Rotating Punching Tool for Flexible Sheet Metal Processing
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Solution Overview
Problem
Existing machines for processing workpieces, particularly metal sheets, are limited by high tool costs and restricted workpiece size due to fixed tool geometries, making them unsuitable for small series production and requiring complex, costly adaptations for different workpiece sizes.
Innovation Solution
A machine with a programmable controller for the punching and injection molding units, allowing the punching tool to rotate and the workpiece to be moved in multiple directions, enabling flexible positioning and processing sequences that allow for complex shapes without the need for large or specialized tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If fixed tool geometries are used for punching and injection molding, then manufacturing precision is maintained, but adaptability to different workpiece sizes and shapes deteriorates
Solution Approach 1:
The punching tool is made rotatable about a vertical axis, allowing it to dynamically change its orientation and processing position. This dynamic capability enables the same tool to process different areas and angles of workpieces without requiring multiple fixed tools, thereby improving adaptability while maintaining precision through controlled movement.
Solution Approach 2:
The punching tool is designed to perform multiple functions by rotating to different positions. A single tool can now process various workpiece sizes, shapes, and locations, replacing the need for multiple specialized tools. This multi-functionality directly addresses the contradiction by providing versatility without sacrificing the precision of each individual processing operation.
2Manufacturing precision
If specialized tools are designed for specific workpiece geometries, then manufacturing precision is improved, but device complexity and tool costs increase
Solution Approach 1:
Instead of designing multiple specialized tools for different workpiece geometries, the invention uses a single punching tool that can be rotated to assume different processing positions. This universal tool approach reduces device complexity and tool costs while maintaining manufacturing precision through programmable positioning and rotation control.
Solution Approach 2:
The tool's effective processing parameters are changed by rotating it to different angular positions and locations. Rather than changing the physical tool geometry, the system changes the tool's orientation and position parameters to adapt to different workpiece requirements, thereby simplifying the tool design while maintaining processing precision.
3Productivity
If fixed processing sequences are used, then manufacturing efficiency is improved, but adaptability to different production requirements deteriorates
Solution Approach 1:
The processing sequence is made dynamic and programmable rather than fixed. The punching tool can be programmed to rotate and process workpieces in different sequences, allowing the system to adapt to various production requirements while maintaining efficiency through automated control. The workpiece can be processed in different areas and orientations according to programmable instructions.
4Adaptability or versatility
If large specialized tools are used to accommodate different workpiece sizes, then adaptability is improved, but device complexity and cost increase
Solution Approach 1:
Instead of using large, complex tools to accommodate all workpiece sizes, the invention uses a smaller, simpler punching tool that can be rotated and repositioned programmatically. This dynamic positioning approach allows a compact tool to process workpieces of various sizes by adjusting its angular and positional parameters, thereby reducing device complexity while expanding adaptability.
Data Source
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AI summary
The invention relates to a machine for processing workpieces, comprising a punching unit (26), which has at least one punching tool (52, 54) that can be moved up and down in a vertical direction and which defines a punching processing region (42), and comprising an injection-molding unit (36), which has at least one injection-molding tool for overmolding the workpiece (20; 180) with plastic material in some regions and which defines an injection-molding processing region (46), and comprising a positioning device (22) for positioning the workpiece (20; 180) in the punching processing region (42) and in the injection-molding processing region (46). In order to further develop the machine in such a way that the workpiece can be economically punched and overmolded with plastic material in some regions, wherein the size of the workpiece is not limited by the size of the tools used, the machine (10) according to the invention has a programmable machine controller (48) for controlling the punching unit (26), the injection-molding unit (36), and the positioning device (22), and the at least one punching tool (52, 54) can be rotated about a vertical axis of rotation (60, 62) in order to process the workpiece (20; 180) in rotational positions that can be specified by means of programming, and the workpiece (20; 180) can be moved back and forth in a horizontal plane in a first feeding direction and a second feeding direction by means of the positioning device (22), wherein the workpiece (20; 180) can be positioned in the punching processing region (42) and in the injection-molding processing region (46) in horizontal positions that can be specified by means of programming and can be repeatedly processed by the punching unit (26) and the injection-molding unit (36) in successive process steps that can be specified by means of programming.