Modular Workpiece Transfer in Multi-Station Forming Machines
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Solution Overview
Problem
Current forming machines lack the ability to produce complex shaped parts at high output while offering flexibility in multi-stage processes at a low cost, with conventional systems being inflexible and costly to expand or modify.
Innovation Solution
A modular transport system with individually controllable transport modules that can be easily scaled and expanded, allowing for flexible routing and movement profiles to optimize workpiece transfer between processing stations, reducing cycle times and setup time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional forming machines use fixed transport systems, then structure is simple, but flexibility and scalability are poor
Solution Approach 1:
The transport system is divided into multiple independent transport modules, each capable of autonomous operation. Each module includes a transport unit that can be individually controlled, allowing the system to be configured for different production requirements by selecting and arranging specific modules.
Solution Approach 2:
The transport units are designed with movable components including a support structure that can shift position. The transport units can move along the transport path and adjust their positions dynamically, enabling flexible routing and adaptation to different workpiece types and processing requirements.
2Productivity
If forming machines have multiple processing stations, then productivity increases, but setup time and alignment requirements increase
Solution Approach 1:
The multi-station forming machine is divided into independent transport modules, each handling specific processing stations. This modular structure allows individual modules to be set up and adjusted independently, reducing overall setup time when adding or modifying processing stations.
Solution Approach 2:
The transport units feature adjustable motion profiles with variable speed, acceleration, and deceleration parameters. The support structures can be repositioned along the transport path, allowing optimization of transfer times and synchronization between stations without requiring complete system reconfiguration.
3Manufacturing precision
If transport system uses precise alignment of workstations, then manufacturing precision is maintained, but system complexity and cost increase
Solution Approach 1:
The support structures are designed to be movable and adjustable along the transport path. This dynamic positioning capability allows the system to accommodate variations in workstation positions while maintaining precise workpiece transfer, eliminating the need for rigid fixed alignment.
Solution Approach 2:
The control unit coordinates the motion of transport units with the processing operations at each workstation. By monitoring and adjusting transport unit positions and speeds in real-time, the system maintains precise workpiece positioning even when workstation arrangements are modified or when tolerances vary.
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 modular transport system enables high-output production of complex parts with increased flexibility and reduced costs, allowing for efficient processing and easy expansion of the forming machine without the need for precise alignment of workstations.
Implementation Method 1
The transport unit can be moved back and forth in a pendulum motion along a module transport path of the transport module between a first end position and a second end position
Data Source
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AI summary
A forming machine (100) for producing complex bent shaped parts from straight workpieces (WS) made of wire or tube comprises a computer numerical control unit (190), several workstations comprising a loading station (110), a first processing station (410) downstream of the loading station and at least one second processing station (420) downstream of the first processing station (410), wherein at least two of the processing stations are designed as forming stations, and a transport system (500) for transporting successive workpieces (WS) from the loading station (400) to downstream workstations under the control of the control unit (190).The transport system (500) is modular in design and has several transport modules (550), each of which is assigned to two consecutive workstations and has the following components: a support structure (510), a transport unit (520) carried by the support structure (510), which can be moved back and forth individually in pendulum operation along a module transport track (525) of the transport module (550) between a first end position (522-1) and a second end position (522-2) under control by the control unit (190), and has a gripping unit (560) for gripping a workpiece.