Vertical Forming Device for Cup Bodies

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Solution Overview

Problem

Existing forming devices for cup-shaped hollow bodies face challenges in achieving accurate machining due to complex structures and issues with play-free mounting and deformation of tool carriers, particularly when accommodating a large number of tools, which leads to undesirable tilting moments and increased weight-related problems.

Innovation Solution

The forming device employs separately designed and mechanically independent drive devices for the workpiece rotary table and tool carrier, with a vertical alignment of the rotary axis and linear movement, allowing for symmetrical loading and simplified structure, and uses electric motors with direct kinematic coupling to the crankshaft for precise control of movements, enabling independent adaptation of cyclical linear and rotary incremental movements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If the tool carrier accommodates a large number of tools (more than 60 tools), then the tool carrier diameter and weight increase, but this leads to play-free mounting problems and deformation of the support tube during movement

Engineering Contradiction:

Improvenumber of toolsVSAvoidmounting accuracy

Core Design Contradiction:

Quantity of substanceVSManufacturing precision

Solution Approach 1:

The patent inverts the conventional horizontal orientation of the tool carrier axis to a vertical orientation. This inversion fundamentally changes the loading pattern on the support tube from asymmetric lateral loads to symmetric vertical loads, eliminating the deformation and play-free mounting problems that occur when accommodating large numbers of tools in a horizontal configuration.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent employs symmetric arrangement of tools on the vertically oriented tool carrier to create balanced loading. The counterbalancing effect of symmetrically distributed tools on opposite sides of the vertical axis compensates for the increased weight, preventing deformation of the support tube and ensuring play-free mounting even when accommodating more than 60 tools.

Inventive Principle:

Principle #8Anti-weight (Counterweight)

2Quantity of substance

If the tool carrier is horizontally aligned with increasing number of tools, then the diameter and weight increase, but this causes sharply increasing problems with play-free mounting and deformation

Engineering Contradiction:

Improvenumber of toolsVSAvoidstructural stability

Core Design Contradiction:

Quantity of substanceVSStability of the object's composition

Solution Approach 1:

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent changes from a horizontal symmetric arrangement that creates unstable lateral loads to a vertical arrangement where the symmetry is oriented differently, creating stable vertical loading conditions. The asymmetric redistribution of tools in the vertical plane creates balanced moments that stabilize the support tube structure.

Inventive Principle:

Principle #4Asymmetry

3Device complexity

If a central drive motor with flywheel is used to provide both cyclic linear and rotary stepping movements, then the structure becomes complex with multiple transmission means

Engineering Contradiction:

Improvedrive structureVSAvoidphase position accuracy

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The patent segments the centralized drive system into two independent drive devices: one for the workpiece rotary table and another for the tool carrier. This segmentation eliminates the complex transmission chain from a central flywheel to multiple components, reducing structural complexity while improving phase position accuracy through direct independent control of each axis.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent replaces the mechanical flywheel-based transmission system with independent electric motor drives. This substitution eliminates the need for complex mechanical transmission means and phase synchronization mechanisms, directly achieving precise phase position control through electronic control while reducing overall structural complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Volume of moving object

If the workpiece rotary table is horizontally oriented, then the structure is compact, but this creates undesirable tilting moments during operation

Engineering Contradiction:

Improvemachine footprintVSAvoidtilting moment

Core Design Contradiction:

Volume of moving objectVSForce

Solution Approach 1:

The patent inverts the orientation of the workpiece rotary table from horizontal to vertical alignment. This inversion eliminates the tilting moments that occur in horizontal configurations by aligning the rotation axis vertically, so that gravitational forces and machining loads act symmetrically along the rotation axis rather than creating destabilizing moments.

Inventive Principle:

Principle #13The other way round (Inversion)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This configuration simplifies the machine structure, reduces deformation and tilting issues, and allows for precise control of machining processes, enhancing the accuracy and reliability of reshaping cup-shaped hollow bodies by ensuring phase position accuracy and dynamic compensation of force fluctuations during machining.

Implementation Method 1

The drive arrangement is designed to provide a rotary incremental movement and a cyclical linear movement between the workpiece rotary table and the tool carrier

Methodology Applied

Scientific EffectElectromagnetic conversion: Electromagnetic Induction

Implementation Method 2

a first drive device assigned to the tool carrier (4) for providing the cyclical linear movement

Methodology Applied

Scientific EffectCrank mechanism: Crankshaft

Data Source

PatentEP3053668B1Forming device

Publication Date: 2019.11.06 HINTERKOPF

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AI summary

The invention relates to a forming device for cup-shaped hollow bodies (56) comprising a machine frame (2), a drive arrangement, a workpiece rotary table (3) for receiving hollow bodies (56), and a tool holder (4) for receiving machining tools (58). The workpiece rotary table (3) and the tool holder (4) are positioned opposite each other and are rotatable about a rotary axis (5) and linearly adjustable along the rotary axis (5). The drive arrangement is designed to provide a rotary step movement and a cyclic linear movement between the workpiece rotary table (3) and the tool holder (4) to enable the forming of the hollow bodies (56) by means of the machining tools (58) in several successive machining steps. According to the invention, a rotary axis (5) of the workpiece rotary table (3) and a movement axis (5) of the tool holder (4) are aligned in a vertical direction.