Press Brake Dual-Frame Alignment System
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Solution Overview
Problem
Press brake machines face challenges in achieving consistent and precise bending operations due to asymmetric effort distribution, leading to misalignment and varying angles of attack, which can result in imperfections and damage to the workpiece or tools.
Innovation Solution
The implementation of a dual-frame system, where a load bearing frame supports the primary force and an alignment frame ensures predictable tool movement through sliding means, maintaining a predefined path and angle, even when the load bearing frame distorts, using 'C'-shaped frames joined at specific angles to balance load distribution and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single load-bearing frame is used to support the pressing force, then the frame structure is simple, but the tool alignment becomes inconsistent due to asymmetric effort distribution and frame distortion
Solution Approach 1:
The frame structure is segmented into two distinct functional frames: a load-bearing frame (61) that supports the pressing force and an alignment frame (62) that guides tool movement. This segmentation allows each frame to specialize in its respective function, preventing the coupling of load-bearing and alignment functions that causes misalignment in single-frame designs.
Solution Approach 2:
The alignment frame acts as an intermediary element between the load-bearing frame and the tools. It mediates the interaction by providing a stable sliding guide (8) that constrains tool movement to a predefined path, isolating the alignment function from the distortions caused by asymmetric loading on the load-bearing frame.
2Force
If the frame is designed to bear asymmetric loading, then the load-bearing capacity is sufficient, but the tool movement path becomes unpredictable due to frame distortion
Solution Approach 1:
The system segregates the force-bearing function (load-bearing frame 61) from the path-stability function (alignment frame 62). The load-bearing frame is optimized to handle asymmetric pressing forces, while the alignment frame provides a stable sliding guide that maintains predictable tool movement regardless of load-induced distortions in the load-bearing frame.
Solution Approach 2:
The sliding guide (8) formed by the alignment frame serves as a mechanical intermediary that decouples the tool movement path from the distortions of the load-bearing frame. It enforces a predefined movement path through physical constraint, acting as a mediator that translates asymmetric loading into controlled, predictable tool motion.
3Manufacturing precision
If sliding means are added to guide tool movement, then alignment precision is improved, but the device complexity increases
Solution Approach 1:
The sliding guide (8) is merged into the alignment frame (62) structure itself, forming an integrated C-shaped assembly. This merging eliminates the need for separate, complex alignment mechanisms by incorporating the sliding function directly into the frame structure, achieving alignment precision without proportionally increasing device complexity.
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 configuration ensures consistent and uniform bending or pressing operations by maintaining tool alignment and reducing tension in the frames, thereby improving the quality of workpieces and reducing the risk of damage.
Implementation Method 1
the sliding means (8) are a sliding joint (8A, 8B)
Data Source
Figure 1
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Figure 3
AI summary
Press brake (1) comprising a top tool (2) and a bottom tool (3), for bending or pressing workpieces between said opposing tools; a displaceable upper beam (4), wherein the top tool (2) is mounted upon; a bottom beam (5), wherein the bottom tool (3) is mounted upon; a load bearing frame (61) mounted extending transversally, comprising a concave opening, wherein the bottom beam (5) is mounted on the bottom part; force means (7) mounted between the upper beam (4) and the upper part of the load bearing frame (61) for opposing the upper and lower tools (2, 3); an alignment frame (62) mounted extending transversally, comprising a concave opening, wherein the bottom beam (5) is mounted on the bottom part of the alignment frame (62); sliding means (8) mounted between the upper beam (4) and the upper part of the alignment frame (62).