Pneumatic Part Transfer From Multi-Stage Presses Without Jamming

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Solution Overview

Problem

Conventional methods for producing shaped parts from wire, such as screws and rivets, face challenges in achieving high-quality production cost-effectively and resource-sustainably with a high output rate, often resulting in damaged or jammed parts during transport, which can lead to intermingling and processing issues.

Innovation Solution

A multi-stage press system integrated with a pneumatic conveyor system that uses a transporting pipe with an insertion opening to positionally orient and suction-transport shaped parts directly from the ejector system, minimizing contact with machine oil and reducing the risk of damage, allowing for efficient and cost-effective transportation to subsequent stations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional conveyor belts and mechanical transport systems are used to transport shaped parts from the shaping press, then the parts can be moved to subsequent processing stations, but the parts may become damaged, jammed, or intermingled during transport, and machine oil contamination occurs

Engineering Contradiction:

Improvetransport reliabilityVSAvoidpart damage and oil contamination

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent employs a pneumatic conveyor system that uses compressed air to transport shaped parts through a transporting pipe. The ejector system directs finished shaped parts into the transporting pipe where they are conveyed pneumatically to subsequent stations. This eliminates mechanical contact that causes damage and prevents machine oil contamination by replacing mechanical conveyor belts with air-based transport.

Inventive Principle:

Principle #29Pneumatics and hydraulics

Solution Approach 2:

The invention replaces the conventional mechanical conveyor belt system with a pneumatic transport system. Instead of using mechanical belts, rollers, or slides that cause friction, jamming, and oil contamination, the system uses compressed air flow to move parts through a pipe, substituting mechanical transport with pneumatic transport to eliminate harmful effects.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Object-affected harmful factors

If multiple washing and transport stations are added to process the shaped parts, then oil contamination can be removed, but the production complexity and resource usage increase

Engineering Contradiction:

Improveoil contamination removalVSAvoidtransport system complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The pneumatic conveyor system converts the potential harm of machine oil presence into a benefit by creating a closed pneumatic transport environment. The compressed air flow naturally prevents oil contamination from occurring in the first place, eliminating the need for separate washing stations and reducing overall system complexity while maintaining part cleanliness.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Ease of operation

If conventional mechanical transport methods are used, then the shaped parts can be moved to subsequent stations, but the parts may lose their positional orientation and become intermingled

Engineering Contradiction:

Improvepart transportVSAvoidpart orientation

Core Design Contradiction:

Ease of operationVSStability of the object's composition

Solution Approach 1:

The pneumatic conveyor system maintains part orientation by using controlled air flow through a transporting pipe. The ejector system feeds parts in a positionally oriented manner into the pipe, and the pneumatic flow preserves this orientation during transport, preventing intermingling and maintaining the stability of part composition throughout the transport process.

Inventive Principle:

Principle #29Pneumatics and hydraulics

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 pneumatic conveyor system ensures controlled, oil-free transport of shaped parts, reducing resource usage and costs by eliminating the need for conveyor belts and oil-related equipment, while maintaining part orientation and preventing intermingling, thus enhancing the production efficiency and quality.

Implementation Method 1

taking up the shaped parts inserted into the transporting pipe by suction into the transporting pipe

Methodology Applied

Scientific EffectSuction: Suction

Implementation Method 2

pneumatically transporting the sucked-on shaped parts through the transporting pipe in a direction of a subsequent station

Methodology Applied

Scientific EffectPneumatic transport:

Data Source

PatentUS12076779B2Method and system that produces formed parts by a multi-stage press

Publication Date: 2024.09.03 WAFIOS UMFORMTECHN

AI summary

A method of producing shaped parts includes drawing in the wire in cycles conveying the wire; severing wire portions in cycles; gripping and feeding the wire portion into work area; shaping the wire portion in multiple stages to form a shaped part with shank and head portions; ejecting formed shaped parts in cycles; transporting the fully formed shaped parts with a pneumatic conveyor system including a transporting pipe with an insertion opening: arranging the insertion opening near an ejector system such that the finished shaped parts can be inserted into the insertion opening directly in a positionally oriented manner by the ejector system; successively feeding the finished shaped parts into the transporting pipe by the ejector system; taking up the shaped parts inserted into the transporting pipe by suction into the transporting pipe; and pneumatically transporting the shaped parts through the transporting pipe in a direction of a subsequent station.