Multistation Carousel for Automated Press Tool Change
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Solution Overview
Problem
Current single-station tool change systems for presses are time-consuming and labor-intensive, requiring manual handling of tools, especially for larger and heavier tools, which increases setup time and complexity.
Innovation Solution
A multistation carousel with loading/unloading, die changing, and pressing simulation stations allows for quick and automatic tool changes, enabling simultaneous execution of multiple operations on different tools, equipped with a circular conveyor system, slewing ring, toothed pinion-crown assembly, and hydraulic components for efficient tool management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single-station tool change table is used, then the structure is simple, but the tool change time is long and manual handling is required
Solution Approach 1:
The tool changing system is divided into multiple independent stations (loading station, pressing simulation station, die changing station, unloading station) arranged in a circular carousel configuration. Each station performs a specific function, allowing parallel processing of multiple tools simultaneously, thereby reducing overall tool change time while maintaining manageable structural complexity through modular design
Solution Approach 2:
Tools are pre-loaded onto the carousel at the loading station before the press is needed. The carousel rotates to position the required tool at the loading station, allowing the press to be quickly reconfigured without manual tool handling during production stops. This preliminary preparation eliminates waiting time for tool changes
2Ease of manufacture
If manual handling of tools is used, then the equipment cost is low, but the setup time increases and operator skill is required
Solution Approach 1:
The carousel system is equipped with automated handling mechanisms including hydraulic cylinders for tool transfer, a robotic arm for die replacement, and automatic positioning systems. These self-service features eliminate the need for manual operator intervention, reducing setup time and eliminating the requirement for experienced operators while keeping the system relatively simple and cost-effective
3Loss of time
If a multistation carousel is used, then the tool change time is reduced and automation is improved, but the device complexity increases
Solution Approach 1:
The carousel serves multiple functions: it stores multiple tools simultaneously, rotates to position required tools, transfers tools between stations using automated mechanisms, and coordinates with the press operation. This multi-functionality consolidates what would otherwise require separate systems into a single integrated unit, reducing overall device complexity while achieving rapid automated tool changes
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 multistation carousel significantly reduces tool change time and complexity by automating the process, allowing for simultaneous execution of various operations on multiple tools, thereby minimizing setup time and enhancing operational efficiency.
Implementation Method 1
The station (21) for loading/unloading the tool (A) from the press comprises... a suspension frame (29), equipped with guides and a hydraulic cylinder, suitable for the translation of the tool (A)
Implementation Method 2
The rotation means (31) comprise at least one slewing ring and a toothed pinion-crown assembly driven by a gear motor which controls the rotation
Implementation Method 3
a toothed pinion-crown assembly driven by a gear motor which controls the rotation
Implementation Method 4
The handling device (26)... is equipped with a vertical ram, driven by a hydraulic cylinder and equipped with automatic locks, to lift the upper die half
Data Source
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AI summary
A multistation carousel (1) for changing a tool (A) wherein is placed a die of a press, comprises a supporting structure and a rotating table (3) divided into at least three segments (31) each of which corresponds to a station (21, 23, 25, 27). In particular, the multistation carousel (1) comprises a loading/unloading station (21) of the tool (A) from the press, a standby station (27) and a die changing station (23). Such carousel not only allows a tool and a die of a press to be changed quickly and automatically, but rather, being equipped with different types of stations, it allows the simultaneous execution of several different operations on different tools, all loaded on the carousel itself.