Gas Cooling Press Tools for Uniform Hot Blank Quenching
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Solution Overview
Problem
Existing multistep press systems for manufacturing hot formed structural components face challenges in maintaining homogeneous and constant cooling, requiring significant maintenance and resulting in long startup times and production losses, especially when resuming after interruptions.
Innovation Solution
The integration of gas cooling tools within the press system, allowing for flexible cooling parameters and reduced maintenance, with upper and lower gas cooling tools connected to the mobile and fixed bodies via biasing elements, ensuring consistent cooling and efficient transfer times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If contact plate cooling tools are used, then cooling capability is improved, but maintenance requirements increase significantly and startup time increases
Solution Approach 1:
The patent replaces mechanical contact plate cooling tools with a gas-based cooling system. Gas jets are directed against the blank surface to achieve cooling without physical contact, eliminating the wear and maintenance issues associated with contact plates while maintaining effective heat removal capability.
Solution Approach 2:
The invention uses pressurized gas (pneumatics) as the cooling medium. Gas nozzles deliver high-velocity gas streams to the blank surface, providing efficient convective cooling without the mechanical contact problems that plague traditional plate-based systems.
2Temperature
If contact plate cooling tools are used, then cooling capability is improved, but production losses increase due to long startup times
Solution Approach 1:
By substituting mechanical contact plates with gas-based cooling, the system eliminates the long warm-up and stabilization periods required for contact plates to reach operating temperature. Gas cooling is immediately effective upon system startup, reducing production losses during changeovers and interruptions.
3Ease of repair
If gas cooling tools are used, then maintenance needs are reduced and cooling flexibility is improved, but system complexity increases
Solution Approach 1:
While introducing gas delivery systems adds some complexity compared to simple contact plates, the overall system becomes easier to maintain. The gas cooling system uses standard pneumatic infrastructure with no moving parts in contact with the workpiece, reducing maintenance needs despite the added complexity of nozzle positioning and gas flow control.
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 solution enhances production efficiency by reducing maintenance needs, achieving consistent and homogeneous cooling, and allowing for flexible cooling adjustments, thereby improving productivity and formability without cracking issues.
Implementation Method 1
a cooling tool configured to cool down a previously heated blank
Implementation Method 2
upper and lower biasing elements, ensuring consistent cooling and efficient transfer times
Implementation Method 3
blanks may need to be quenched (i.e. be cooled down rapidly) to achieve the high tensile strengths
Implementation Method 4
Hot Forming Die Quenching (HFDQ) (also known as hot stamping or press hardening)
Data Source
Figure 1
Figure 1A~1C
Figure 1D~1F
AI summary
Press apparatus and methods for manufacturing hot formed structural components are provided. The apparatus comprise a fixed lower body, and a mobile upper body. The apparatus comprise a cooling tool and a press tool which is arranged downstream from the cooling tool, and a blank transfer mechanism to transfer the blank from the cooling tool to the press tool. The cooling tool has an upper gas cooling tool connected to the mobile upper body and/or a lower gas cooling tool connected to the fixed lower body. The press tool comprises an upper pressing die connected to the upper body and a lower pressing die is connected to the lower body.