Star-Shaped Embossing Tools for Combustion Chamber Tube Synchronization
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The production of combustion chamber tubes for motor vehicle restraint systems faces challenges with synchronization and quality issues due to separate work processes in hydraulic machines, leading to limited production speed and precision.
Innovation Solution
A method and device utilizing a star-shaped arrangement of embossing tools and a ring press module with synchronously radial plungers, along with inner dies and mandrels, for precise shaping and calibration, combined with a punching tool system for self-centering and precise machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate hydraulic machines are used for each work process (crimping, stamping, calibrating), then each process can be performed with dedicated equipment, but synchronization problems and quality issues occur between processes
Solution Approach 1:
The patent combines multiple work processes (crimping, stamping, calibrating) into a single integrated machine with multiple tools arranged around a central processing position. This merging eliminates synchronization problems between separate machines while maintaining dedicated functionality for each operation through specialized tools within the integrated system.
2Ease of manufacture
If separate hydraulic machines are used for each work process, then process specialization is achieved, but production speed is limited due to sequential processing
Solution Approach 1:
By integrating multiple specialized tools into one machine that can perform crimping, stamping, and calibrating operations in a single setup, the system enables parallel processing capabilities while maintaining process specialization, thereby significantly increasing production speed.
Solution Approach 2:
The patent arranges multiple tools in a radial configuration around the workpiece, transitioning from sequential linear processing to concurrent radial processing. This spatial reorganization allows multiple operations to be performed simultaneously on different locations of the combustion chamber tube, enhancing productivity.
3Device complexity
If conventional separate machines are used, then equipment simplicity is maintained, but machining precision and accuracy are reduced
Solution Approach 1:
The integrated machine provides a unified reference frame and positioning system for all tools, ensuring that crimping, stamping, and calibrating operations are all performed with consistent precision relative to the same datum, thereby achieving higher overall manufacturing accuracy than separate machines could provide.
4Adaptability or versatility
If multiple separate hydraulic machines are used, then each process can be optimized independently, but changeover times increase between different production runs
Solution Approach 1:
By housing all process-specific tools within a single machine, the system requires only one setup and positioning operation per production run regardless of how many different operations are performed. This eliminates the repeated positioning and alignment required when using multiple separate machines, significantly reducing changeover times.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a method and a device for manufacturing a combustion chamber tube (1) for restraint systems in motor vehicles. The combustion chamber tube (1) is embossed by several embossing tools (4) arranged in a star shape around the combustion chamber tube (1) and movable by a ring press module with several radially synchronized rams (3) and two inner punches projecting into the ends of the combustion chamber tube (1), each with a support mandrel (29, 30) and a forming mandrel (31, 32) movable relative to the support mandrel (29, 30), wherein the combustion chamber tube (1) is embossed from the outside by the embossing tools (4) which are radially movable via the rams (3) against the support domes (29, 30) and the ends of the combustion chamber tube (1) are formed by forming mandrels (31, 32) which are movable relative to the support domes (29, 30) when the embossing tools (4) are closed.