Synchronizer Ring Punching Layout for Dual-Ring Production
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Solution Overview
Problem
The existing manufacturing methods for ring-shaped members, such as synchronizer rings, are inefficient and costly, as they typically involve forming one ring-shaped member from a single workpiece, leading to suboptimal use of materials and processing inefficiencies.
Innovation Solution
A method and system that punch out a ring-shaped workpiece in a circumferential direction to form a pair of ring-shaped members with tapered tubular portions and claw pieces, utilizing a movable punching tool for multiple punching processes and optionally forming a concave surface to enhance the process, allowing for the formation of ring-shaped members with improved efficiency and reduced material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If one ring-shaped member is formed from a single workpiece using conventional methods, then the manufacturing process is simple, but the manufacturing efficiency is low and material waste is high
Solution Approach 1:
The invention divides a single ring-shaped workpiece into multiple ring-shaped members by punching out intermediate portions. The workpiece is segmented into first and second ring-shaped members with claw pieces formed in the intermediate portion, allowing one workpiece to produce multiple finished products and improving material utilization efficiency.
Solution Approach 2:
The invention combines multiple manufacturing operations into a single integrated punching process. The punching tool simultaneously forms the intermediate portion and creates claw pieces while separating the workpiece into multiple members, reducing the number of separate processing steps and improving overall manufacturing efficiency.
2Productivity
If conventional punching methods are used, then the process is straightforward, but only one ring-shaped member is produced per workpiece
Solution Approach 1:
The punching tool is designed with movable elements that can dynamically adjust during the punching process. The tool includes a main body portion and an intermediate portion that moves relative to each other, enabling the formation of complex claw piece geometries and the simultaneous production of multiple ring-shaped members from one workpiece.
Solution Approach 2:
The punching tool structure incorporates nested components where the intermediate portion is positioned within or on the main body portion. This nested configuration allows the tool to perform multiple functions - punching, shaping, and forming claw pieces - in a single integrated device, increasing production output without proportionally increasing device complexity.
3Quantity of substance
If multiple punching processes are performed on different regions, then more ring-shaped members can be formed, but the processing time increases
Solution Approach 1:
The punching process is designed to continuously form multiple ring-shaped members in a single uninterrupted operation. The movable intermediate portion continuously shapes and separates multiple members simultaneously, eliminating idle time between processing different regions and maintaining continuous productive action throughout the manufacturing cycle.
Solution Approach 2:
The punching tool performs preliminary shaping and claw piece formation during the main punching operation itself, rather than requiring separate subsequent processing steps. The intermediate portion is preliminarily formed and shaped concurrently with the separation of ring-shaped members, reducing total processing time while producing multiple finished members.
Data Source
Figure 1(A)~1(G)
Figure 2(A)~3
Figure 4(A)~4(I)
AI summary
Provided are a method and a system for producing a ring-shaped member, said method and system improving production efficiency. A punching process is carried out on an axial intermediate part of a first intermediate annular material (25) so as to produce a pair of ring-shaped members (a first ring-shaped member 28A and a second ring-shaped member 28B). A punching step comprises a step in which a first punching process is carried out over a first range of the axial intermediate part in the circumferential direction, and a step in which a second punching process is carried out over a second range of the axially-oriented intermediate part, which is at least partially different than the first range, in the circumferential direction. The first punching process is carried out such that at least one tab (15a, 15b) is formed. The second punching process is carried out such that at least one separate tab (15a, 15b) is formed, thereby producing the pair of ring-shaped members (28A, 28B).