Simultaneous Stamping of Interlocking Metallic Subcomponents
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Solution Overview
Problem
Existing processes for manufacturing metallic end products from separate work blanks with differing configurations are inefficient, as they require sequential operations that increase overall production time, especially when forming products that require interlocking or connecting subcomponents without welding, glue, or fasteners.
Innovation Solution
A process involving simultaneous feeding and processing of two elongated work blanks through conveyances with synchronized mechanical operations, where each blank undergoes specific stages of perforation, bending, and cutting to form interlocking components, ultimately using a toggle locking process to couple the components without additional fasteners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If sequential operations are used to form subcomponents from separate work blanks, then manufacturing precision can be maintained, but productivity decreases due to increased production time
Solution Approach 1:
The patent combines multiple sequential stamping operations into a single synchronized press cycle. Multiple work blanks are positioned in different stations of a progressive die system, and all are stamped simultaneously in one press cycle, merging what would otherwise be sequential operations into a parallel process that maintains precision while reducing production time
Solution Approach 2:
The manufacturing process is segmented into multiple independent work blank streams that can be processed simultaneously. Each work blank is fed through its own conveyance system and stamped at its own station, allowing the system to handle different configurations and operations on different blanks in parallel, thereby increasing overall productivity without sacrificing precision
2Productivity
If simultaneous stamping operations are performed on multiple work blanks, then productivity increases, but device complexity increases due to synchronization requirements
Solution Approach 1:
The press system is designed as a universal multi-functional device that can simultaneously perform different stamping operations on multiple work blanks with different configurations. The progressive die system accommodates various stamping functions (punching, forming, cutting) at different stations, allowing the same press to handle diverse production requirements without requiring separate dedicated machines for each operation
Solution Approach 2:
Conveyance systems act as intermediaries between the work blanks and the stamping stations. These conveyances synchronize the movement and positioning of multiple work blanks, ensuring that each blank is in the correct position at the correct time for its specific stamping operations, thereby managing the synchronization complexity through dedicated transport mechanisms
3Ease of manufacture
If separate work blanks with differing configurations are processed sequentially, then ease of manufacture is maintained, but loss of time increases
Solution Approach 1:
The manufacturing system is made dynamic by allowing the conveyance systems to adjust the speed and positioning of different work blanks according to their specific requirements. Each work blank can move through its own sequence of operations at its own pace, with the conveyances dynamically coordinating to ensure all blanks are ready for their respective stamping operations simultaneously, thereby reducing idle time while maintaining manufacturing simplicity
Data Source
AI summary
A process provides for manufacturing and formation of a series of metallic end products within a stamping machine. The metallic end products are formed from two subcomponents comprising a first work component and a second work component. The work components are coupled together through a toggle lock procedure formed as part of the process. The two resultant work components which form the end product are simultaneously formed, thereby providing significant advantages with respect to work cycle time to produce the resultant product, relative to the time required when individual work components are sequentially produced through the use of mechanical operations to which a first work component is processed, and then formation of a second work component is processed.