Gas Cooling Press Transfer for Uniform Hot Blank Cooling
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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 prolonged startup times and loss of productivity, especially when resuming production after interruptions.
Innovation Solution
Incorporating a gas cooling tool with upper and lower gas cooling tools connected to the mobile and fixed bodies, respectively, and using biasing elements to maintain a consistent distance for effective cooling, allowing for flexible cooling parameters and reduced maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If contact-based cooling tools are used to cool down heated blanks, then cooling effectiveness is improved, but maintenance requirements increase significantly and startup time is prolonged
Solution Approach 1:
The patent replaces contact-based mechanical cooling tools with a gas-based cooling system. Gas jets are directed at the heated blanks to achieve rapid cooling without physical contact, eliminating the wear and maintenance issues associated with contact-based cooling tools while maintaining effective cooling capability.
Solution Approach 2:
The invention utilizes pneumatic systems to deliver cooling gas to the blanks. Gas nozzles and flow control mechanisms are employed to direct cooled gas onto the heated blanks, providing a non-contact cooling method that avoids the maintenance problems of mechanical contact cooling tools.
2Temperature
If contact-based cooling tools are used, then cooling capability is improved, but productivity is reduced due to prolonged startup times
Solution Approach 1:
By replacing mechanical contact cooling tools with a gas-based system, the invention eliminates the prolonged startup time required for mechanical tools to reach optimal cooling conditions. Gas cooling can be activated immediately upon system startup, allowing rapid cooling of blanks without the delay associated with mechanical system warm-up.
3Productivity
If multistep press systems are used to manufacture hot formed components, then production output is improved, but complexity of the system increases
Solution Approach 1:
The gas cooling system is integrated into the existing multistep press system, serving multiple functions: cooling blanks during transfer, preparing blanks for subsequent forming operations, and potentially serving different cooling zones. This multi-functionality reduces the need for separate dedicated cooling equipment, thereby managing system complexity while maintaining high productivity.
4Strength
If rapid cooling is applied to achieve high tensile strengths, then material strength is improved, but risk of microcracks increases
Solution Approach 1:
The gas cooling system allows for localized and controlled cooling of different regions of the blank. By adjusting gas flow distribution and cooling intensity in specific zones, the system achieves the necessary cooling rates for high strength development while minimizing thermal gradients that could cause microcracks in sensitive areas.
Solution Approach 2:
The cooling process can be applied in controlled periodic cycles rather than continuous maximum intensity cooling. This allows the material to undergo controlled thermal cycles that promote uniform microstructure development and reduce the risk of crack formation while still achieving the required cooling rates for high tensile strength.
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 ensuring consistent and homogeneous cooling, reducing maintenance needs, and allowing for faster startup times while maintaining formability and productivity without causing cracks in the blanks.
Implementation Method 1
a cooling tool configured to cool down a previously heated blank
Implementation Method 2
using biasing elements to maintain a consistent distance for effective cooling
Data Source
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.