Press Conveying Nozzle Control for In-Motion Scrap Discharge
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Solution Overview
Problem
Conventional press forming processes face challenges in efficiently conveying and discharging scrap while maintaining cycle time, as existing solutions often result in scrap scattering or incomplete discharge during the transition between processes.
Innovation Solution
A conveying device equipped with holding parts for both product and scrap, a separate nozzle for discharging compressed fluid, and a controller to release the scrap during conveyance, ensuring precise disposal into an underground pit without sacrificing cycle time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the conveying device stops to discharge scrap during conveyance, then the scrap can be released from suction and dropped into the underground pit, but the cycle time cannot be improved
Solution Approach 1:
The conveying device performs preliminary actions by maintaining forward movement and preparing the nozzle positioning system in advance. The nozzle is pre-positioned to follow the scrap's trajectory, and the suction release timing is calculated based on predicted scrap position, allowing discharge without stopping the conveyance device.
Solution Approach 2:
The system dynamically adjusts the nozzle position to track the moving scrap throughout conveyance. The nozzle follows the scrap's movement in real-time, and the suction release moment is dynamically determined based on the scrap's position and velocity, enabling discharge during continuous motion rather than static release.
2Productivity
If the scrap is released from suction during conveyance, then the conveyance speed is accelerated, but the scrap scatters on the die instead of dropping into the underground pit
Solution Approach 1:
The nozzle acts as an intermediary that follows the scrap during conveyance and provides controlled air pressure. When the nozzle releases the scrap, it creates a controlled trajectory that guides the scrap into the underground pit opening, preventing scattering while maintaining conveyance speed.
Solution Approach 2:
The system replaces purely mechanical suction release with a combined pneumatic-mechanical approach. The nozzle uses compressed air to control the scrap's motion after suction release, substituting uncontrolled mechanical dropping with controlled pneumatic guidance to achieve precise dropping without scattering.
3Ease of manufacture
If a tunnel structure is set inside the die for scrap discharge, then scrap can be discharged in the conventional second process, but the die investment cost increases and space is consumed
Solution Approach 1:
The invention extracts the scrap discharge function from the die structure itself. Instead of embedding a tunnel within the die, the conveying device with its integrated nozzle and suction system performs the discharge function externally, eliminating the need for complex internal die modifications while maintaining scrap discharge capability.
Solution Approach 2:
The conveying device is designed with multi-functionality, serving both as a product conveyance system and a scrap discharge system. The same device that conveys the formed product also handles scrap removal through its suction and nozzle mechanisms, eliminating the need for separate dedicated scrap discharge infrastructure.
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 reliable discharge of scrap into a predetermined position, integrating drawing and cutting processes without tunnel structures within the die, improving die rigidity, reducing downtime, and enhancing product quality by maintaining high conveyance speed and precision.
Implementation Method 1
a conveying part 200 that includes respective holding parts 21, 22 for holding a product part W1 and a scrap part W2 of a workpiece after a cutting process
Implementation Method 2
a nozzle part 23 that is provided separately from the holding parts 21, 22 in the conveying part 200, and discharges compressed fluid toward the scrap part W2
Implementation Method 3
the scrap is dropped into a take-out hole provided between the first process and the second process
Data Source
AI summary
There is provided a conveying device that reliably discharges only scrap when simultaneously conveying the scrap and a pressed product without sacrificing cycle time. A conveying device for use in press forming includes: a conveying part that holds a product part and a scrap part of a workpiece after a cutting process, and conveys the product part and the scrap part to a next process; a nozzle part that is provided in the conveying part, and discharges compressed fluid toward the scrap part; and a controller that performs a control to release holding of the scrap part during conveyance of the workpiece and to blow compressed fluid toward the scrap part.