Forming Tool Die Coding and Magazine System
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Solution Overview
Problem
Existing forming tools face issues with incorrect die insertion due to reliance on bushings for coding, which can lead to reduced die strength and increased downtimes during die changes, as operators must manually compare inscriptions for process-safe die exchange.
Innovation Solution
Implementing electronic or mechanical coding and decoding means directly on the die and die receiver, eliminating the need for bushings and allowing for a larger die shank diameter, combined with a magazine system for rapid die replacement with integrated decoding means to ensure correct die insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a receiving bushing is inserted in the die receiver with coding to prevent mistaken interchanges, then the reliability of die insertion is improved, but the device complexity increases and the die strength is reduced due to reduced shank diameter
Solution Approach 1:
The invention extracts and eliminates the receiving bushing component from the system. Instead of inserting a separate bushing with coding into the die receiver, the coding means are integrated directly onto the die receiver itself. This removes the unnecessary intermediate component while maintaining the reliability function through direct coding-decoding interaction between the die and die receiver.
Solution Approach 2:
The invention merges the coding function with the die receiver structure. The decoding means are integrated directly into the die receiver, combining what were previously separate functions (bushing insertion and coding verification) into a unified system. This reduces device complexity by eliminating the bushing component while maintaining the reliability of die insertion through direct mechanical or electronic coding verification.
2Reliability
If a receiving bushing is inserted in the die receiver with coding, then the reliability of die insertion is improved, but the die strength is reduced due to reduced shank diameter
Solution Approach 1:
The invention removes the receiving bushing from the system, eliminating the need for it to support or transmit any load. The die shank can now be designed with its full required diameter for strength, as the coding verification function is handled by the integrated decoding means in the die receiver without requiring a separate bushing component.
Solution Approach 2:
By integrating the decoding means directly into the die receiver structure, the invention eliminates the intermediate bushing that would have been in the load path. This allows the die shank to maintain its full diameter and strength characteristics, as the coding verification function is performed without interfering with the mechanical strength requirements of the die assembly.
3Reliability
If operators manually compare inscriptions to ensure correct die insertion, then the reliability of die insertion is improved, but the loss of time increases during die changes
Solution Approach 1:
The invention implements a self-verifying system where the coding means on the die and the decoding means in the die receiver automatically verify compatibility through mechanical or electronic interaction. This eliminates the need for operators to manually compare inscriptions, as the system itself provides immediate verification of correct die insertion, thereby maintaining reliability while significantly reducing the time required for die changes.
Solution Approach 2:
The invention replaces the manual operator action of comparing inscriptions with an automated mechanical or electronic coding-decoding system. The coding means and decoding means automatically verify die compatibility through their interaction, substituting human manual verification with an automated system that is both more reliable and faster, thus reducing die change time while maintaining insertion reliability.
4Productivity
If a magazine with replacement dies is provided on the forming tool, then the productivity is improved by rapid die replacement, but the device complexity increases
Solution Approach 1:
The magazine system is designed with multi-functionality, serving both as a storage facility for replacement dies and as an integrated verification system. The decoding means in the magazine not only verify the correctness of replacement dies but also manage the die change process automatically. This universal design reduces the need for separate verification procedures, thereby limiting the increase in device complexity while maximizing productivity benefits.
Solution Approach 2:
The magazine system performs preliminary verification of replacement dies before they are installed in the forming tool. The decoding means check the coding of replacement dies in advance, ensuring compatibility before the actual die change occurs. This preliminary action streamlines the die replacement process, enabling rapid changes without requiring complex post-installation verification procedures, thus improving productivity with controlled complexity.
Data Source
Figure 1
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Figure 4
AI summary
Die (22) for a forming tool (10), in particular for a punch riveting or clinching tool, having a first axial side (30), on which there is realized a recess (32) for receiving material to be formed, having an axially opposite, second side (34), and having coding means (36) realized to act together with corresponding decoding means (38) of the forming tool (10), the coding means (36) being realized on the second side (34).