Radial Press Electromechanical Positioning for High-Force Forming
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Solution Overview
Problem
Existing radial presses are limited in their ability to form large workpieces with high pressing force and efficient cycle times, particularly when dealing with large diameters or high forces, and often suffer from hydraulic inefficiencies and material damage due to foaming.
Innovation Solution
An electromechanical rapid positioning drive with synchronous cylinders and parallel positioners, coordinated by a servo motor and self-locking gear mechanism, allows for rapid and precise movement of ring structures without hydraulic components, enabling high pressing forces and efficient cycle times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If hydraulic cylinder-piston units are used for rapid positioning of ring structures, then positioning speed is improved, but hydraulic fluid loss and foaming occur leading to material damage
Solution Approach 1:
The patent extracts and removes the hydraulic rapid positioning system from the press, eliminating the source of hydraulic fluid loss and foaming. Instead, a mechanical rapid positioning system using cam mechanisms and springs is implemented, which does not involve hydraulic fluids and thus eliminates the harmful effects associated with hydraulic systems during rapid positioning operations.
Solution Approach 2:
The patent replaces the hydraulic positioning system with a purely mechanical rapid positioning system. The mechanical system uses cam mechanisms, levers, and springs to achieve rapid positioning of the ring structures without any hydraulic components, thereby eliminating fluid loss and foaming while maintaining positioning speed.
2Speed
If stepped construction of bracing faces is used for rapid positioning, then positioning speed is improved, but pressing force is reduced due to smaller contact area
Solution Approach 1:
The patent implements a dynamic system where the bracing faces transition from a stepped configuration during rapid positioning to a full-contact configuration during power pressing. The mechanical rapid positioning system enables the ring structures to approach quickly with stepped faces engaged, then transitions to full surface contact for high-force pressing, optimizing both speed and force at different stages of the cycle.
Solution Approach 2:
The patent employs periodic action by alternating between two distinct operational phases: a rapid positioning phase using stepped bracing faces for high-speed approach, and a power pressing phase using full-contact bracing faces for high-force deformation. This periodic switching between configurations optimizes both positioning speed and pressing force throughout the press cycle.
3Loss of time
If hydraulic rapid positioning is used, then cycle time is reduced, but hydraulic inefficiencies and energy loss occur
Solution Approach 1:
The patent replaces the hydraulic rapid positioning system with a mechanical system using cam mechanisms, levers, and springs. This mechanical system achieves rapid positioning without the energy losses associated with hydraulic fluid compression, leakage, and foaming, thereby reducing energy consumption while maintaining short cycle times.
Solution Approach 2:
The mechanical rapid positioning system is designed to be self-powered through the press's own operational cycle. The cam mechanisms and springs utilize the natural motion and forces generated during pressing to accomplish rapid positioning without requiring additional hydraulic energy input, making the system energy-efficient and self-sufficient.
Data Source
AI summary
A radial press is provided having a first and a second ring structure which extend around a press axis and a plurality of pressing elements, which are disposed around the press axis and are translatably supported on supporting surfaces associated with the ring structures. The axial distance of the two ring structures from each other can be changed using a hydraulic drive system, which has a plurality of hydraulic cylinder-piston units oriented parallel to and distributed around the press axis, the cylinder of each cylinder-piston unit being coupled to a first of the two ring structures and the piston rod of each cylinder-piston unit being coupled to the second ring structure. At least the supporting surfaces associated with one of the two ring structures are oriented at an inclination with respect to the press axis. An electromechanical rapid adjustment drive comprising a plurality of adjusters is also provided.