Radial Forging Machine Automated Tool Loading System
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Solution Overview
Problem
Current radial forging machines require manual and time-consuming processes for loading and unloading tools, which affects productivity, safety, and homogeneity of production lots due to the need for tools to cool down before unloading and transitionary heating during loading.
Innovation Solution
An automated or semi-automated loading/unloading system using a support frame with two-sided restraining means and actuation mechanisms allows for the complete removal of operators from the machine, enabling tool replacement without waiting for tools to cool down and preheating during production cycles, ensuring uniformity of production lots.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual loading and unloading of tools is used, then operators can handle tools directly, but replacement time is significant (one work shift) and productivity is reduced
Solution Approach 1:
The system enables automatic tool loading and unloading without operator intervention. The support frame with housing automatically positions tools, and the two-sided restraining means (reaction plates and tie rods) automatically secure tools to forging devices, eliminating manual handling and significantly reducing replacement time from one work shift to minutes
Solution Approach 2:
Tools are pre-positioned in the support frame housing before the loading cycle begins. The support frame maintains tool readiness in advance, allowing immediate transfer to forging devices when needed, thus eliminating waiting time and improving productivity
2Ease of operation
If tools are unloaded manually after forging, then operators can remove tools, but they must wait for tools to cool down which postpones the unloading cycle
Solution Approach 1:
The automatic unloading system removes tools without operator contact, eliminating safety concerns about hot tools. The robotic support frame and restraining means handle tool extraction autonomously, allowing immediate unloading regardless of tool temperature, thus eliminating the cooling wait time while maintaining operator safety
Solution Approach 2:
The support frame with housing acts as an intermediary between the hot tool and the operator. It provides safe handling and positioning of hot tools during unloading, eliminating the need for operators to directly contact hot tools while enabling immediate tool removal without cooling delays
3Ease of manufacture
If tools are loaded at ambient temperature, then tools can be introduced to the machine, but transitionary heating occurs during first processing which affects homogeneity of production lots
Solution Approach 1:
Tools are pre-heated in the support frame housing during the time masked by the production cycle before being transferred to forging devices. This preliminary heating ensures tools reach optimal temperature before contact with workpieces, eliminating transitionary heating effects during first processing and ensuring homogeneity across all production lots
Solution Approach 2:
The system maintains continuous tool heating throughout the production cycle by keeping tools in the heated support frame housing. This continuous thermal action ensures tools remain at optimal temperature consistently, eliminating temperature variations and ensuring homogeneity across all production lots
4Productivity
If automated loading/unloading system is implemented, then operator safety is enhanced and productivity increases, but device complexity increases with support frame and actuation means
Solution Approach 1:
The support frame with housing serves multiple functions: it positions tools during loading, restrains tools with two-sided restraining means, and can pre-heat tools during production. This multi-functionality reduces the need for separate dedicated components, managing device complexity while achieving automated operation and improved productivity
Solution Approach 2:
The automated system is divided into modular components: support frame, housing, two-sided restraining means (reaction plates and tie rods), and actuation means. This segmentation allows independent optimization and maintenance of each component, managing overall system complexity while enabling automated operation and improved productivity
Data Source
Figure 1a~1d
Figure 2~2a
Figure 3~3a
AI summary
A radial forging machine comprising one or more forging devices arranged radially about a first longitudinal axis (Z) of feeding of the product to be forged, a respective tool (5) being able to be mounted on each of said forging devices, characterized in that there is provided an automatic tool loading/unloading system for automatically loading/unloading said tools (5) onto/from said forging devices without the manual intervention of an operator.