Upper Die Carriage Positioning for Fast Bending Press Changeover
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Solution Overview
Problem
The existing methods for replacing the upper die in bending press machines used for manufacturing large diameter steel pipes are inefficient, requiring extensive time and safety measures due to the inability to accurately position and mount new dies, leading to reduced productivity and increased load on the punch and beam.
Innovation Solution
An upper die carriage system that allows collective mounting and precise positioning of divided upper die segments, utilizing a steel pipe carrying-out device to move the carriage longitudinally and integrate with the press machine's steel pipe carrying-out mechanism for efficient and safe replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional methods are used for upper die replacement in bending press machines, then safety measures can be implemented, but the replacement time is excessively long and productivity is reduced
Solution Approach 1:
An upper die carriage is introduced as an intermediary device to carry and position the upper die segments. The carriage includes a carriage body with upper die segment holding portions and positioning mechanisms, acting as a mediator between the storage area and the punch assembly, enabling precise positioning without time-consuming manual operations
Solution Approach 2:
The upper die segments are pre-assembled on the upper die carriage at a convenient location before being needed at the punch. The carriage allows preliminary preparation and positioning of all die segments in advance, so that when replacement is needed, the pre-positioned segments can be quickly transferred to the punch without time-consuming assembly operations
2Adaptability or versatility
If upper die segments are handled individually, then flexibility in replacement is maintained, but the replacement process becomes time-consuming and complex
Solution Approach 1:
Multiple upper die segments are merged into a single integrated upper die carriage structure. The carriage body includes multiple holding portions that collectively support all upper die segments, combining what would be separate handling operations into a single unified handling unit, thereby reducing replacement time while maintaining the ability to work with individual segments when needed
3Device complexity
If the punch and beam structure is used for upper die replacement, then the existing structure is utilized, but the load on the punch and beam increases significantly
Solution Approach 1:
The upper die carriage and its positioning functions are extracted from the punch and beam structure. The carriage is a separate, independent device that handles upper die positioning and replacement operations, removing the burden of supporting replacement operations from the punch and beam, thereby significantly reducing the load and stress on these critical structural components
Data Source
Figure 1~2(b)
Figure 3~4
Figure 5(a)~5(f)
AI summary
When replacing an upper die of a leading end of a punch of a bending press machine that bends a steel plate on dies by a pair of dies and a punch vertically moving between the dies, carry-in of the upper die to just below the punch and carry-out of the upper die from just below the punch are performed, by the use of an upper die carriage that is movable between the pair of dies in a longitudinal direction of the punch and has an upper die storing unit configured to store the upper die and a lifting/lowering mechanism capable of vertically lifting and lowering the upper die storing unit. Accordingly, provided are an upper die replacing method of the bending press machine capable of efficiently and safely performing the replacement of the upper die in a short time, and a carriage for upper die replacement used for the method.