Press Die Loading on Linear Sliding Paths With Existing Robots
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Solution Overview
Problem
The existing methods for loading and unloading dies in press lines are inefficient and time-consuming, requiring human intervention and additional driving units, leading to significant downtime and increased operational costs.
Innovation Solution
A handling system that utilizes existing robots in the press line, equipped with a linear sliding path, to automate the loading and unloading of dies, allowing for horizontal displacement and minimizing the need for external driving units, thus reducing downtime and operational effort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If operators use forklifts to manually load and unload dies, then the operation can be performed, but the process is time-consuming and requires operator availability, leading to long downtimes
Solution Approach 1:
The robot utilizes the existing linear sliding paths originally designed for die movement to transport dies to and from the press, eliminating the need for separate forklift operations. The system serves itself by using already-present infrastructure for dual purposes: die positioning during operation and die transport during replacement.
Solution Approach 2:
The linear sliding paths are employed for multiple functions: transporting dies during normal production, moving dies during replacement operations, and serving as guidance rails for the robot. This multi-functional use eliminates the need for dedicated forklift paths and reduces overall system complexity.
2Extent of automation
If a die replacement system uses consoles with rolling elements and drive units, then dies can be automatically positioned, but the system requires additional driving units connected to power sources, increasing complexity
Solution Approach 1:
The patent removes the drive units from the die replacement system entirely. Instead of using powered conveyors or positioning mechanisms, the robot directly manipulates dies using the existing linear sliding paths as guidance and support, extracting the complex powered transmission elements from the system.
Solution Approach 2:
The linear sliding paths serve as an intermediary between the robot and the die. Rather than the robot directly gripping and moving the heavy die through complex mechanisms, the sliding paths provide a low-friction interface that enables easy die movement with minimal robotic force requirements.
3Extent of automation
If small robots are used to handle low weight workpieces, then the press line can be compact, but the robots cannot handle the heavier dies for automatic loading
Solution Approach 1:
The linear sliding paths act as a mechanical intermediary that supports the full weight of the die. The robot only needs to provide lateral guidance and positioning forces along the pre-established path, rather than supporting the entire die weight, enabling small robots to handle heavy dies.
Solution Approach 2:
The sliding paths create a low-resistance environment for die movement by providing continuous support and minimizing friction. This equipotential surface allows the robot to move the die horizontally with minimal energy expenditure, comparable to moving much lighter objects on frictionless surfaces.
4Productivity
If additional driving units are installed for die handling, then automated die replacement is possible, but the cost and operational complexity increase
Solution Approach 1:
The existing linear sliding paths, originally installed for die positioning during production, are repurposed for die transport during replacement operations. This universal use of existing infrastructure eliminates the need for additional powered conveyors, reducing both capital and operational costs.
Solution Approach 2:
The system uses its own existing infrastructure (sliding paths) to perform die replacement operations, making the system self-sufficient. No external forklifts or additional powered transport mechanisms are required, as the press line's own components facilitate the entire die replacement process.
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 system enables efficient, automated die handling with minimal downtime, reducing the need for human intervention and lowering operational costs by leveraging existing robots and sliding paths to support and move the dies within the press line.
Implementation Method 1
the path is configured to reduce the friction between the die and the surfaces on which the die has to move, and therefore to allow it to slide
Data Source
AI summary
Systems and methods for loading and/or unloading a die in a press are disclosed. A handling system for loading a die may include a linear sliding path between a supply position outside the press and a press position on the press base, configured to support a die such that the die is displaceable while it is supported on the path, and a robot configured to displace the die between the supply position and the press position along the linear sliding path. A method may include providing a robot for loading workpieces in the press, providing a linear sliding path between a supply position outside the press and a press position on the press base, placing a die in the supply position, and causing the robot to displace the die on the linear sliding path, from the supply position to the press position.