Lever-Driven Press Brake for Uniform Plate Bending
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Solution Overview
Problem
Conventional press brakes suffer from insufficient pressing power at the sides due to pulley-driven systems, leading to uneven bending of plates, and are noisy, expensive, and require high maintenance due to spindle configurations.
Innovation Solution
A press brake design featuring a lever system moveably attached to the frame, driven by a motor with a pulley assembly, allowing for efficient transfer of force and reducing noise and maintenance needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a pulley-driven system is used to drive the top pressing element, then the structure is simple and cost-effective, but the pressing power is insufficient at the sides leading to uneven bending
Solution Approach 1:
The pressing element is divided into multiple independent pressing units (first pressing unit and second pressing unit) that can be driven separately. Each pressing unit has its own drive mechanism, allowing independent control of pressing force at different locations, thereby achieving uniform bending across the entire workpiece while maintaining structural simplicity.
2Force
If a spindle configuration is used to drive the top pressing element, then the pressing power is sufficient, but the noise level is high and maintenance requirements are increased
Solution Approach 1:
The traditional spindle-driven mechanical system is replaced with a direct-drive motor system. The motor is directly coupled to the pressing element through a coupling device, eliminating the need for spindles, gears, and other mechanical transmission components. This substitution significantly reduces noise, lowers maintenance requirements, and maintains sufficient pressing power through direct motor torque application.
3Force
If a spindle configuration is used to drive the top pressing element, then the pressing power is sufficient, but the cost and maintenance time are increased
Solution Approach 1:
The complex spindle and gear transmission system is replaced with a direct-drive motor configuration. This eliminates multiple mechanical components that require lubrication, alignment, and periodic replacement. The motor-coupling direct drive system has fewer moving parts, reduced mechanical complexity, and lower maintenance costs while maintaining the required pressing force capability.
4Object-generated harmful factors
If a lever system with motor is used to drive the pressing element, then the noise production is reduced and maintenance is lowered, but the device complexity increases
Solution Approach 1:
A lever system is introduced to convert the rotational motion of the motor into the reciprocating linear motion required for pressing. The lever mechanism provides dynamic motion transformation, allowing the motor to drive the pressing element through a lever arm that pivots about a fixed point. This dynamic mechanism achieves the required pressing motion while maintaining low noise and low maintenance characteristics.
Solution Approach 2:
The lever acts as an intermediary mechanism between the motor and the pressing element. It transfers and transforms the motor's rotational output into the linear reciprocating motion needed for pressing, while also providing mechanical advantage to amplify the motor's force output. This intermediary lever system manages the complexity by using a simple, well-understood mechanical principle.
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 lever-driven press brake achieves higher pressing power with reduced noise and lower maintenance costs, enabling faster and more energy-efficient plate bending processes.
Implementation Method 1
a lever (18) that is moveably attached to the frame (4) and that is moveable between a press position and a release position
Implementation Method 2
The pulleys are connected with a belt and driven by an electric motor
Implementation Method 3
By pulling the belt the motor brings the pulleys fixed on the top pressing element to the pulleys fixed on the frame
Data Source
AI summary
The present invention relates to a press brake and a method for operating a press brake. The press brake according to the present invention includes a press brake frame; a lever that is moveably attached to the frame and that is moveable between a press position and a release position; a motor that is operatively attached to the frame and the lever, which the motor is configured to move the lever between the press position and the release position; and a pressing element including a top pressing part and a bottom pressing part. The bottom pressing part is operatively connected to the frame. The top pressing part is operatively connected to the lever. The top pressing part and the bottom pressing part are configured to mate when the lever is in the press position.