Stepped Hold-Down Clamp for Automated Sheet Metal Ejection
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Solution Overview
Problem
Current methods for automatically ejecting larger sheet metal parts and residual strips from punching machines are inefficient and unreliable, particularly due to varying part sizes and orientations, leading to manual removal and increased costs.
Innovation Solution
An offset hold-down device with a stepped design and integrated hydraulic system allows for precise clamping and controlled ejection of sheet metal parts by utilizing a dual-surface mechanism to secure and release parts at defined positions, enabling automated ejection of both sheet metal parts and residual strips.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If handling systems with grippers are used to remove larger sheet metal parts, then automated removal is achieved, but the system becomes complex and difficult to operate due to varying part sizes and orientations
Solution Approach 1:
The holding down clamp is divided into a first holding down clamp portion and a second holding down clamp portion that can be independently positioned and controlled. This segmentation allows each portion to adapt to different part geometries and orientations, simplifying the automated handling of varied sheet metal parts without requiring complex reconfiguration
2Extent of automation
If handling systems with suction pads are used to remove larger sheet metal parts, then automated removal is achieved, but the system becomes unreliable for parts with punched holes
Solution Approach 1:
The invention extracts the holding function from the punching operation and implements it separately through the holding down clamp system. The clamp portions can be positioned to hold parts at optimal locations away from punched holes, ensuring reliable automated handling without the reliability issues of suction pads
3Productivity
If part flaps or rigid slides are used to discharge smaller sheet metal parts, then ejection is achieved, but smaller parts not positioned above the chute cannot be ejected
Solution Approach 1:
The holding down clamp portions are designed to be movable and repositionable, allowing the system to adapt to parts at different positions on the sheet. This dynamic positioning capability enables automated ejection of parts regardless of their initial position, overcoming the limitation of fixed part flaps and rigid slides
4Productivity
If the existing ejection process with multiple individual steps is used, then larger parts can be ejected, but the process is time-consuming and not process-reliable
Solution Approach 1:
The invention merges the holding down function and the ejection function into a single integrated system. The holding down clamp portions are positioned to enable direct ejection of parts onto the part flap or rigid chute, eliminating intermediate steps and reducing overall process time while maintaining reliability
5Loss of substance
If skeleton-free processing is used to maximize material utilization, then material efficiency is improved, but the residual strip becomes difficult to remove automatically
Solution Approach 1:
The holding down clamp portions can be independently positioned to apply holding force at specific locations on the residual strip. This localized holding capability allows the system to grip and eject long, flexible residual strips that would otherwise be difficult to handle automatically, enabling full automation of skeleton-free processing
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 solution ensures reliable and automated ejection of sheet metal parts and residual strips, reducing manual intervention and associated costs by ensuring consistent orientation and secure handling across different sizes and orientations.
Implementation Method 1
integrated hydraulic system allows for precise clamping and controlled ejection
Implementation Method 2
the separated sheet metal part becomes free, tips over due to gravity and can thus be ejected forwards
Data Source
Figure 1a
Figure 1b
Figure 2
AI summary
The blank holder (1) has a lower side which has two surfaces that do not lie on one level. The two surfaces lie in two levels in a parallel manner. The level of the former surface and the level of the latter surface are connected with each other by a joining surface. An opening (3) is provided for passage of a plunger. Independent claims are included for the following: (1) a punching tool with a lower punch; (2) a punching machine with a control device; and (3) a method for expelling sheet metal components from a punching machine.