Rotating Mandrel Tube Pressing to Eliminate Cooling Delays
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Solution Overview
Problem
Conventional tube manufacturing processes, such as extruding and drawing, result in unwanted heating of mandrels, leading to inefficiencies and increased production time due to the need for cooling before further processing can occur.
Innovation Solution
A machine with a rotatable plate allows for switching between multiple mandrels, enabling offline cooling of one mandrel while another is used for pressing, thereby reducing production time by allowing continuous operation without waiting for a mandrel to cool.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single mandrel is used for pressing the billet into the die assembly, then the structure is simple, but the mandrel heats up and must be cooled before the next operation, increasing production time
Solution Approach 1:
The single mandrel is divided into multiple mandrels (first platform mandrel and second platform mandrel) that can be selectively positioned. This segmentation allows one mandrel to be used for pressing while another cools offline, eliminating the production time loss from cooling and maintaining simple individual mandrel structures.
Solution Approach 2:
The cooling of the mandrel is performed in advance during the stroke-out portion of the press cycle when the mandrel is not needed for pressing. By preparing the mandrel for the next operation during idle time, the system ensures the mandrel is ready without extending the overall production cycle.
2Temperature
If the mandrel is cooled before the next pressing operation, then the mandrel temperature is controlled, but the production time increases due to waiting for cooling
Solution Approach 1:
The pressing operation continues continuously by switching between multiple mandrels. While one mandrel is cooling, another is being pressed, ensuring that the useful action of pressing never stops. This eliminates idle cooling wait time from the production cycle while maintaining proper mandrel temperature control.
Solution Approach 2:
The cooling process is performed preliminarily during the stroke-out portion of the press cycle when the mandrel is not needed. By utilizing this idle time for cooling preparation, the system ensures temperature control without adding to the overall production time.
3Productivity
If multiple mandrels are used with a rotatable plate for switching, then continuous operation is enabled, but the device complexity increases
Solution Approach 1:
A rotatable plate is introduced to dynamically switch between multiple mandrels positioned at different locations. This dynamic switching mechanism allows the system to adaptively select which mandrel to use based on its thermal state, enabling continuous operation while keeping each individual mandrel simple in structure.
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
This approach decreases production time by enabling continuous processing as one mandrel cools offline, while another is used, thus improving efficiency and reducing the overall time required to manufacture tubes.
Implementation Method 1
a rotatable platform selectively aligns a first platform mandrel and a second platform mandrel with the die assembly
Implementation Method 2
The rotatable platform is configured to move the second platform mandrel into the container with the cooling fluid therein during the stroke-out portion of the press cycle
Data Source
Figure 1~3D
Figure 4A~5B
Figure 6
AI summary
A method is used to manufacture an article using a machine having a fixed base and a press structure movable toward the fixed base. The machine also includes a die assembly and a container both coupled to the fixed base. The machine further includes a mandrel assembly comprising a rotatable platform coupled to the press structure and having a first platform mandrel aligned with the fie assembly and a second platform mandrel aligned with the container. The method includes the steps of placing a first starting component into the die assembly, pressing the first starting component to form the article, moving the second platform mandrel into the container simultaneously with the step of pressing the first starting component, and rotating the rotatable platform to align the second platform mandrel with the die assembly and to align the first platform mandrel with the container.