Pneumatic Part Removal in Multi-Stage Pressing for Clean Orientation
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Solution Overview
Problem
Conventional methods for producing formed parts like screws and rivets using multi-stage presses face challenges in achieving cost-effective and resource-efficient production while maintaining high quality, as they often result in parts being damaged or mixed during transport, and require subsequent processing steps like washing and thread formation.
Innovation Solution
A pneumatic conveying system is introduced to control the removal of finished formed parts, using a transport tube with a suction mechanism to orient and transport parts directly from the forming machine, reducing contact with machine oil and minimizing damage, and allowing for flexible positioning of production systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional transport methods (conveyor belts or chutes) are used to remove formed parts, then the parts can be transported away from the forming machine, but the parts may become damaged or mixed during transport
Solution Approach 1:
The patent employs a pneumatic conveying system where formed parts are suctioned through a transport tube using a vacuum generator. This pneumatic method replaces conventional mechanical conveyor belts or chutes, providing gentle handling that prevents part damage and mixing while maintaining transport functionality. The suction-based approach allows controlled, orientation-preserving transport of the formed parts.
2Ease of manufacture
If formed parts are transported using conventional methods, then they can be moved to subsequent processing stations, but they require washing to remove adhering machine oil
Solution Approach 1:
The pneumatic conveying system creates a controlled air stream that prevents formed parts from contacting machine oil in the forming area. By suctioning parts directly through a transport tube positioned above the forming zone, the system eliminates the need for subsequent washing steps, reducing resource consumption and production time while maintaining part cleanliness.
Solution Approach 2:
The invention extracts the formed parts from the oil-prone forming environment before they can become contaminated. The transport tube inlet is positioned to receive parts directly from the forming station, and the suction action quickly removes parts from the forming area, preventing oil adhesion and eliminating the need for washing.
3Manufacturing precision
If multiple forming stations are used to produce formed parts, then high-quality parts can be produced through multi-stage forming, but additional equipment and space are required
Solution Approach 1:
The patent integrates multiple forming stations within a compact forming press unit, combining several forming operations in one location. The pneumatic conveying system then directly connects this integrated forming station to the transport tube, eliminating the need for separate transport equipment between multiple pressing stations, thereby reducing overall space requirements while maintaining multi-stage forming capability.
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
This solution enables the cost-effective and resource-efficient production of high-quality formed parts by preventing oil contamination, reducing the need for washing, and ensuring parts are transported in the correct orientation, thereby minimizing damage and mixing, while also reducing the need for additional equipment and space.
Implementation Method 1
The formed parts, which have been fed into the transport tube for at least part of their length, are sucked into the transport tube and then pneumatically transported through the transport tube
Implementation Method 2
The formed parts, which have been fed into the transport tube for at least part of their length, are sucked into the transport tube and then pneumatically transported through the transport tube
Data Source
Figure 1
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AI summary
In a process and system for manufacturing formed parts (W) from wire (D) using a multi-stage press (100), wire (D) is drawn from a wire supply and fed to a cutting system (120). There, wire sections (DA) are cut from the supplied wire (D) in increments. These are gripped and fed to the working area of forming tools (200). Through multi-stage forming of the wire section, a formed part (W) is created, consisting of a shaft section and a head section that is wider than the shaft section. The formed parts are then successively ejected by means of an ejector system (300). A pneumatic conveying system (400) is used to transport the finished formed parts. This system includes a transport tube (410) with an inlet opening (412) for successively receiving the finished formed parts.The inlet opening is positioned near the ejector system (300) such that the finished formed parts (W) can be inserted directly into the inlet opening (412) in the correct orientation by means of the ejector system. These parts are then picked up by suction from the transport tube (410) and pneumatically conveyed towards a subsequent station.