Metal Forming Carousel Drive With Direct Motor Synchronization
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional apparatuses for processing metallic bodies by plastic deformation face limitations at high speeds, requiring mechanical intervention to adjust the rod-and-crank assembly, and have high production costs, making them less reliable and economically disadvantageous.
Innovation Solution
The apparatus employs a direct drive system with a constantly engaged actuation motor and actuation shaft, incorporating a braking mechanism directly on the actuation shaft and a counterweight for stable motion control, allowing for synchronized motion of the front table and carousel without mechanical adjustments, and uses a control unit to manage motor operations for flexible speed variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a conventional flywheel and brake-clutch transmission system is used, then the apparatus can operate at standard speeds, but mechanical intervention is required to adjust the rod-and-crank assembly when operating at high speeds, reducing reliability and increasing complexity
Solution Approach 1:
The patent replaces the conventional mechanical transmission system (flywheel and brake-clutch) with a direct drive system where the actuation motor connects directly to the actuation shaft. This eliminates the need for mechanical adjustments to the rod-and-crank assembly when varying speeds, as the control unit can electronically adjust motor parameters to maintain optimal performance across different operating speeds.
2Adaptability or versatility
If mechanical intervention on the rod-and-crank assembly is performed to vary travel at high speeds, then speed adaptation is achieved, but production costs increase and reliability decreases
Solution Approach 1:
The patent changes the control approach from mechanical parameter adjustment (modifying rod-and-crank assembly travel) to electrical parameter control (adjusting motor speed, torque, and positioning via control unit). This allows the apparatus to adapt to different operating speeds without mechanical intervention, thereby maintaining reliability while achieving speed variation capability.
3Productivity
If a conventional transmission system with flywheel is used, then motion can be transmitted to the rod-and-crank assembly, but the apparatus requires mechanical parts intervention when speed varies, making it less economically advantageous
Solution Approach 1:
The patent extracts and removes the flywheel and brake-clutch components from the transmission system, simplifying the overall apparatus structure. This reduction in mechanical components not only lowers manufacturing costs but also eliminates the need for maintenance and adjustments when operating at varying speeds, thereby improving productivity and economic advantage.
4Ease of operation
If a direct drive system with control unit is used, then mechanical intervention is eliminated and operational flexibility is improved, but the system requires precise control mechanisms
Solution Approach 1:
The patent substitutes the complex mechanical adjustment system with an electronic control system that manages the actuation motor. The control unit receives signals and adjusts motor parameters electronically, which is simpler to operate and maintain than mechanical adjustments, even though it introduces electronic control components. This substitution improves ease of operation while keeping the control system manageable.
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
This solution ensures reliable and flexible operation at varying speeds without mechanical intervention, reducing production costs and enhancing operational efficiency by maintaining a consistent transmission ratio and high braking torque, thus improving the apparatus's economic and technical performance.
Implementation Method 1
an actuation motor (10) for moving the front table (5) and connecting means (20) between an actuation shaft (11), supported so that it can rotate by the supporting framework (2), and the front table (5)
Implementation Method 2
braking means (30) that act directly on the actuation shaft (11)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An apparatus (1) for processing metallic bodies by plastic deformation, which comprises a supporting framework (2) for a carousel (3) that can rotate intermittently about a main rotation axis (100) and defines a plurality of supporting seats (3a) for respective metallic bodies to be processed fed to the carousel (3) by way of a feeder device, a front table (5) being provided which can move with an alternating translational motion along a direction that is substantially parallel to the main rotation axis (100) of the carousel (3), the front table (5) supporting a plurality of processing stations (5a) that are designed to engage sequentially the metallic bodies supported by the carousel (3), an actuation motor (10) being provided for moving the front table (5) and connecting means (20) being provided between an actuation shaft (11), supported so that it can rotate by the supporting framework (2), and the front table (5), the connecting means (20) being adapted to convert the rotation of the actuation shaft (11) into alternating translational motion of the front table (5), the actuation motor (11) being constantly engaged with the actuation shaft (10).