Horizontal Hemming Press Die Configuration
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Solution Overview
Problem
Conventional hemming presses are limited by their vertical orientation, which increases the size and complexity of the system, requires significant floor space, and poses safety hazards due to the weight and height of the dies, making it difficult to maintain and assemble multiple products in a single line efficiently.
Innovation Solution
A horizontal stack press with a plurality of cooperably operable hemming die sets arranged in series, allowing for reduced or expanded die configurations from two to five or more, with a single drive system operating all dies, and incorporating a material handling robot to save floor space and reduce the need for a die change system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a vertical press configuration is used, then the die stacking is compact, but the gravitational load increases the drive size and creates safety hazards
Solution Approach 1:
The patent inverts the conventional vertical press configuration by arranging multiple die sets in a horizontal stack rather than vertically. This inversion eliminates the gravitational load on the drive system, as the dies are now moved horizontally rather than lifted vertically. The drive mechanism only needs to overcome friction and inertial forces, significantly reducing the required drive size and eliminating safety hazards associated with heavy overhead dies.
Solution Approach 2:
The patent transitions from a vertical arrangement (stacking dies upward in the Z-dimension) to a horizontal arrangement (stacking dies along the X-dimension). This dimensional change allows multiple die sets to be configured in series horizontally, enabling the press to handle multiple products in a single line while avoiding the gravitational penalties of vertical stacking.
2Adaptability or versatility
If a vertical press with multiple dies is configured, then more products can be processed, but the clearance height and maintenance difficulty increase significantly
Solution Approach 1:
By inverting the press configuration from vertical to horizontal, the patent achieves multi-product capability through horizontal die stacking rather than vertical stacking. This allows multiple die sets to be arranged in series along the horizontal axis, providing versatility for processing multiple products while keeping the press height at reasonable levels for maintenance and operation.
Solution Approach 2:
The patent utilizes the horizontal dimension (X-axis) rather than the vertical dimension (Z-axis) to accommodate multiple die sets. This dimensional reconfiguration allows for extended press length to house multiple dies in series, while maintaining a compact and accessible press height, thereby achieving multi-product capability without excessive clearance height requirements.
3Device complexity
If conventional press arrangements are used, then the system is simple, but floor space requirements increase by up to 75%
Solution Approach 1:
The patent merges multiple individual press functions into a single horizontal stack press by arranging multiple die sets in series within one press frame. This consolidation allows multiple products to be processed in a single line within one press footprint, dramatically reducing the total floor space required compared to using separate conventional presses for each product.
Solution Approach 2:
The horizontal stack press achieves multi-functionality by incorporating multiple die sets that can process different products within a single press unit. The press can be configured with dies for various hemming operations and product types, eliminating the need for multiple dedicated presses and thereby reducing floor space requirements while maintaining operational simplicity.
4Adaptability or versatility
If a die change system is implemented for multiple parts, then product flexibility is achieved, but the expense, space, and complexity increase
Solution Approach 1:
The patent achieves product flexibility inherently by designing the press with multiple die sets permanently mounted in a horizontal stack configuration. Each die set can be dedicated to a specific product or operation, eliminating the need for a mechanical die change system. The press can process multiple products in sequence or parallel without requiring complex die changing mechanisms, thereby reducing expense, space, and complexity while maintaining adaptability.
Solution Approach 2:
The patent prepares for multi-product processing by pre-configuring multiple die sets in the horizontal stack before production begins. Each die set is positioned and ready for its specific product, allowing the press to handle product changes simply by reconfiguring the die arrangement or selection rather than requiring complex automated die changing systems during operation.
Data Source
AI summary
A horizontally stacked hemming press includes a horizontally disposed base. A first vertical support is mounted on the base and disposed generally perpendicular to the base. A linear track is mounted on the base. A horizontally disposed die stack including a plurality of cooperably operable die sets are horizontally arranged in series and moveable along the linear track. Each die set includes a pair of vertically disposed die shoes. A guided press platen is horizontally moveable along the linear track. A second vertical support is mounted on the base distal from the first vertical support and disposed generally perpendicular to the base. A drive mechanism is supported by one of the supports and connected to the press platen for opening and closing the die sets. Actuation of the drive mechanism horizontally moves the press platen and thereby horizontally opens one of the die sets.