Flat Harness Punching Machine with Rotatable Inserts
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Solution Overview
Problem
Existing flat harness machining methods require multiple punching devices and complex setups to form various hole profiles, leading to increased production costs, management complexity, and potential worker confusion during the formation of different hole types.
Innovation Solution
A punching machine with multiple punching devices, such as a first and second punching device, forms different types of hole portions simultaneously or sequentially, allowing for efficient production of hole profiles with various purposes without the need for multiple machines, reducing confusion and setup complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple punching devices are used to form different hole profiles, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The punching device is designed with interchangeable punch inserts that can be rotated to different orientations, allowing a single device to perform multiple punching operations (round holes, slots, positioned holes) that previously required separate dedicated devices. This multi-functional design maintains manufacturing precision while reducing device complexity.
Solution Approach 2:
Multiple punching functions (round hole formation, slot formation, positioned hole formation) are merged into a single punching device through the use of a rotatable punch insert mechanism. This consolidation eliminates the need for multiple separate punching devices and complex setups, while maintaining the precision required for different hole profiles.
2Manufacturing precision
If multiple punching devices are used to form various hole types, then manufacturing precision is improved, but production cost increases
Solution Approach 1:
A single punching device with rotatable punch inserts replaces multiple dedicated punching devices, significantly reducing equipment investment costs. The device maintains manufacturing precision for different hole types (round holes, slots, positioned holes) while eliminating the need to purchase and maintain multiple separate machines.
Solution Approach 2:
The patent merges multiple punching functions into one device, reducing not only equipment costs but also associated costs for device management, maintenance, and operator training. This consolidation maintains high manufacturing precision while making production more cost-effective.
3Manufacturing precision
If multiple punching devices are used for different hole profiles, then manufacturing precision is improved, but productivity decreases
Solution Approach 1:
The punch insert is pre-configured with multiple punching patterns (round holes, slots, positioned holes) that can be rapidly rotated into position. This preliminary preparation of the punch insert allows the operator to switch between different hole profiles quickly without requiring complex setups or multiple devices, thereby maintaining positioning accuracy while improving productivity.
Solution Approach 2:
By combining multiple punching functions in one device with quick-change punch inserts, the patent eliminates the time-consuming process of switching between multiple dedicated punching devices. The merging of functions maintains manufacturing precision while significantly reducing setup time and improving overall machining efficiency.
4Manufacturing precision
If multiple punching devices are used to form different hole types, then manufacturing precision is improved, but ease of operation decreases
Solution Approach 1:
The punching device is designed as a universal tool that can perform all punching operations (round holes, slots, positioned holes) through simple rotation of the punch insert. This eliminates the complexity of managing multiple dedicated devices and their respective setups, while maintaining high manufacturing precision for all hole types.
Solution Approach 2:
The patent merges multiple punching operations into a single device with a unified control mechanism. The operator simply rotates the punch insert to the desired orientation rather than changing entire punching devices or performing complex setups, thereby maintaining manufacturing precision while dramatically simplifying operation.
Data Source
AI summary
A flat harness is machined by providing a punching machine that includes a first punching device and a second device, and forming different types of hole portions in the shape on the insulating portion of the flat harness in a die cutting process by using the first punching device and the second punching device.