Powder Press Toggle Drive Electric Actuation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing powder presses face challenges in achieving high compressive forces efficiently while maintaining precision, flexibility, and reducing energy consumption and maintenance costs, particularly with complex compact shapes and non-linear drive systems being susceptible to failure and wear.
Innovation Solution
A powder press incorporating an electric drive unit with a toggle lever drive and adjustable fixed stop devices, utilizing a servo motor arrangement and solid-state joints for precise control and reduced energy requirements, allowing for high rigidity and dynamic movement control, and enabling the production of complex compact shapes with reduced complexity and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If hydraulic drive systems are used to achieve high pressing forces and flexible independent movement of punch assemblies, then pressing force and flexibility are improved, but energy consumption increases and system complexity increases
Solution Approach 1:
The patent replaces hydraulic drive systems with an electromechanical drive system consisting of an electric motor and a toggle lever mechanism. The electric motor converts electrical energy to mechanical energy, which is then transmitted through the toggle lever mechanism to generate high pressing forces. This substitution eliminates the need for hydraulic fluid and pumps, thereby reducing energy consumption and system complexity while maintaining the capability to generate high pressing forces through mechanical advantage.
2Adaptability or versatility
If hydraulic drive systems are used for flexible independent movement of punch assemblies, then flexibility is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex hydraulic drive systems with a simpler electromechanical system. The electric motor provides rotational motion that is converted to linear motion through the toggle lever mechanism. This mechanical substitution reduces the number of components (hydraulic pumps, valves, fluid lines) while maintaining flexibility through the controllable nature of the electric motor and the mechanical advantage of the toggle lever system.
3Force
If toggle lever drives are used to achieve high pressing forces, then pressing force is improved, but reliability deteriorates due to susceptibility to failure and wear
Solution Approach 1:
The patent introduces the toggle lever mechanism as an intermediary between the electric motor and the punch assemblies. The toggle lever acts as a mechanical multiplier that converts the rotational motion of the motor into high-force linear motion. By positioning the toggle lever as an intermediary, the system achieves high pressing forces while the solid-state joints and articulated connections are designed to minimize wear and failure, thereby improving reliability compared to direct mechanical connections.
4Manufacturing precision
If electric drive systems are used to achieve precision and flexibility, then manufacturing precision and adaptability are improved, but productivity decreases due to medium stroke rates
Solution Approach 1:
The patent employs a dynamic toggle lever mechanism that can adjust its mechanical advantage ratio during the pressing cycle. By varying the angle and position of the toggle lever, the system can optimize both the speed of stroke (for productivity) and the force multiplication (for precision). The electric motor provides dynamic control, allowing the system to achieve high stroke rates while maintaining manufacturing precision through real-time adjustment of the drive characteristics.
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 achieves high precision, energy efficiency, and reliable controllability in the pressing process, reducing the risk of operating errors and extending the application range of toggle lever drives, while minimizing energy consumption and maintenance needs.
Implementation Method 1
an upper punch assembly (14) having a plurality of additional axes (15), which can be moved into individual press positions, is operatively connected to an electric drive unit (12) in such a way that a toggle lever drive (16) with a plurality of coupling elements moves the upper punch assembly (14) along the press axis (18) into a final press position
Implementation Method 2
A first arm (30) for connection to the press frame (10) and a second arm (32) for connection to the upper punch assembly (14) are pivotally connected to a second end (28) of each lever
Implementation Method 3
wherein preloadable bearings are provided for the articulated connection of coupling elements of the toggle lever drive by means of solid joints
Implementation Method 4
wherein mechanical fixed stops (50) are provided for determining the individual press positions of the additional axes (15)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Powder press (1) for producing a compact from a compressible material, comprising a press frame (10), an upper and/or lower punch assembly (14), and a die assembly defining a mold cavity into which the compressible material can be filled, and an electric drive unit (12) operatively connected to the punch assemblies (14) and/or the die assembly, wherein, for forming the compact, the punch assemblies (14) and the die assembly are movable relative to each other and can be pressed against each other along a press axis (18) by means of the electric drive unit (12). Furthermore, the operative connection between the electric drive unit (12) and one of the punch assemblies (14) includes a toggle lever drive (16) which moves the punch assembly (14) along the press axis (18) into a press end position.