Hemming Die Change Layout for Shorter Multi-Model Cycle Time
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing hemming systems require significant time to replace dies in the processing station, which prolongs the cycle time and hampers efficiency in processing different types of workpieces.
Innovation Solution
A hemming system and method that incorporates a processing station, a processing robot, a die storage, a first-stage changing station, a second-stage changing station, and mobile robots with linear guide mechanisms and actuators to facilitate rapid transfer and storage of dies, allowing for simultaneous preparation and replacement of dies during the hemming process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a die replacement robot is used to take out the die from the processing station, move it to die storage, and then bring in the next die, then the die can be replaced automatically, but the cycle time becomes long due to the sequential operations required
Solution Approach 1:
The system prepares the next die in advance by placing it in the first-stage changing station before the current die is removed. This preliminary preparation allows the next die to be ready for immediate transfer when the current die is removed, eliminating waiting time and enabling continuous operation without interrupting the processing cycle.
Solution Approach 2:
The die replacement process is divided into two independent stages: the first-stage changing station handles preparation and transfer of the next die, while the second-stage changing station handles removal and transfer of the current die. This segmentation allows both operations to proceed simultaneously through separate transfer mechanisms, dramatically reducing the total replacement time compared to sequential single-stage operations.
2Ease of operation
If the die replacement process is simplified to reduce complexity, then the system becomes easier to operate, but the ability to handle multiple die types efficiently is reduced
Solution Approach 1:
The transfer mechanisms (first and second transfer means) are designed with universal functionality to handle multiple die types. The first transfer means can transfer any die from the first-stage changing station to the processing station, and the second transfer means can transfer any die from the processing station to the second-stage changing station. This universal design allows the system to efficiently handle various workpiece types without requiring complex specialized mechanisms for each die type.
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 configuration enables rapid die replacement without waiting time, significantly shortening the cycle time and enhancing the system's ability to handle different types of workpieces efficiently.
Implementation Method 1
a first LM guide including a linear guide mechanism configured to guide a die disposed in the first-stage changing station toward the processing station in a straight line
Implementation Method 2
a second LM guide including a linear guide mechanism configured to guide a die disposed in the processing station toward the second changing station in a straight line
Data Source
AI summary
A hemming system includes a processing station; a processing robot for performing hemming on a workpiece in the processing station; a die storage for storing dies for hemming in association with types of workpiece; a first-stage changing station in which a die used by the processing robot when performing hemming on a next different type of workpiece and corresponds to the next different type of workpiece is disposed on standby; first transfer means for transferring the die in the first-stage changing station to the processing station; a second-stage changing station in which the die disposed in the processing station is temporarily disposed; second transfer means for transferring the die disposed in the processing station to the second-stage changing station; and a mobile robot for moving the die from the second-stage changing station to the die storage and move the die from the die storage to the first-stage changing station.