Toggle-Driven Moulding Press for Lower Punch Energy Use
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Solution Overview
Problem
Existing moulding presses face high energy consumption issues, particularly when using electric motor drives, and require redesigning for efficient energy regulation.
Innovation Solution
A moulding press with a toggle mechanism for electrically operated punches, featuring a toggle mechanism and crank-rod drive unit that optimizes energy efficiency by aligning connecting rods at dead centre positions, reducing the need for high drive energy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If hydraulic drive is used to power the press, then high force and pressure are achieved, but energy consumption increases due to maintaining large oil volume under pressure
Solution Approach 1:
The patent replaces the hydraulic drive system with an electric motor drive system. The electric motor directly powers the crank-rod mechanism, eliminating the need for hydraulic fluid under pressure. This substitution reduces energy consumption while maintaining the ability to generate high pressing forces through the mechanical advantage of the crank-rod mechanism.
Solution Approach 2:
The patent employs periodic action by using the crank-rod mechanism to convert continuous rotational motion from the electric motor into reciprocating linear motion for the punch. The mechanism naturally provides high force during the pressing stroke and reduces force requirements during the return stroke, optimizing energy consumption through periodic variation in mechanical advantage.
2Use of energy by moving object
If electric motor drive is used for the press, then energy regulation efficiency is improved, but the machine configuration must be redesigned from hydraulic drive
Solution Approach 1:
The patent applies universality by designing the press frame and tooling to accommodate both electric motor drive and traditional hydraulic drive configurations. The press structure, guides, and mould mounting are designed to be drive-agnostic, allowing the same basic press architecture to work with different power source options without requiring complete redesign.
Solution Approach 2:
The patent uses the crank-rod mechanism as an intermediary between the electric motor and the punch. This intermediate mechanical transmission system bridges the gap between the rotary motion of the electric motor and the linear reciprocating motion required for pressing, while also providing mechanical advantage to generate high forces without requiring a completely new machine design.
3Manufacturing precision
If toggle mechanism is used to drive punches, then shaping capability is improved, but energy consumption increases due to continuous pressure requirements
Solution Approach 1:
The patent modifies the traditional toggle mechanism by incorporating a crank-rod drive that provides periodic action. The mechanism achieves the necessary shaping pressure during the forward stroke when the crank is in the appropriate position, then naturally reduces the force requirement during the return stroke. This periodic variation in mechanical advantage maintains shaping capability while significantly reducing continuous energy consumption compared to traditional toggle mechanisms that require constant pressure maintenance.
Data Source
Figure 1A~1B
Figure 1C~3E
Figure 2A~2B
AI summary
A moulding press is disclosed comprising a lower basement (1) equipped with a workpiece holder (1a), a deformation mould (2) attached to a moulding carriage (C) mounted vertically movable above said basement (1) by means of a power actuator (M1), and a plurality of punch devices (3a-3d), converging radially towards said workpiece holder (1a), wherein said punch devices (3a-3d) have at least a punch carriage (12) sliding longitudinally in relation to a base block (11) by means of a punch actuator (M2), and a toggle drive mechanism provided with a pair of connecting rods (13a, 13b), wherein said connecting rods (13a, 13b) are linked to said punch carriage (12) and to said base block (11) on the one hand and to a crank head (14a) of a crank arm (14) on the other hand, respectively, a base end of said crank arm (14) being hinged in rotation to a thrust shaft (15) arranged eccentrically on a wheel (16) driven by said punch actuator (M2).