Tandem Press Line Layout for Stable Coil Strip Transfer
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Solution Overview
Problem
Conventional tandem press lines face challenges in achieving high-speed operation due to long line lengths, material breakage caused by excessive tension, and difficulty in synchronizing press machine operations with feeding devices, leading to inefficient processing.
Innovation Solution
A tandem press line design featuring synchronized first and second press machines with an intermediate feeding device that grips and releases the coil strip, maintaining consistent tension and angle, and coupling press machines to reduce distance fluctuations, allowing for stable and high-speed processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If an intermediate loop portion is provided to adjust material length between press machines, then the coil strip length can be adjusted, but the feeding path becomes greatly curved and the line length increases
Solution Approach 1:
The patent extracts the material length adjustment function from a separate intermediate loop portion and integrates it into the material lifter mechanism itself. The material lifter's stroke length variation directly controls the effective material length between press machines, eliminating the need for a dedicated loop portion and reducing line length.
Solution Approach 2:
The material lifter is given multiple functions: it not only performs the traditional material lifting and positioning function but also serves as the mechanism for adjusting material length between press machines. This multi-functionality eliminates the need for separate adjustment mechanisms and reduces overall system complexity.
2Ease of operation
If four feeding devices are provided (two for each press machine), then each press machine can be fed independently, but the device scale becomes large and the line length increases
Solution Approach 1:
The patent merges the feeding functions for both press machines into a single intermediate feeding device located between them. This feeding device feeds the coil strip to both press machines simultaneously, reducing the number of feeding devices from four to one while maintaining independent operation capability through synchronized control.
Solution Approach 2:
The intermediate feeding device acts as a mediator between the coil strip source and both press machines. It coordinates the feeding to both machines, managing the material flow and timing to enable independent operation of each press machine while using a single feeding mechanism.
3Manufacturing precision
If the coil strip is transferred in a lifted state by material lifter, then the material can be positioned for pressing, but the coil strip may interfere with feeding rollers and break due to excessive tension
Solution Approach 1:
The patent makes the material lifter dynamic by varying its stroke length according to the operational phase. During feeding operations, the stroke length is reduced to minimize material lift and prevent interference with feeding rollers. During pressing operations, the stroke length is increased to provide adequate material positioning. This dynamic adjustment prevents coil strip breakage while maintaining positioning accuracy.
Solution Approach 2:
The patent changes the stroke length parameter of the material lifter based on operational requirements. By adjusting this key parameter, the system optimizes the balance between material positioning accuracy and tension control, preventing excessive tension that could lead to coil strip breakage.
4Productivity
If press machines are operated at high speed, then productivity increases, but the operation timings of press machines and feeding device must be precisely synchronized
Solution Approach 1:
The patent implements feedback control in the synchronization mechanism, where the operation timing of press machines and the intermediate feeding device is continuously monitored and adjusted. This feedback system ensures precise coordination even at high speeds, maintaining synchronization without requiring overly complex mechanical linkages.
Solution Approach 2:
The patent ensures continuous coordinated operation of all components through the synchronized control mechanism. The intermediate feeding device and press machines operate in a continuous, smoothly coordinated manner, eliminating idle time and maintaining high productivity while keeping synchronization control manageable through integrated timing mechanisms.
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3B
AI summary
A tandem press line 10 is provided in which the possibility of occurrence of a breakage of a coil strip W can be suppressed even in a case where there is no loose in a coil strip W fed intermittently. The tandem press line 10 is provided with: a first press machine 11 configured to perform punching on the coil strip W fed intermittently; a second press machine 12 configured to further perform punching on the coil strip W fed from the first press machine 11, in synchronization with the first press machine 11; and an intermediate feeding device 37 provided between the first press machine 11 and the second press machine 12, the intermediate feeding device being configured to grip the coil strip W when feeding the coil strip W and release when performing pressing. The first press machine 11 and the second press machine 12 are provided with a first forming die 40 and a second forming die 41, respectively, the first forming die 40 and the second forming die 41 being each provided with a material lifter 45 having the same stroke length h on a lower die 40a, 41a. A lower die upper surface height of the first forming die 40 and a lower die upper surface height of the second forming die 41 are the same, and the feeding line of the intermediate feeding device 37 is higher than the upper surface of the forming dies by 1/2 of the stroke length h of the material lifter 45.