Modular Linear Actuator Press for High-Speed and High-Force Forming
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Solution Overview
Problem
Large press machines face challenges in achieving high productivity due to the limitations of motors that cannot deliver both high-speed and high-torque conditions, leading to inefficiencies in forming parts, and hydraulic actuators suffer from issues like temperature dependency and mechanical complexity.
Innovation Solution
A press machine utilizing a planetary gear system with two motors, one for high-speed and one for high-force conditions, to drive a linear actuator, enabling independent control of speed and force for improved productivity and avoiding hydraulic actuator problems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a single motor is used to drive the press ram in large presses, then the motor can be sized to deliver high torque for forming parts, but the rotational speed and vertical speed of the moving tool are limited, compromising productivity
Solution Approach 1:
The drive system is segmented into two independent motors: a high-torque motor for delivering forming force and a high-speed motor for delivering rotational speed. This segmentation allows each motor to be optimized for its specific function without compromise, resolving the contradiction between torque and speed requirements.
Solution Approach 2:
The high-speed motor serves multiple functions: driving the press ram during the approach stroke (when minimal force is needed) and driving the crankshaft during the return stroke. This multi-functionality allows the system to achieve high productivity while maintaining the capability for high-force forming operations.
2Productivity
If hydraulic actuators are used to deliver high forces with acceptable speed, then productivity is improved, but temperature dependency of working fluid and fluid leaks occur
Solution Approach 1:
The patent replaces the hydraulic actuation system with a mechanical drive system using two motors directly coupled to the crankshaft. This substitution eliminates hydraulic fluid and its associated problems (temperature dependency, leaks) while maintaining the ability to deliver high forces and acceptable speeds for productivity.
3Force
If crankshafts with connecting rods are used in large presses, then high forces can be delivered, but timing issues and deformation occur under overload conditions
Solution Approach 1:
The patent employs a dynamically adaptable drive system where the high-speed motor can independently control the crankshaft speed and timing. This dynamic control allows the system to maintain accurate timing under varying load conditions and prevents the deformation issues associated with rigid crankshaft-connecting rod systems operating under overload.
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 system achieves high forces and speeds, enhancing productivity while eliminating the drawbacks of hydraulic actuators and crankshafts, ensuring efficient part formation with reduced mechanical complexity.
Implementation Method 1
The planetary gear system includes a ring gear, a sun gear, and a plurality of planet gears between the sun gear and the ring gear
Implementation Method 2
The linear actuator has a male-female screw arrangement and an actuator rod that is threadably coupled to the male-female screw arrangement
Data Source
AI summary
A linear-actuated press machine comprises a press ram with a tool, a first linear actuator having a first actuator rod, a second line actuator having a second linear actuator rod, a high-speed motor coupled to the first linear actuator for providing a high-speed condition on the press ram, a first high-torque motor coupled to the first linear actuator, and a second high-torque motor coupled to the second linear actuator. The press machine (i) advances the tool toward the part by operation of the high-speed motor associated with the first linear actuator, (ii) forms the part with the tool by simultaneous operation of the first high-torque motor associated with the first linear actuator and the second high-torque motor associated with the second linear actuator, and (iii) retracts the tool from the part by operation of the high-speed motor associated with the first linear actuator.