Hot-Hardening Press Layout for Faster Sheet Metal Forming
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Solution Overview
Problem
Current methods for producing heat-hardened sheet-metal workpieces are inefficient in terms of energy and production time, as they do not effectively optimize thermotechnical processes during and after forming, leading to suboptimal manufacturing quality and efficiency.
Innovation Solution
A system comprising an input magazine, annealing furnace, temperature-controlled hot-hardening forming press, and synchronized workpiece transfer and removal devices that allow for continuous movement and temperature control, enabling optimal thermotechnical processes by maintaining existing temperature distributions in the pressing tool and reducing cycle times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional sequential processing is used (heating, forming, then cooling/removal), then the process is simple to implement, but the cycle time is long and production efficiency is low
Solution Approach 1:
The patent introduces a vertical dimension by positioning the loader and unloader at different heights within the forming press. The loader operates at a lower level while the unloader operates at an upper level, allowing simultaneous vertical stacking of operations that were previously sequential in time.
Solution Approach 2:
The patent enables continuous operation by allowing the loader to insert a new blank while the unloader simultaneously removes the previously formed workpiece. This eliminates idle time between loading and unloading operations, creating a continuous production flow where the forming press is constantly utilized.
2Loss of energy
If the forming press is opened completely for each cycle, then workpiece removal is easy, but heat loss increases and energy efficiency decreases
Solution Approach 1:
The unloader is positioned at an upper level within the forming press, allowing it to access and remove the workpiece from above without requiring the press to open completely. This vertical access path maintains the thermal insulation of the press while enabling efficient workpiece removal.
Solution Approach 2:
The upper-level unloader acts as an intermediary that bridges the gap between the closed forming press and the workpiece removal requirement. It provides a thermal bridge that allows workpiece extraction without compromising the overall thermal integrity of the press system.
3Loss of time
If the loader and unloader operate at the same level sequentially, then the system is simple to design, but the cycle time cannot be reduced below the sequential operation limit
Solution Approach 1:
The patent utilizes the vertical dimension within the forming press to position the loader and unloader at different heights. This spatial separation in the vertical dimension allows both devices to operate simultaneously without interfering with each other, effectively parallelizing the loading and unloading operations.
Solution Approach 2:
The loader and unloader are nested within the forming press at different vertical levels, with the loader operating at a lower level and the unloader at an upper level. This nested arrangement allows both devices to coexist and operate concurrently within the same press volume, maximizing space utilization and enabling simultaneous operations.
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 system enhances manufacturing quality and energy efficiency by optimizing thermotechnical processes during and after forming, allowing for high-quality, efficiently produced heat-hardened sheet-metal parts with reduced cycle times.
Implementation Method 1
an annealing furnace downstream of the input store, through which the sheet metal blanks can preferably be continuously moved
Implementation Method 2
a vertically opening and downstream of the annealing furnace to be closed, temperature-controlled hot-hardening forming press
Implementation Method 3
a cooling station downstream of the hot-hardening forming press
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A system for producing a heat-hardened sheet-metal workpiece, in particular a body part (2), comprises an input store (4) for storing a plurality of unhardened sheet metal blanks (1), an annealing furnace (6) downstream of the input store (4) with a workpiece inlet and a workpiece outlet, a workpiece feed device (7) arranged between the input store (4) and the workpiece inlet of the annealing furnace (6), a temperature-controlled, vertically opening and closing hot-hardening forming press (19) downstream of the annealing furnace (6), one between the workpiece outlet the annealing furnace (6) and the hot-hardening forming press (19) arranged workpiece transfer device with a loader (21) that can be moved into and out of the open hot-hardening forming press (19), a cooling station (32) downstream of the hot-hardening forming press (19) and a workpiece removal egg located between the hot hardening forming press (19) and the cooling station (32). Device (28) with an unloader (30) that can be moved into and out of the open hot-hardening forming press (19). The loader (21) and the unloader (30) are arranged at two different heights and are designed to remain in the open hot-hardening forming press (19) at the same time.