Wire-Rope Pretensioned Forging Frame for Precise Ram Guidance
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Solution Overview
Problem
Existing multi-part machine frames for forging machines, such as forging hammers, suffer from manufacturing and assembly challenges due to the use of tie rods, which limit the accuracy and stability of the ram's movement, leading to wear and inefficiencies in impact efficiency.
Innovation Solution
A multi-part machine frame design using wire ropes for pre-tensioning, allowing for precise guidance and connection of frame parts, enabling the combination of different materials and reducing assembly space, with wire ropes providing higher tensile stress and stability compared to tie rods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If tie rods are used to connect frame parts, then the frame can be assembled from separate parts, but the movement accuracy and stability of the ram deteriorates
Solution Approach 1:
The frame is divided into separate parts (frame base, uprights, head part) that can be manufactured and transported independently, then assembled using tie rods with pretensioning elements. This segmentation enables easier manufacturing and assembly while the pretensioning mechanism maintains structural integrity and movement accuracy during operation.
2Ease of manufacture
If tie rods are used to connect frame parts, then the frame can be assembled from separate parts, but the impact efficiency deteriorates due to gaps
Solution Approach 1:
Pretensioning elements are used to apply preliminary compressive forces to the frame parts before operation. This preliminary action closes gaps between connected frame parts, ensuring stable contact during impact operations and maintaining high impact efficiency while allowing modular assembly.
3Strength
If a one-piece frame is used, then the frame has high strength, but the production and transport costs increase
Solution Approach 1:
The frame is segmented into separate manufacturable parts that can be produced using standard casting or fabrication processes, reducing production complexity and cost. These parts are then connected using tie rods with pretensioning elements that replicate the structural strength and rigidity of a one-piece frame.
4Strength
If a one-piece frame is used, then the frame has high strength, but the transport and assembly effort increase
Solution Approach 1:
The frame is divided into smaller, manageable parts that can be transported more easily to the installation site. These segmented parts are then assembled using standardized tie rods with pretensioning elements, which simplifies the assembly process compared to handling a single large one-piece frame while maintaining equivalent structural strength.
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
The frame design ensures stable and precise movement of the ram, enhances impact efficiency, reduces wear, and maintains frame rigidity by preventing gaps during impacts, while allowing for easier transport and assembly.
Implementation Method 1
The frame parts are supported against one another in a force-fitting manner and/or are prestressed against one another by means of pre-tensioning means with a set or adjustable prestress
Data Source
AI summary
Multi-part machine frame (12) for a, preferably percussive, forging machine, preferably a forging hammer (10), for forging workpieces, a) including at least two prefabricated frame parts (14, 15, 16) which are formed separately from each other, rest against each other in at least one or at least two support areas (65, 66) and are mutually supported and are pretensioned against each other with a set or adjustable pre-tension by way of pre-tensioning elements, preferably a wire rope, and are thereby pressed onto each other in the one or more support area(s) (65, 66) and/or are connected to one another in a force-fitting manner, b) in which in the support area or at least one or each of the at least two support areas (65, 66) between two frame parts at least two pairs of abutting support surfaces (45A and 55A, 45B and 55B, 46A and 56A, 46B and 56B) are formed, which are separated by free surfaces (45C and 55C, 46D and 56D) arranged therebetween, between which an intermediate space is formed, c) wherein the support area(s) or the at least two pairs of support surfaces in the associated support area(s) constitute or act as a positive and/or self-positioning connection.