Spring Plunger Workpiece Ejection for Low-Downtime Stamping
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Solution Overview
Problem
Conventional workpiece ejecting systems in stamping machines require experienced operators for complex setups and maintenance, and they often result in significant machine downtime due to the use of cam mechanisms and air flow paths, which are labor-intensive and costly, especially when dealing with workpieces of varying shapes and orientations.
Innovation Solution
A workpiece ejecting system utilizing a spring plunger mechanism aligned underneath the die cavity, integrated with a linear actuator and positioning sensor, which allows for easy installation and adjustment, and incorporates a vacuum system for secure workpiece handling, enabling direct ejection and transfer without part-to-part contact, and is adaptable to different workpiece sizes and shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a cam mechanism is used for workpiece ejection, then the ejection function is achieved, but the device complexity and operational difficulty increase
Solution Approach 1:
The invention extracts the ejection function from the complex cam mechanism and implements it through a simple spring-loaded plunger system. The cam mechanism is removed entirely, and only the essential ejection function remains, achieved through the spring plunger that can be easily installed and maintained.
Solution Approach 2:
The invention replaces the mechanical cam mechanism with a spring-based mechanical system. The spring plunger uses elastic potential energy storage and release instead of cam rotational motion, simplifying the mechanical system while maintaining the ejection function.
2Ease of manufacture
If an air ejector system is used, then workpiece ejection is achieved, but machining costs increase due to air path drilling
Solution Approach 1:
The invention removes the air path drilling requirement from the ejection system. Instead of modifying the punch with air holes, the system uses a spring plunger that makes direct contact with the workpiece, eliminating the need for additional machining operations on the punch component.
Solution Approach 2:
The invention replaces the pneumatic air ejection system with a mechanical spring-based system, eliminating the need for air paths, compressors, and control valves, thereby reducing machining costs while maintaining reliable ejection.
3Device complexity
If air flow path is drilled in punch, then ejection is achieved, but the punch component complexity and cost increase
Solution Approach 1:
The invention extracts the ejection function from the punch component itself and relocates it to a separate spring plunger mechanism. This removes the need to drill air paths in the punch, keeping the punch component simple and reducing manufacturing costs.
4Productivity
If cam mechanism is used for synchronization, then workpiece holding is achieved, but machine downtime increases during setup and maintenance
Solution Approach 1:
The invention removes the cam mechanism entirely from the synchronization function, using instead a straightforward spring plunger system that operates independently of the cam shaft. This eliminates the need for experienced operators to perform complex setup and maintenance tasks, reducing machine downtime.
Solution Approach 2:
The spring plunger system is designed to be self-contained and easy to service. The spring can be easily replaced or adjusted without requiring specialized knowledge or tools, enabling quick maintenance and minimizing machine downtime.
5Adaptability or versatility
If air ejector system is used, then workpiece ejection is achieved, but the system adaptability to different workpiece shapes is limited
Solution Approach 1:
The invention removes the air path configuration constraints by using a mechanical spring plunger that can be positioned and oriented to accommodate different workpiece shapes. The plunger can be adjusted to contact various parts of the workpiece, providing versatility without complex air path design.
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
The system reduces machine downtime and operational complexity by allowing for easy installation and maintenance, enabling efficient ejection and transfer of workpieces with reduced labor and machining costs, and accommodating various workpiece shapes and orientations.
Implementation Method 1
a spring plunger mechanism which can be fitted and aligned to the die cavity (111)
Implementation Method 2
the workpiece is held by using a vacuum system
Data Source
AI summary
An ejecting system for a workpiece from a die cavity in a stamping machine is disclosed. The ejecting system has a spring plunger mechanism to fetch the workpiece from the die cavity of the die platen of the stamping machine. The spring plunger mechanism is provided with a picker which is integrated with a vacuum system to hold the workpiece. Underneath the spring plunger mechanism, there is an actuator, including a positioning sensor, for triggering both synchronous upward and downward movement of the linear actuator to the punch of a die set.