Modular Progressive Tooling for Reconfigurable Web Processing
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Solution Overview
Problem
Existing apparatuses for working with webs of material, such as progressive tools, face challenges due to fixed tool arrangements, leading to high loads, increased wear, and frequent maintenance needs, making them difficult to convert for different products and resulting in production interruptions and quality losses.
Innovation Solution
The apparatus is designed with modular individual tools that can be easily assembled and disassembled, allowing for customizable configurations and reduced load peaks by using autonomously driven modules that can be activated independently, reducing the need for central drives and allowing precise positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If individual tools are rigidly fixed in a progressive tool, then the web of material can be worked simultaneously multiple times, but the arrangement cannot be easily converted for other products and requires complete replacement
Solution Approach 1:
The progressive tool is divided into multiple individual tool modules that can be independently removed and replaced. Each tool is mounted on a separate support element that can be detached from the tool holder, allowing selective replacement of individual tools rather than replacing the entire tool assembly, thus enabling product conversion while maintaining simultaneous working capability.
Solution Approach 2:
The tool arrangement transitions from a rigid, fixed configuration to a dynamic, reconfigurable system. Tools can be selectively mounted and dismounted from the tool holder using the removable support elements, allowing the tool configuration to adapt to different product requirements while maintaining the structural integrity needed for simultaneous operation.
2Productivity
If all individual tools work the web of material simultaneously, then productivity is high, but high loads and increased wear lead to frequent maintenance and production interruptions
Solution Approach 1:
The system enables dynamic control of tool operation where individual tools or groups of tools can be selectively activated or deactivated independently. This allows the web processing to continue at high speed with only the necessary tools operating, reducing overall loads and wear while maintaining productivity for the required work operations.
Solution Approach 2:
The tool system is segmented into independently controllable units, each capable of being operated separately. This segmentation allows selective engagement of tools based on the specific processing needs, distributing loads more evenly and reducing peak stresses on individual tools and the overall system, thereby extending operational life and reducing maintenance frequency.
3Productivity
If a compound tool with multiple individual tools is used, then the web can be worked in one pass, but the fixed arrangement makes simple conversion for other products extremely difficult
Solution Approach 1:
The compound tool is segmented into modular components where individual tools can be independently removed and replaced. Each tool is mounted on a separate support element that can be detached from the tool holder, allowing rapid reconfiguration for different products without requiring complete tool replacement, thus maintaining processing efficiency while enabling easy conversion.
Solution Approach 2:
The tool holder and support element design provides a universal mounting interface that can accommodate different tool types and configurations. This universal interface allows the same tool holder structure to support various tool arrangements for different products, enabling multi-functionality and easy conversion while maintaining the compound tool's efficient one-pass processing capability.
Data Source
AI summary
The invention relates to an apparatus for working, in particular for working without machining, for example for separating and/or forming, a web of material, having a plurality of individual tools for different manners of working the web of material with designated workpieces temporarily held therein, and having a machine direction along which the web of material with the designated workpieces and the plurality of individual tools can be moved incrementally relative to one another in such a way that the web of material can be worked multiple times within one work cycle by means of the plurality of individual tools, wherein the individual tools are designed as individual modules which can be fixed to one another to form an individual module cluster, but can be detached as well.