Low-Profile Hydraulic Punch Head with Fiber Optic Sensor
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Solution Overview
Problem
Existing punch dies for lead-acid battery case manufacturing are bulky and inefficient, slowing down the manufacturing process due to their specific configurations and slow positioning methods.
Innovation Solution
A low-profile hydraulic punch head system with a position sensor and vacuum tube for rapid and precise punching, featuring a hydraulic anvil piston and punch die configuration that allows for simultaneous punching of multiple holes with improved material extraction through a compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If existing bulky punch dies are used, then punching function is achieved, but manufacturing speed decreases and positioning time increases
Solution Approach 1:
The punch die is divided into separate modular components including a punch head, anvil, and positioning elements that can be independently adjusted. This segmentation allows for faster positioning and reconfiguration compared to bulky integrated punch dies, directly improving manufacturing speed while maintaining the punching function.
Solution Approach 2:
The punch die incorporates dynamic positioning mechanisms and adjustable components that enable rapid repositioning during manufacturing operations. This dynamic capability eliminates the slow positioning associated with fixed bulky punch dies, increasing productivity without sacrificing structural integrity.
2Manufacturing precision
If precise positioning is achieved using position sensors, then punching accuracy improves, but device complexity increases
Solution Approach 1:
The system replaces complex mechanical positioning measurement methods with optical position sensors. This substitution achieves high punching accuracy through non-contact optical measurement, avoiding the need for complex mechanical measurement mechanisms while maintaining precision.
Solution Approach 2:
The position sensor serves multiple functions including positioning verification, alignment confirmation, and quality control monitoring. This multi-functionality reduces the need for separate measurement devices, thereby limiting the increase in device complexity while achieving precise positioning.
3Speed
If low-profile hydraulic anvil piston is used, then positioning speed increases, but sealing requirements become more stringent
Solution Approach 1:
The seal design incorporates optimized geometric parameters and material properties specifically tailored for the low-profile hydraulic anvil piston configuration. By adjusting seal cross-section dimensions, material hardness, and installation parameters, the system achieves reliable sealing performance despite the reduced profile and increased positioning speed requirements.
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 enables continuous and rapid operation with increased speed and reliability, addressing the inefficiencies of existing technologies by allowing for faster and more precise positioning and material extraction.
Implementation Method 1
hydraulic fluid may be alternately applying pressure to a first side of the hydraulic anvil piston, moving the punch from an initial position in a direction toward the punch die, and applying pressure to a second side of the hydraulic anvil, opposite from the first side of the hydraulic anvil, such that the punch moves away from the punch die
Implementation Method 2
material punched by operation of the punch and punch die may be vacuumed from the punch body using a vacuum tube
Data Source
AI summary
A punch head comprises a low profile hydraulic anvil piston with a punch across from a die on opposite sides of a gap between two legs. One of the legs comprises a position sensor disposed on the bottom of the leg. For example, a plurality of punch heads are disposed on a jig or frame and are positioned using one or more of the position sensors. For example, the position sensor is a mini fiber optic position sensor mounted in a recessed portion at the bottom of one or more of the punch heads.