Adjustable Press Brake Die With Rack-and-Pinion Width Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing adjustable dies for press brakes are cumbersome, costly, and require frequent repositioning, making them impractical for operations requiring frequent changes in bending parameters, and they often necessitate manual handling which can be labor-intensive and risky due to weight.
Innovation Solution
An adjustable die with two movable half portions connected by a rack-and-pinion translation device, allowing for precise and rapid adjustment of the mold cavity width, featuring a clamping system that includes a clamping rod with notches and grooves for secure positioning, and a lifting system to facilitate easy movement and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If fixed dies are used for press brake operations, then the die structure is simple and easy to manufacture, but frequent changes in bending parameters require numerous die repositionings which consume large amounts of time and labor
Solution Approach 1:
The die is designed with two movable half-portions that can dynamically adjust their relative position to change the mold cavity width. The translation device with rack and pinion mechanisms enables the half-portions to move along the longitudinal direction, allowing rapid adaptation to different bending parameters without time-consuming manual repositioning
Solution Approach 2:
The die is segmented into two independent half-portions that can move relative to each other. This segmentation allows the mold cavity width to be adjusted by moving one or both half-portions, providing versatility for different bending operations while maintaining a relatively simple overall structure
2Adaptability or versatility
If adjustable dies with considerable length are used, then the die can accommodate various bending radii, but the weight of half portions requires several people to move and reposition them
Solution Approach 1:
The translation device converts rotational motion of the handwheel into linear motion of the half-portions through rack and pinion mechanisms. This mechanical advantage system enables a single operator to move heavy half-portions along the longitudinal direction, eliminating the need for multiple people while maintaining the die's length for accommodating various bending radii
Solution Approach 2:
The rack and pinion mechanism acts as an intermediary between the operator's manual input and the heavy half-portions. The handwheel rotates pinions that engage with racks attached to the half-portions, providing mechanical advantage to move the heavy components with minimal effort from a single operator
3Ease of operation
If lead screw drive devices or hydraulic actuators are used to move half portions, then the translation mechanism is functional, but the system becomes particularly complicated and costly to produce
Solution Approach 1:
The invention extracts only the essential translation function needed to move the half-portions, eliminating complex lead screw drives or hydraulic actuators. The simplified rack and pinion mechanism with handwheel provides the necessary functionality while dramatically reducing system complexity and manufacturing cost
Solution Approach 2:
The translation device uses simple, inexpensive mechanical components (rack, pinion, handwheel) rather than expensive lead screws or hydraulic systems. While the components are simple and potentially less precise, they provide sufficient functionality for the application at a fraction of the cost and complexity of alternative systems
4Device complexity
If manual handling of heavy dies is used, then no additional translation mechanism is needed, but the operation is labor-intensive and risky
Solution Approach 1:
The rack and pinion mechanism serves as a mechanical intermediary that translates small rotational movements of the handwheel into large linear movements of the heavy half-portions. This intermediary system maintains structural simplicity while dramatically improving ease of operation, allowing a single operator to safely and easily reposition the die components
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 rapid and precise adjustment of the die to accommodate different metal plate thicknesses and bending radii, reducing operational time, weight, and maintenance needs, while ensuring stability and ease of use, making it more cost-effective and practical compared to prior art.
Implementation Method 1
the translation device comprises a shaft on which at least two pinions are mounted to mesh with at least a first rack and at least a second rack respectively on a first plate and and on a second plate
Implementation Method 2
Guides obtained in the plates engage the aforesaid shaft and ensure that, following rotation, the two half portions are moved away from or toward each other
Implementation Method 3
a clamping system of the half portions, configured to clamp the two half portions in the selected position
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a die (1) for a press brake comprising a base (10), a first half portion (20) and a second half portion (30) of a mold, each comprising a plurality of plates (22, 32) parallel to one another and alternated in a longitudinal direction (X) of the die, the die comprising a translation device to move said half portions (20, 30) away from and toward each other, said device comprising a plurality of guides (24, 34) obtained on the plates (22, 32), a shaft (41) slidingly engaged with said guides (24, 34), a first pinion (42) and a second pinion (43) mounted on said shaft (41) and at least a first rack (25) and at least a second rack (35) respectively on a first plate (22) of the first half portion (20) and on a second plate (32) of the second half portion (30) and meshed respectively with said first and second pinion.