained and monitored for purposes of determining the undesirable presence of foreign objects in the press operating path. If a sensor determines that the gaps are not maintained then the computer which operates valves that supply the pressure from the hydraulic system will shut the press down.