Hot Stamp Cell Blank Positioning Across Multi-Zone Heating
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Solution Overview
Problem
Existing hot stamp cells face inefficiencies due to inaccurate blank placement and displacement during the heating and forming process, leading to interruptions and waste, as well as complex and inefficient handling methods that do not effectively control the metallurgical properties of the blanks.
Innovation Solution
A hot stamp cell system utilizing robots and a transfer table with adjustable guides and proximity sensors for precise blank positioning, allowing for controlled movement and handling of blanks through multiple heating zones and a press, ensuring accurate orientation and placement to maintain continuous production flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a linear conveyor is used to move blanks through a heating zone, then the blanks can be transported through the heating process, but inaccurate placement and displacement occur leading to production interruptions
Solution Approach 1:
A robotic gripper system acts as an intermediary between the blank and the forming tool, providing precise control and positioning throughout the heating and forming process. The robot maintains accurate placement while transporting the blank through multiple heating zones, eliminating the displacement problems associated with linear conveyors.
Solution Approach 2:
The patent replaces the mechanical linear conveyor system with a robotic manipulation system that uses sensors and controlled movement to achieve precise blank placement. This substitution allows for real-time adjustment and maintains positioning accuracy throughout the process.
2Ease of operation
If rotating ceramic rollers are used to move blanks through a heating zone, then the blanks can be transported, but blanks can wander and drift out of position
Solution Approach 1:
The robotic gripper serves as a controlled intermediary that actively maintains blank position rather than passively allowing it to ride on rollers. The robot's precision control system prevents wandering and drifting by continuously adjusting the blank's position throughout the heating process.
Solution Approach 2:
The system incorporates sensors that provide feedback on blank position, allowing the robotic system to make real-time corrections and maintain precise positioning throughout the heating zone, preventing the drift that occurs with roller-based systems.
3Device complexity
If a single door furnace is used, then the structure is simpler, but each blank must be inserted and removed through the same door causing inefficiency
Solution Approach 1:
The furnace system is segmented into multiple heating zones with separate access points. This allows different blanks to be processed simultaneously through different doors, eliminating the bottleneck of single-door furnaces while maintaining manageable structural complexity.
Solution Approach 2:
The system transitions from a single-access-point furnace to a multi-access-point configuration, adding spatial dimensionality to the loading/unloading process. This allows parallel processing of multiple blanks through different doors, significantly improving throughput.
4Ease of manufacture
If blanks are gripped at opposite ends and dropped on the conveyor, then the handling process is simple, but the blanks are easily misplaced
Solution Approach 1:
The robotic gripper system acts as a precision intermediary between the blank and the forming tool, providing controlled placement rather than simple dropping. The robot maintains accurate positioning throughout the process, eliminating misplacement while keeping the handling process efficient.
Solution Approach 2:
The simple mechanical gripping and dropping system is replaced with a robotic manipulation system that uses sensors and controlled movement to achieve precise placement. This substitution maintains ease of operation while dramatically improving placement accuracy.
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
The system ensures accurate and efficient transformation of blanks into finished components by maintaining control over blank placement and handling, reducing interruptions and waste, and allowing for continuous operation even with malfunctioning heating zones, thereby enhancing production efficiency and metallurgical property control.
Implementation Method 1
a series of heating zones (108) arranged vertically above one another within the housing (100)
Implementation Method 2
The cooling results in a change of the metallurgical structure and enhances the properties of the finished article
Data Source
AI summary
A method of forming a finished component in a hot stamp cell having a press to form a blank in to a finished component. The press has a form tool and a piercing tool and the method includes the steps of inserting a blank in to the form tool in a first metallurgical condition, operating the press to close the form tool and form the blank, dwelling the press with the form tool closed while the blank changes from the one metallurgical condition to another metallurgical condition, and maintaining the blank within the form tool while operating the piecing tool when the other condition is attained.