Mechanical Converter for Carrierless Die Motion Control
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Solution Overview
Problem
Current die systems, such as progressive, carrierless progressive, and transfer dies, face limitations in flexibility, material efficiency, and complexity, particularly in terms of motion synchronization and tooling access, which restrict their manufacturing capabilities and cost-effectiveness.
Innovation Solution
A movement device that converts slave motion into drive, pitch, and elevation motions using a mechanical converter, allowing for modular and versatile motion systems with reduced carrier usage, enabling efficient transfer and manipulation of parts within a die system, and incorporating assisting motions through PTO systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a progressive die uses a carrier to tie parts together, then parts can be produced quickly in high volume, but more material is used and access to the part profile is limited
Solution Approach 1:
The patent removes the traditional carrier component from the progressive die system. Instead of using a continuous carrier to tie parts together, the invention extracts this function and replaces it with individual part handling mechanisms that allow parts to be separated and manipulated independently, eliminating material waste while maintaining production efficiency
Solution Approach 2:
The patent introduces an intermediary mechanical converter system that mediates between the press drive motion and the part transfer requirements. This converter uses a rack and pinion mechanism with cam-actuated fingers to grab and transfer parts without requiring a continuous carrier, thus reducing material usage while preserving high-volume production capability
2Loss of substance
If a transfer die system is used to handle parts without a carrier, then material is saved and parts can be turned over or rotated, but the system becomes more complex and requires larger presses
Solution Approach 1:
The patent merges multiple functions into a single integrated mechanical converter unit. The rack and pinion mechanism combines drive motion conversion, part gripping, and transfer capabilities in one compact assembly, reducing overall system complexity compared to traditional transfer die systems while maintaining the ability to handle and reorient parts
Solution Approach 2:
The mechanical converter is designed as a universal mechanism that can perform multiple functions: converting drive motion to pitch and elevation motions, gripping parts, transferring parts, and enabling part rotation. This multi-functionality reduces the need for separate specialized components, thereby reducing system complexity
3Loss of substance
If carrierless progressive die is used to eliminate off-fall, then material savings are achieved, but access to the part profile is limited due to finished edge to finished edge contact
Solution Approach 1:
The patent introduces cam-actuated fingers as intermediary elements between the part and the die structure. These fingers can be positioned and timed to provide access to the part profile at specific points in the cycle, allowing operations on the part without requiring a continuous carrier while maintaining the material savings of a carrierless system
Data Source
AI summary
Mechanical converter in a movement device generally for transferring parts with respect to a die converts slave motion in a first direction into basic motions of a drive motion in a second direction different from the first direction, and a pitch motion in a third direction different from the first and second directions, which may be such that it is not converted through a plate or rotating cam. Additional motion(s) of an elevation motion in a fourth direction different from the second and third directions but including a vector component along or opposite to the first direction and/or further motion(s) radial to one or more of the first, second, third or fourth directions may be provided from the mechanical converter, another mechanical converter and/or from another source. Also, assisting motion(s), which can assist the die in performing an operation on a work piece, i.e., part, can be provided, for example, by drawing a motion from the pitch, drive and/or elevation motion(s).