Movable Spindle Change Unit for Faster Flow-Forming Setup
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Solution Overview
Problem
In flow-forming processes, especially in serial production of large and heavy parts, the limited workspace and need for precise transfer movements lead to slow handling and reduced machine utilization due to restricted accessibility and the requirement for precise collision avoidance, making the handling of workpieces difficult and time-consuming.
Innovation Solution
A device and method where the spindle and clamping means are combined into a changing unit that can be adjusted transversely to the axis of rotation, allowing the unit to move between a forming position and a set-up position outside the workspace, enabling easier supply and discharge of workpieces and reducing the need for complex handling robots, thus increasing machine efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If handling means with grippers or multiaxial robots are used for supply and discharge, then workpiece handling is enabled, but the workspace limitation and restricted accessibility lead to slow transfer movements and reduced machine utilization
Solution Approach 1:
The device employs a movable housing that can be shifted between a closed position during forming operations and an open position during setup and workpiece handling. This dynamic reconfiguration of the workspace enclosure allows rapid access to the spindle and clamping means, eliminating the need for slow, precision transfer movements while maintaining protection during operation. The housing mobility directly resolves the contradiction by providing both ease of operation and high productivity.
2Reliability
If the workspace is closed by a housing for splash protection, then cooling liquid containment is improved, but accessibility to the spindle and clamping means is restricted
Solution Approach 1:
The housing is designed as a movable structure that transitions between closed and open states. During forming operations, the housing remains closed to contain cooling liquid and provide splash protection. During setup, workpiece loading, and clamping operations, the housing is opened to provide unrestricted access to the spindle and clamping means. This dynamic behavior simultaneously achieves reliable cooling liquid containment and ease of operation.
3Reliability
If transfer movements are performed with high precision to avoid collision, then workpiece safety is improved, but transfer speed is reduced
Solution Approach 1:
By making the housing movable rather than fixed, the system eliminates the need for slow, precision-controlled transfer movements. The operator can rapidly access the workspace when the housing is open, and the workpiece remains protected during forming operations when the housing is closed. This dynamic approach achieves both workpiece safety and high transfer speed by removing the speed limitation imposed by precision requirements.
Data Source
AI summary
The invention relates to a device and a method for forming, in which at least one spindle is driven in a rotating manner by means of a rotary drive, a workpiece is received on the spindle by means of a clamping means and clamped on the spindle and at least one forming roller is fed axially and/or radially relative to the workpiece in order to carry out a spinning or flow-forming process. In accordance with the invention provision is made for the spindle and the clamping means to be combined to a changing unit which is adjustable transversely to the axis of rotation, wherein the changing unit is adjusted between a forming position and a set-up position.