Modular Tool System for Rapid Die-Cutting Changeover
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Solution Overview
Problem
Sheet-fed stamping and embossing machines require significant setup time when switching between processes or tools, limiting productivity.
Innovation Solution
A modular tool system with a fixed and movable crucible, featuring a tool holder with support rails, locking elements, and a connector for an electrically operable heating plate, allowing for quick exchange and conversion between different stamping and embossing processes, including cold and hot processes, with tools designed for rectangular insertion and optional reinforcement for mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If traditional fixed tools are used in sheet punching and embossing machines, then structural stability is maintained, but setup time increases significantly when switching between processes or tools
Solution Approach 1:
The tool is divided into modular components: a tool frame with parallel support rails, interchangeable tool inserts, and separate heating plate. This segmentation allows individual components to be quickly exchanged without replacing the entire tool assembly, dramatically reducing setup time when switching between punching and embossing processes.
Solution Approach 2:
The tool design incorporates movable and interchangeable elements rather than fixed components. The tool insert can be removed and replaced, and the heating plate can be independently exchanged, transforming the tool from a static structure to a dynamic, reconfigurable system that adapts to different production requirements.
2Productivity
If multiple processes (punching, embossing, hot foil embossing) are integrated into one machine, then productivity increases, but device complexity increases
Solution Approach 1:
The tool frame with parallel support rails serves multiple functions: it supports punching tools, embossing tools, and heating plates. This universal base structure allows a single machine to perform punching, embossing, and hot foil embossing by simply changing the tool insert and heating plate configuration, thereby increasing productivity without proportionally increasing structural complexity.
3Adaptability or versatility
If heating plates are permanently installed for hot processes, then heating functionality is reliable, but flexibility to switch between cold and hot processes decreases
Solution Approach 1:
The heating plate is separated from the permanent tool structure and made interchangeable with the tool insert. This segmentation allows the heating plate to be installed only when hot processes are required and removed when cold processes are needed, providing flexibility while maintaining reliable heating functionality when the plate is in place.
Solution Approach 2:
The heating plate is extracted from the permanent tool assembly and made into a removable component. This extraction allows the machine to switch between cold and hot processes by simply removing or installing the heating plate as needed, while the parallel support rails remain as a permanent structural element.
4Speed
If traditional tool holding mechanisms are used, then tool stability during operation is maintained, but tool change time increases
Solution Approach 1:
The tool insert and heating plate are designed to be self-aligning within the parallel support rails. The rectangular outer contour of the tool insert automatically guides it into the correct position between the rails, eliminating the need for complex alignment mechanisms and enabling rapid tool changes while maintaining precise positioning.
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
Enables rapid tool changes and process switching, reducing setup time and increasing productivity by simplifying tool insertion and electrical connections, while using cost-effective and less prone to failure tools for hot processes, and providing mechanical stability with lightweight plastic frames reinforced with fibers.
Implementation Method 1
the outer edges of two parallel frame bars of the tool frame also form the outer edges of the tool, i.e. have a greater distance to one another than the extent of all plate elements arranged next to one another in this direction
Data Source
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AI summary
The object of the present invention is to reduce the setup time of a sheet-fed die-cutting and embossing machine, for example when changing the type of die-cutting or embossing to be produced or when switching from one type of process to another, and thus to increase the productivity of the sheet-fed die-cutting and embossing machine. For this purpose, a tool for such a machine is proposed that makes it possible to carry out different die-cutting and embossing processes on one and the same machine and to perform the machine changeover for different processes quickly and easily.