Forming Device Dual Drive Ram Positioning
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Solution Overview
Problem
Existing forming devices face challenges in achieving high forming quality and additional work steps during the closing and opening movement of the ram, with a need for improved guidance and power transmission to enhance efficiency and reduce operational costs.
Innovation Solution
A forming device with a detachable, non-position-controlled main drive unit and a position-controlled intermediate drive, featuring a flywheel mass, eccentric guide unit, and gear system, which allows for precise positioning of the ram with low energy consumption and high operational reliability through a parallel drive system and independent drive shafts, ensuring mechanical separation and synchronous operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single main drive unit is used to drive the plunger, then the device structure is simple, but the positioning precision and guidance of the plunger deteriorate
Solution Approach 1:
The drive system is segmented into two independent parts: a non-position-controlled main drive unit for generating high force and a position-controlled intermediate drive for precise positioning. This segmentation allows each subsystem to be optimized for its specific function, resolving the contradiction between structural simplicity and positioning precision.
Solution Approach 2:
The patent merges two different drive concepts (main drive and intermediate drive) into a single coordinated system. The main drive unit and intermediate drive are mechanically coupled through the plunger but controlled independently, combining their advantages to achieve both high force and precise positioning.
2Manufacturing precision
If a position-controlled main drive is used to achieve high forming quality, then the positioning precision improves, but the energy consumption increases
Solution Approach 1:
The position-controlled intermediate drive operates only partially during the plunger's movement cycle, specifically for positioning at the end of the stroke where high precision is needed. The main drive handles the bulk of the work with lower energy consumption, while the intermediate drive provides precise positioning only when necessary.
Solution Approach 2:
The intermediate drive provides enhanced positioning capability only in the critical region near the end of the plunger stroke where high forming quality is required. This localized application of position control optimizes energy usage by applying precision control only where needed rather than throughout the entire stroke.
3Device complexity
If the main drive and intermediate drive are mechanically coupled, then the synchronization is simplified, but the operational reliability deteriorates due to mechanical damage risks
Solution Approach 1:
The plunger serves as a mediator between the main drive unit and the intermediate drive. This mechanical coupling through the plunger allows synchronization while maintaining operational reliability, as the plunger naturally coordinates the motion of both drives without requiring complex direct mechanical linkages between them.
4Productivity
If additional processing steps are added during closing and opening movement, then the productivity increases, but the device complexity increases
Solution Approach 1:
The position-controlled intermediate drive enables continuous useful action by allowing additional processing steps to be performed during the closing and opening movements of the plunger. The precise positioning capability ensures that these additional operations can be executed accurately without interrupting the main forming cycle, thereby increasing productivity while maintaining manageable device complexity.
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 design enables precise positioning and efficient operation of the ram, reducing energy consumption and mechanical damage risks, while allowing for high-precision movement and enhanced forming quality, particularly suitable for presses with pressing forces of 400 t or more.
Implementation Method 1
a non-position-controlled main drive unit (3) with a drive motor with flywheel mass (4)
Implementation Method 2
a drive shaft (4) with an eccentric guide unit (5)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a press with a ram that is movable back and forth in at least one predetermined direction. To provide a press with which forming operations can be carried out with particular precision and efficiency, the press comprises a main drive unit (3) for driving the ram (16), which includes a engageable, non-position-controlled drive motor with a flywheel and a drive shaft (4) with an eccentric guide unit (5), a gearbox connected to the eccentric guide unit (5) and the ram (16), and a position-controlled intermediate drive (19) with a separate intermediate drive shaft (20), which is connected to the ram (16) and designed to generate a positioning movement of the ram (16).