Planetary Gear Press Drive for High-Speed and High-Force Forming
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Solution Overview
Problem
Large press machines face challenges in achieving high productivity due to the inability of motors to deliver both high-speed and high-torque conditions necessary for linear-actuated presses, leading to compromised productivity and issues associated with hydraulic actuators such as temperature dependency and messiness.
Innovation Solution
A press machine utilizing a planetary gear system coupled with two motors, one for producing high-speed conditions and another for producing high-force conditions, allowing for linear actuation with high forces and controllable speeds without the drawbacks of hydraulic systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a motor is chosen that is capable of delivering high torque for high force on the moving tool, then the force capability is improved, but the rotational speed and vertical speed of the moving tool is limited, compromising productivity
Solution Approach 1:
The system dynamically switches between two motors based on operational requirements. Motor 1 (high-speed motor) operates during advancement and retraction strokes to maximize speed, while Motor 2 (high-torque motor) operates during the forming stroke to maximize force. This dynamic allocation allows the press to achieve both high productivity during non-forming phases and high force during forming, resolving the contradiction between force capability and productivity.
2Force
If hydraulic actuators are used to deliver high forces with acceptable speed, then the force and speed requirements are met, but temperature dependency and fluid leakage issues arise
Solution Approach 1:
The invention replaces the hydraulic actuation system with a dual motor-driven planetary gear system. This mechanical system eliminates the need for hydraulic fluid, pumps, valves, and filters, thereby removing the sources of temperature dependency and fluid leakage. The planetary gear system provides mechanical advantage to deliver high forces while the motor-driven approach ensures reliable, maintenance-free operation without hydraulic fluid concerns.
3Force
If crankshafts are used to drive the press ram, then high forces can be delivered, but the system requires significant bearings with tight tolerances and lubrication systems, increasing complexity
Solution Approach 1:
The invention extracts and removes the crankshaft mechanism entirely from the press system. Instead of using a crankshaft with its associated bearings, tight tolerances, and lubrication systems, the design employs a direct motor-to-planar gear connection that drives the linear actuator. This extraction eliminates the complex bearing and lubrication infrastructure while maintaining the capability to deliver high forces through the planetary gear system's mechanical advantage.
4Device complexity
If a single motor is used to drive the press, then the system is simpler, but it cannot deliver both high-speed and high-torque conditions necessary for large presses
Solution Approach 1:
The invention implements a multi-functional motor system where two motors serve different functional requirements within the same press. Motor 1 is optimized for high-speed operations (advancement and retraction), while Motor 2 is optimized for high-torque operations (forming). The planetary gear system acts as a universal interface that can transmit power from either motor to the linear actuator, enabling the system to adapt to different operational phases and deliver both high-speed and high-torque capabilities.
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 solution enables high productivity in forming parts by delivering high forces with controlled speed, avoiding the limitations of hydraulic presses and crankshaft-driven systems, thus improving operational efficiency and reducing maintenance complexities.
Implementation Method 1
The planetary gear system includes a ring gear, a sun gear, and a plurality of planet gears in connection between the sun gear and the ring gear
Implementation Method 2
A first motor is coupled to the planetary gear system for producing a high-speed condition on the linear actuator. A second motor is coupled to the planetary gear system for producing a high-force condition on the linear actuator
Implementation Method 3
The linear motion of the moving tool is typically created by a motor that rotates a male-and-female screw mechanism that directly or indirectly couples the moving tool to the output shaft of the motor
Data Source
AI summary
A press machine for forming a part comprises a planetary gear system, a first motor, a second motor, a linear actuator, and a press ram that holds a tool. The planetary gear system includes a ring gear, a sun gear, and a plurality of planet gears between the sun gear and the ring gear. The planetary gear system has an output shaft that is coupled to the linear actuator. The first motor is coupled to the planetary gear system for producing a high-speed condition on the linear actuator and the press ram. A second motor is coupled to the planetary gear system for producing a high-torque condition on the linear actuator and a corresponding high-force condition the press ram. The press ram forms the part with the tool during the high-force condition.