Stationary-Frame Pressing Tool for Large-Area Web Products
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Solution Overview
Problem
Conventional pressing tools face challenges in processing large-area products due to increased energy costs and limitations in throughput and size, necessitating larger drives and frames that increase mass and energy consumption.
Innovation Solution
A pressing tool design with stationary frames and independently movable upper and lower tool modules, driven synchronously by separate drives controlled by a central or hierarchical system, allowing for reduced mass movement and energy consumption while accommodating larger pressing surfaces and higher process speeds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the size of press plates and frame is increased to accommodate larger products, then the pressing capacity and product size are improved, but the mass of moving parts increases leading to higher energy consumption
Solution Approach 1:
The pressing tool is divided into a stationary frame and two independently movable tool modules (upper and lower). Each tool module can be adjusted and moved separately along guide rails, allowing the pressing function to be segmented from the frame structure. This enables larger pressing surfaces without proportionally increasing the mass of moving parts, as only the tool modules move rather than the entire frame.
Solution Approach 2:
Conventionally, the frame is moved with the press plates. This invention inverts the approach by making the frame stationary and moving only the tool modules mounted on it. This inversion reduces the mass of moving parts significantly, as the heavy frame remains fixed while lighter tool modules with press plates are moved independently by drives.
2Force
If larger drives are used to move increased mass, then the pressing force capacity is improved, but the energy costs increase
Solution Approach 1:
The pressing force generation is segmented into two independent drive systems, one for each tool module. Each drive only needs to move its associated tool module, reducing the mass each drive must accelerate compared to a single drive moving the entire frame with both press plates. This segmentation allows for adequate pressing force capacity with smaller, more energy-efficient drives.
Solution Approach 2:
By inverting the conventional approach and making the frame stationary, the drives only need to move the lighter tool modules rather than the heavy frame. This reduces the energy required to achieve the necessary pressing force capacity, as the mass being accelerated and positioned by the drives is significantly reduced.
3Strength
If the frame mass is increased to handle larger forces, then the structural strength is improved, but the energy costs for movement increase
Solution Approach 1:
The structural strength requirement is segmented between the stationary frame and the movable tool modules. The frame, being stationary, provides the primary structural support and strength to handle large forces without moving. The tool modules are designed with sufficient strength for their specific pressing tasks but can be lighter since they are moved independently. This segmentation allows the frame to be optimized for strength while the movable parts are optimized for lower mass and energy efficiency.
Solution Approach 2:
By making the frame stationary rather than movable, the frame can be designed with maximum structural strength to handle large pressing forces without the penalty of having to move its entire mass. The inversion separates the strength-providing function (frame) from the movement function (tool modules), allowing each to be optimized independently - the frame for strength and the tool modules for low mass and energy-efficient movement.
4Area of stationary object
If larger presses are used for large-area products, then the processing capability is improved, but the throughput and productivity are limited
Solution Approach 1:
The pressing operation is segmented into two independently controllable tool modules that can move and position themselves independently along guide rails. This allows for rapid repositioning and adjustment between pressing cycles, enabling faster throughput. The independent movement of tool modules eliminates the need to move the entire frame, reducing cycle time and increasing productivity while maintaining large processing area capability.
Solution Approach 2:
The tool modules are designed with dynamic movement capability along the guide rails, allowing for rapid positioning, acceleration, and deceleration during pressing cycles. This dynamic design enables faster operation compared to conventional large presses where the entire frame must be moved. The independent drives on each tool module provide precise control for optimized pressing cycles, increasing throughput while maintaining large-area processing capability.
Data Source
Figure 1
AI summary
The invention relates to a pressing tool and a method for pressing a single-layer or multi-layer product in a web-processing process by means of a pressing tool (1) comprising a frame (3), an upper tool module (4) with an upper pressing plate (40) and a lower tool module (5) with a lower pressing plate (50), wherein the upper tool module (4) and the lower tool module (5) are each mounted on the frame so as to be adjustable in the transport direction (I) of the web-processing process, wherein after the pressing tool (1) has been closed during an operating period, the upper tool module (4) and the lower tool module (5) are driven separately for a synchronous movement in the transport direction (I) relative to the frame (3).