Flat Plate Punch Lubrication Control to Reduce Soiling
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Solution Overview
Problem
Existing punching apparatuses for flat metal plates face issues with excessive lubricant usage leading to soiling, time-consuming and ineffective cleaning, and high environmental and energy costs associated with cleaning and drying processes.
Innovation Solution
A punching apparatus with a spray chamber and containment frame to control lubricant distribution, minimizing dripping onto the metal plate, combined with pressurized fluid cleaning means for efficient and rapid cleaning, utilizing a mixture of air and oil as lubricant and employing a metal sheet stamping plant with integrated cleaning and drying stations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If large amounts of lubricating fluid are used during punching, then machining precision is improved, but soiling of components increases and cleaning requirements increase
Solution Approach 1:
The patent introduces a spray chamber as an intermediary device between the lubricating fluid source and the punching components. The spray chamber nebulizes the lubricating fluid into fine droplets that are distributed evenly across the punching area, providing adequate lubrication for precision while preventing excessive fluid accumulation and soiling of components.
Solution Approach 2:
The patent employs pneumatic systems to deliver and control the lubricating fluid through spray nozzles. Compressed air is used to nebulize and distribute the lubricating fluid uniformly across the punching zone, ensuring precise application only where needed, thereby maintaining machining precision while minimizing overall fluid usage and component soiling.
2Ease of operation
If components are washed with water and chemicals to remove lubricating fluid, then cleaning effectiveness is improved, but environmental impact and disposal costs increase
Solution Approach 1:
The patent extracts and removes the spray chamber containing the lubricating fluid from the main punching apparatus. This isolated containment allows the lubricating fluid to be easily separated and removed from the system without contaminating the surrounding environment, eliminating the need for water and chemical washing, and thereby reducing environmental impact and disposal costs.
3Ease of operation
If drying processes are applied to machined components, then moisture removal is improved, but energy costs increase
Solution Approach 1:
The patent implements a self-drying mechanism where compressed air is used to blow dried air across the machined components immediately after punching. This self-service drying system removes moisture without requiring additional energy-intensive heating or drying equipment, thereby eliminating extra energy costs while effectively removing moisture from the components.
4Ease of operation
If cleaning procedures are made more thorough, then cleaning effectiveness is improved, but cleaning time increases
Solution Approach 1:
The patent incorporates preliminary cleaning actions by integrating spray chambers and containment frames that prevent lubricating fluid from soiling components in the first place. By taking preventive measures during the punching operation itself, the need for extensive post-punching cleaning is eliminated, achieving thorough cleanliness without increasing cleaning time.
Solution Approach 2:
The patent uses pneumatic blowers to deliver compressed air for rapid cleaning of components. This high-velocity air stream efficiently removes any remaining lubricating fluid residues in seconds, providing thorough cleaning effectiveness while minimizing cleaning time, unlike manual or chemical cleaning methods that would take longer.
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
Reduces lubricant usage and cleaning time, eliminates the need for water washing, decreases environmental impact, and enhances cleaning effectiveness by using compressed air for efficient component cleaning.
Implementation Method 1
configured for the passage of a nebulised lubricating fluid
Implementation Method 2
means for cleaning the punch (6) configured to operate on the punch (6) through such at least one punch-holder (7)
Implementation Method 3
employing a metal sheet stamping plant with integrated cleaning and drying stations
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The present invention relates to a punching apparatus (1) for flat metal plates, comprising: - an upper load-bearing body (50) configured to be fixed to a slide (B1) of a press (A); - a lower load-bearing body (60) configured to be fixed to a base (B2) of said press (A); - at least one punch-holder (7) fixed to the upper load-bearing body (50); - a punch (6) supported by the punch-holder (7); - an annular die (2) configured to support a portion of a flat metal plate (L) being processed; - a central hole (3) of the annular die (2) configured for the passage of the punch (6) and the passage of processing scrap; - a blank holder (4) constrained to the upper load-bearing body (50) and opposite to said annular die (2); - a pilot hole (5) defined in said blank holder (4) and passed through by the punch (6); - a spray chamber (10) defined around the punch (6), for the passage of a nebulised lubricating fluid towards the pilot hole (5); - a containment frame (11) configured to prevent the outflow of a liquid-state lubricating fluid from the spray chamber (10) to the pilot hole (5); - a lubricating fluid sprayer (12) configured to spray said lubricating fluid towards said pilot hole (5) through said spray chamber (10).