Stamping Die Gap Mapping for Automatic Die Adjustment

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Solution Overview

Problem

Stamping presses face challenges in accurately measuring and maintaining the distance between upper and lower die portions, leading to potential contact and damage during metal shaping, which is currently addressed through costly and time-consuming alignment processes.

Innovation Solution

Incorporating magnets within the upper die portion and magnetic flux sensors within the lower die portion to measure distances and adjust the movement of the die portions using electric motors controlled by a motor control module, generating a gap map to maintain uniform distance and prevent contact.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If traditional alignment processes are used to measure and maintain distance between die portions, then measurement accuracy can be achieved, but the process is costly and time-consuming

Engineering Contradiction:

Improvedistance measurement accuracyVSAvoidalignment process time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent replaces traditional mechanical alignment processes with a magnetic field-based measurement system. Magnetic flux sensors detect the position of magnets embedded in the die portions, enabling non-contact, automated distance measurement that eliminates time-consuming manual alignment while maintaining high measurement accuracy

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system enables automatic die adjustment by using the magnetic flux sensors to continuously monitor distances and providing real-time feedback to the control system. This self-measuring capability eliminates the need for external alignment tools and manual intervention, reducing both time and cost

Inventive Principle:

Principle #25Self-service

2Reliability

If traditional alignment processes are used to prevent die contact, then damage prevention can be achieved, but the process is costly

Engineering Contradiction:

Improvedamage preventionVSAvoidalignment cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent implements a feedback control system where magnetic flux sensors continuously measure the distance between die portions and provide real-time data to the control system. When the distance approaches a critical threshold, the system automatically adjusts the die position or alerts operators, preventing contact and damage while eliminating costly manual alignment procedures

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system replaces expensive manual alignment and monitoring processes with an automated magnetic field-based detection and control system, significantly reducing operational costs while maintaining or improving reliability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If manual die adjustment is performed, then alignment can be achieved, but productivity is reduced due to time-consuming processes

Engineering Contradiction:

Improvedie alignment precisionVSAvoidmetal shaping efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The system performs automatic die adjustment by embedding magnets in the die portions and using magnetic flux sensors to continuously monitor and measure distances. The control system automatically processes this data and adjusts die positions without manual intervention, maintaining high alignment precision while eliminating time-consuming manual processes and improving overall productivity

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The magnetic flux sensors enable continuous monitoring of die positions during the metal shaping process, allowing for real-time adjustments rather than intermittent manual checks. This continuous measurement and adjustment capability maintains precision while maximizing productivity by eliminating downtime

Inventive Principle:

Principle #20Continuity of useful action

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

Automatically maintains consistent distance between die portions, reducing the risk of contact and damage, enhancing the efficiency and accuracy of metal shaping processes while minimizing alignment costs and time.

Implementation Method 1

magnetic flux sensors that are disposed within the second bores, respectively, and that are adjacent to the magnets, respectively, and that are configured to measure distances between the upper and lower portions at the locations

Methodology Applied

Scientific EffectMagnetic flux sensing: Hall Effect

Data Source

PatentUS11845237B2Systems and methods for automatic die adjustment

Publication Date: 2023.12.19 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A die of a stamping press includes: an upper portion including one or more first features and first bores that extend partially through the upper portion; magnets disposed within the first bores, respectively; a lower portion including one or more second features that are complementary to the first features and second bores at locations, respectively, that extend partially through the lower portion; and magnetic flux sensors that are disposed within the second bores, respectively, and that are adjacent to the magnets, respectively, and that are configured to measure distances between the upper and lower portions at the locations.