Two-Stage Pressure Generator for Precise Riveting Press Positioning
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Solution Overview
Problem
Existing riveting and punching tools experience handling difficulties due to the hydraulic piston needing to travel a significant distance before applying high pressure, leading to precise positioning challenges and excessive wear on seals.
Innovation Solution
A pressure generator with a pneumatic-hydraulic pump system that allows independent pneumatic pressure to move the hydraulic piston close to the workpiece, followed by activation of a pressure intensifier for the forming process, reducing the need for extensive initial travel and minimizing seal wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a rivet or punching press is used, then high forces are required for riveting or punching operations, but the existing machine frame and drive unit cannot accommodate these high forces without risking damage or operational failure
Solution Approach 1:
The drive system is segmented into a motor unit and a separate gear unit. The gear unit acts as a mechanical multiplier that amplifies the motor's output torque, allowing the press to generate high forces while the motor itself remains sized for standard power supplies. This segmentation enables the machine to deliver high force without requiring an oversized motor or reinforcing the entire machine frame.
Solution Approach 2:
A gear unit serves as an intermediary between the motor unit and the press mechanism. This gear unit multiplies the torque from the motor, enabling the press to generate high forces (up to 1000 kN) while the motor operates at standard power levels. The gear unit protects the motor and machine frame from the full burden of high forces while still achieving the required punching or riveting force.
2Force
If standard presses are used for riveting or punching, then high forces can be generated, but the machine requires a large floor space and high installation costs
Solution Approach 1:
The press utilizes the vertical dimension by utilizing the press frame's inherent stiffness to resist bending moments, rather than requiring a large horizontal footprint. The C-shaped press frame is designed to withstand the bending moments generated during high-force operations, allowing the machine to achieve high force output in a compact vertical configuration rather than requiring a large horizontal spread.
Solution Approach 2:
The press is designed with a universal application capability, serving both punching and riveting functions with a single machine. The press frame and drive unit are configured to handle various sheet metal operations, reducing the need for multiple specialized machines and thereby minimizing the total floor space required for the facility.
3Force
If high forces are applied during riveting or punching, then the desired mechanical action is achieved, but harmful forces are transmitted to the machine frame and drive unit
Solution Approach 1:
The gear unit acts as a protective intermediary that isolates the motor unit from the high forces generated during punching or riveting. The gear unit absorbs and manages the mechanical stresses, allowing the motor to operate within safe force limits while still delivering the required high force to the tool. This protects the drive unit from damage while achieving the necessary operational forces.
Solution Approach 2:
The machine is segmented into functional zones with the press frame designed to handle and dissipate harmful forces through its rigid C-shaped structure. The frame's geometry and bracing are optimized to resist bending moments and redirect harmful forces away from sensitive components, protecting the drive unit while allowing high-force operations to proceed.
4Force
If the press is designed for high-force operations, then riveting or punching can be performed, but the machine requires extensive bracing and becomes top-heavy
Solution Approach 1:
The press frame utilizes vertical bracing elements that extend upward to counteract top-heaviness, transforming the structural challenge into a vertical design feature. The C-shaped frame with integrated bracing creates a rigid structure that resists bending moments without requiring excessive horizontal bracing, maintaining stability while achieving high-force capability.
Data Source
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AI summary
The invention relates to a pressure generator for a riveting, stamping, pressing or drawing tool, in particular for use in the bodywork area. The pressure generator includes a hydraulic area, which can be subjected to pneumatic pressure independently of a pneumatic-hydraulic pressure booster.