Indexing Rotation Plate Punching for Cylindrical Workpieces
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Solution Overview
Problem
Conventional stamping processes for cylindrical workpieces require multiple task stations and machines, leading to low positioning accuracy and production efficiency due to the complexity of performing punching operations at multiple angles on a circumferential surface, resulting in increased costs and compromised product quality.
Innovation Solution
A punching mold device with an upper and lower mold base, an indexing rotation plate, a servo motor, and a position-fixing element that synchronously rotates the workpiece and indexing rotation plate, allowing for precise 360-degree punching by controlling a positioning pin and punching head module through a central control unit, enabling continuous and efficient punching across the entire surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple task stations and punching machines are used to perform punching operations at multiple angles on a cylindrical workpiece, then the punching operation can be completed, but the device complexity increases and production efficiency decreases
Solution Approach 1:
The patent combines multiple punching operations at different angles into a single integrated device. The indexing rotation plate allows one punching machine to perform operations that previously required multiple separate machines and task stations, thereby reducing device complexity while maintaining versatility.
Solution Approach 2:
The patent introduces a dynamic indexing rotation plate that can rotate to different angular positions and lock at predetermined intervals. This dynamic positioning capability enables a single stationary punching machine to access different circumferential locations on the workpiece, replacing multiple fixed task stations.
2Adaptability or versatility
If multiple task stations are used for punching operations on cylindrical workpieces, then all angles can be covered, but positioning accuracy decreases due to cumulative errors
Solution Approach 1:
The patent incorporates a sensor that detects the position of the positioning pin in the indexing rotation plate, providing feedback to the control system. This feedback mechanism ensures precise angular positioning and eliminates cumulative errors that would occur with manual or open-loop multi-station systems.
Solution Approach 2:
The patent replaces the mechanical positioning system of multiple fixed task stations with a controlled rotation system. The indexing rotation plate with positioning pins and sensors provides automated, precise angular positioning, substituting the error-prone mechanical alignment of multiple stations with a single controlled rotation mechanism.
3Adaptability or versatility
If multiple punching machines are used for different task stations, then punching operations can be performed, but production efficiency decreases
Solution Approach 1:
The patent merges the functions of multiple punching machines into a single machine equipped with an indexing rotation plate. This allows one machine to perform the work of several machines by rotating the workpiece to different angular positions, thereby improving production efficiency while maintaining full punching functionality.
Solution Approach 2:
The indexing rotation plate enables continuous punching operations around the entire circumferential surface of the workpiece in a single setup. The workpiece can be rotated and punched at multiple angles without being removed and repositioned on different machines, eliminating idle time and improving productivity.
4Adaptability or versatility
If conventional task stations are used for punching, then punching operations can be completed, but cost increases
Solution Approach 1:
The patent combines multiple punching operations into a single device, reducing the total number of machines and task stations required. This consolidation lowers capital investment, maintenance costs, and operational expenses while maintaining the ability to perform punching operations at all necessary angles.
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 solution allows for precise control of the workpiece rotation angle, improving production efficiency and product quality by enabling simultaneous punching across all directions with a single machine, reducing errors and costs while ensuring consistent stamping processes on the circumferential surface.
Implementation Method 1
The servo motor is a power source for synchronously rotating the indexing rotation plate and the workpiece
Implementation Method 2
The position-fixing element is controlled by, for example, a solenoid valve or a rotary encoder, so as to perform indexing, rotating and positioning of an indexing plate
Data Source
AI summary
A punching mold device capable of rotating a workpiece includes an upper mold base, a lower mold base opposite to the lower mold base, an indexing rotation plate, a servo motor and a position-fixing element. The lower mold base includes a clamping portion for fixedly clamping a workpiece. The indexing rotation plate is formed with holes which collectively form a circular contour. The servo motor is connected to the indexing rotation plate and the workpiece, and synchronously rotates the indexing rotation plate and the workpiece. The position-fixing element includes a positioning pin which aims towards and is pluggably connected to one of the holes for stopping the rotation of the indexing rotation plate and the workpiece. The upper mold base includes a punching head module aligned with the clamping portion for punching the workpiece.