Movable Gantry Press Forming With Multi-Die Part Production
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Solution Overview
Problem
Conventional methods for forming large and complex aircraft parts are inefficient, leading to increased costs, complexity, and production time due to the need for large raw materials and extensive machining processes.
Innovation Solution
A system utilizing a movable gantry press and multiple stationary die assemblies, with robots and a controller to automate the process of loading and forming blanks into die assemblies, allowing for the formation of parts with complex shapes using smaller, thinner blanks and continuous heating to reduce material waste and processing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional processes (creep forming and milling) are used to form large angled parts, then the parts can be produced, but material costs increase, waste increases, and production time increases
Solution Approach 1:
The patent applies parameter changes by transitioning from conventional creep forming and milling processes to a new forming process that directly creates complex angled parts. This process change enables the use of thinner blanks with less material, directly reducing material waste while maintaining production efficiency. The new process parameters allow for direct forming of complex geometries without requiring subsequent milling operations.
2Loss of substance
If conventional processes are used to form large angled parts, then the parts can be produced, but raw material costs increase due to requiring larger blanks
Solution Approach 1:
The patent implements parameter changes by adopting a new forming process that allows direct creation of complex angled parts from thinner blanks. This eliminates the need for conventional creep forming followed by milling, thereby reducing raw material consumption while simplifying the manufacturing process. The new process parameters enable direct forming of complex geometries in a single operation.
3Productivity
If a movable gantry press system with multiple die assemblies is used, then productivity increases and material usage decreases, but device complexity increases
Solution Approach 1:
The patent applies universality by designing a movable gantry press system that can selectively operate multiple die assemblies located at different positions. This multi-functional system can produce various finished parts using different die assemblies, increasing productivity and material efficiency. The controller coordinates the movable press and robots to efficiently manage the complex system operations.
Solution Approach 2:
The patent implements self-service through automated robots that load blanks into die assemblies and remove finished parts. The system uses automated material handling and positioning, reducing manual intervention and increasing production efficiency. The controller automatically manages the coordination between the movable press, robots, and multiple die assemblies.
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 approach significantly reduces material usage, processing time, and costs while increasing productivity and reducing worker stress and tool consumption, enabling efficient production of large and complex parts with improved material utilization and reduced waste.
Implementation Method 1
actuate an actuator of the movable gantry press to compress the first blank between the upper die section and the lower die section of the first die assembly to fabricate the first finished part
Data Source
AI summary
Systems, devices, and methods for fabricating finished parts include a system that includes a plurality of die assemblies located at a plurality of respective locations, each die assembly being configured to fabricate a respective finished part. The system further includes a movable gantry press and a robot, each configured to move between the plurality of respective locations. The system further includes a controller configured to receive a input to fabricate a finished part and identify a die assembly of the plurality of die assemblies. The controller is further configured to instruct the movable gantry press and the robot to move to the location of the die assembly. The controller is further configured to instruct the robot to load a blank into the die assembly, and instruct the movable gantry press to operate the die assembly to fabricate the finished part.