Multi-Punch Tool for Accurate Panel Hole Patterns
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Solution Overview
Problem
The existing methods for creating knock-outs in electrical enclosures and panels are time-consuming, inaccurate, generate noise and debris, and can damage sensitive electronics due to the need for manual layout, drilling, and sawing, requiring multiple tools and additional finish work.
Innovation Solution
A multi-punch tool that allows for the simultaneous formation of multiple holes in a metal plate using a primary and secondary punch system, with a die holder and draw bar mechanism, enabling precise alignment and punching without automated equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual layout and drilling methods are used, then flexibility in creating custom hole patterns is achieved, but time consumption and accuracy deteriorate
Solution Approach 1:
The template includes pre-marked hole locations and patterns that have been predetermined and prepared in advance. The installer simply needs to position the template on the panel and punch through the pre-marked locations, eliminating the need for manual measurement and layout calculations.
Solution Approach 2:
The template serves as a physical copy or replica of the desired hole pattern. By transferring the template's pre-defined geometry directly onto the panel through punching, the exact hole pattern is replicated without requiring the installer to recreate it manually.
2Adaptability or versatility
If manual drilling and sawing are used, then custom cutout shapes can be created, but manufacturing precision and hole accuracy deteriorate
Solution Approach 1:
The template incorporates pre-marked hole locations and cutout boundaries that have been precisely determined in advance. This preliminary preparation ensures that all subsequent punching operations occur at exact, pre-calculated positions, guaranteeing high manufacturing precision.
Solution Approach 2:
The template acts as an intermediary tool that transfers the precise design geometry from the design phase to the manufacturing phase. It serves as a physical mediator between the design intent and the actual hole creation, ensuring accuracy is maintained throughout the process.
3Manufacturing precision
If grinding and finishing work are used, then clean edges and burr-free surfaces are achieved, but noise generation and debris creation worsen
Solution Approach 1:
The invention replaces the mechanical grinding and filing processes with a punching mechanism. Instead of using rotating abrasive wheels or files that generate noise and debris, a punch tool directly creates clean holes through controlled material displacement, eliminating the harmful effects of traditional finishing operations.
Solution Approach 2:
The punching process itself performs the function that previously required separate finishing operations. The punch tool creates clean-edged holes directly during the hole creation process, making the system self-sufficient and eliminating the need for additional grinding or filing steps that would generate noise and debris.
4Adaptability or versatility
If multiple tools are used for hole creation, then various hole patterns can be achieved, but device complexity and operation difficulty worsen
Solution Approach 1:
The template is designed as a universal tool that can create multiple different hole patterns and configurations. By incorporating various pre-marked hole locations and patterns on a single template, it replaces multiple specialized tools, allowing the installer to achieve diverse hole patterns using one multi-functional device.
Solution Approach 2:
The invention combines multiple hole creation functions into a single template tool. Instead of requiring separate tools for drilling, sawing, and finishing, the template integrates all these functions into one device that performs hole creation and pattern transfer simultaneously, reducing the total number of tools needed.
Data Source
AI summary
A tool for punching a work piece has a multi-punch surface equipped to punch one or more hole in a work piece with interchangeable punch surfaces and uses a threaded draw bar and threaded nut, wherein the draw bar is configured to fit in die punch and maintain a punch surface relative to a die holder.