Modular Power Pack Assembly for Die Stripping
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Solution Overview
Problem
Existing metal forming systems require individual pressure modules built into each die for stripping, which increases costs and complicates adjustments for different metals or thicknesses, as the entire die must be disassembled to modify the pressure module.
Innovation Solution
A modular power pack assembly where pressure modules are removable from individual dies and mounted to the ram or press-bed, allowing standard dies to use a press-mounted pressure module, enabling easy replacement and adjustment without disassembling the die, using a top plate, transfer plate, and resilient members like rubber or gas cylinders for stripping pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If individual pressure modules are built into each die for stripping, then stripping pressure can be provided for metal forming dies, but the cost of each die set increases and adjustments for different metals or thicknesses require disassembling the entire die
Solution Approach 1:
The pressure module is separated from the die set into an independent component. The die and pressure module become separate interchangeable elements, allowing the pressure module to be adjusted or replaced without affecting the die structure. This segmentation resolves the contradiction by enabling easy pressure adjustments while keeping the die structure simple and standardized.
Solution Approach 2:
A single standardized pressure module design serves multiple dies and applications. Instead of custom-building pressure modules into each die, a universal pressure module can be attached to various dies, providing the same stripping function across different metal forming operations. This universality reduces die complexity while maintaining operational flexibility.
2Ease of repair
If pressure modules are built into individual dies, then stripping pressure is provided, but the entire die must be removed and disassembled to access or replace pressure module components
Solution Approach 1:
The pressure module is extracted from the die structure and made independently removable. This allows the pressure module to be accessed, serviced, or replaced by simply detaching it from the die, without requiring removal or disassembly of the die itself. This extraction principle directly addresses the accessibility and time loss issues.
Solution Approach 2:
The system transitions from a static integrated design (pressure module permanently built into die) to a dynamic modular design where the pressure module can be easily attached and detached. This dynamic configuration enables quick servicing by allowing operators to swap pressure modules without time-consuming die disassembly procedures.
3Ease of manufacture
If standard dies are used without built-in pressure modules, then die cost is reduced, but a separate pressure module system is required on the press
Solution Approach 1:
The pressure module serves as an intermediary component between the press and the die. Rather than integrating pressure mechanisms directly into dies or building complex systems into the press, the modular pressure module acts as a bridge that can be attached to standard dies, providing the necessary stripping function while keeping both die and press relatively simple.
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 reduces costs by allowing standard dies to use a press-mounted pressure module, simplifies pressure adjustments, and enables quick servicing without removing dies, improving efficiency and flexibility in metal forming operations.
Implementation Method 1
the resilient member may be operative upon release of the press to expand to its original length and thereby provide a restoring force
Data Source
AI summary
Provided herein are pressure modules for use with die pressing operations for stripping work pieces from individual dies. The pressure modules include a top plate and a transfer plate that is separated by a resilient member that is compressed when a die set is closed and which provides a restoring force when the die set is opened. The pressure modules are formed independent of the dies and supported relative to the ram or press-bed of the press. In this regard, transfer pins may be utilized to transfer the restoring force from the resilient member to a stripper mechanism. In another arrangement, a press is provided that allows the pressure modules to be removed from or inserted into the press without removing a die attached to the press.