Movable Nesting Blocks for Jam-Resistant Workpiece Accumulation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Workpiece accumulators in progressive die stamping machines often jam due to misalignment or misfeeding, leading to stoppages and productivity losses in industries like automotive and electronics.
Innovation Solution
A workpiece accumulator system incorporating programmable linear actuators and nesting blocks, controlled by a first controller that communicates with the stamping machine, allows for precise positioning and stacking of workpieces, retracting to accommodate placement on exit rails when a desired quantity is reached, and resetting for continuous operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If workpieces are stacked in a fixed position in the accumulator, then stacking is simple, but misalignment or misfeeding causes jamming and stoppages
Solution Approach 1:
The nesting blocks are made movable rather than fixed, allowing them to be repositioned dynamically. The system includes movable nesting blocks that can be positioned at different locations along the exit rail, enabling the accumulator to adapt to varying workpiece positions and prevent jamming while maintaining operational reliability.
2Productivity
If nesting blocks remain in initial position, then structure is simple, but workpieces cannot be properly accommodated or stacked efficiently
Solution Approach 1:
The system performs preliminary positioning of nesting blocks before workpieces are stacked. The controller pre-positions the nesting blocks at appropriate locations based on the expected workpiece quantity and stack height requirements, enabling efficient stacking operations and preventing jams before they occur.
Solution Approach 2:
The system incorporates feedback mechanisms where the controller monitors the stacking process and adjusts nesting block positions accordingly. This feedback control ensures that nesting blocks are positioned optimally for each stacking operation, improving productivity while managing device complexity through intelligent control.
3Quantity of substance
If workpieces are stacked in large quantities, then batch output is improved, but exit rail movement speed and clearance are reduced
Solution Approach 1:
The workpiece stack is divided into smaller batches or groups. Instead of accumulating all workpieces in one large stack, the system creates multiple smaller stacks or releases workpieces in controlled batches, maintaining sufficient clearance and movement speed on the exit rail while still achieving the desired quantity output over time.
Data Source
AI summary
A workpiece accumulator system for a stamping machine includes linear actuators, nesting blocks, exit rails, and a first controller. The nesting blocks are disposed on moveable members of the linear actuators and arranged to vertically stack workpieces being fabricated by the stamping machine. The first controller communicates with a second controller that controls the stamping machine. The first controller controls the linear positions of the linear actuators to retract the nesting blocks from an initial position to accommodate placement of the one of the plurality of workpieces in a stack on the nesting blocks. The linear actuators are controlled to retract the nesting blocks to fully retracted positions to place the plurality of workpieces in the stack onto the exit rails when a quantity of the plurality of workpieces in the stack is equal to a desired quantity.