EP4695038A1

EP4695038A1 - Process for manufacturing vehicle parts

Info

Publication number: EP4695038A1
Application number: EP24787717.8A
Authority: EP
Inventors: Eric Denijs; Nick LIPSON; Mark BONELLO; Ajith JOSEPHS; Pascal Charest; Francis Boyer; Mitul Kamlesh Bhai SHAH
Original assignee: Magna International Inc
Current assignee: Magna International Inc
Priority date: 2023-04-14
Filing date: 2024-04-12
Publication date: 2026-02-18
Also published as: CN121001836A; WO2024212006A1

Abstract

A micro-transfer system for transferring metal components from one die station to a following die station in a die stamping system is provided. The die stamping system is similar to a typical progressive die stamping system and includes a plurality of die stations disposed on a die shoe in a press. The micro-transfer system further includes part handling rails and grippers attached to the part handling rails for engaging the metal components. The micro-transfer system further includes a plurality of motors and guides for driving the part handling rails and grippers, which move the metal components from one die station to the next.

Description

PROCESS FOR MANUFACTURING VEHICUE PARTS

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This PCT International Patent Application claims the benefit of and priority to U.S. Provisional Patent Application Serial No. 63/459,371, filed April 14, 2023, titled “Process For Manufacturing Vehicle Parts,” and U.S. Provisional Patent Application Serial No. 63/465,421, filed May 10, 2023, titled “Process For Manufacturing Vehicle Parts,” the entire disclosures of which are hereby incorporated by reference in its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

[0002] The invention relates generally to a micro-transfer system for use with a die stamping system, a die stamping system including the micro-transfer system, and a method for manufacturing metal components, such as steel parts for vehicles, using the die stamping system.

2. Related Art

[0003] Progressive die stamping is a process used to form metal components, for example steel components for vehicles. The progressive die stamping system includes a plurality of die stations which are aligned with one another and located in a stamping press. The process includes feeding and conveying a coil of metal through each die station. Each die station performs a stamping or forming operation on the coil to form the metal components having a desired shape. Each die station includes a top die and bottom die, and the top die moves upward and downward along with an upper portion of the stamping press to stamp and shape the metal components. The metal components remain connected as they move through the die stations, for example by a web or carrier strips formed from the metal coil. [0004] The metal punched away at the die stations, as well as the material of the webs that is cut away, is scrap which is ultimately removed from the stamping press. The amount scrap metal is significant, and thus a reduction in the amount of scrap generated during the progressive die stamping process is desired.

SUMMARY

[0005] One aspect of the disclosure provides a micro-transfer system for transferring metal components from a first die station to a second die station. The micro-transfer system includes at least one part handling rail, at least one gripper attached to the at least one part handling rail for engaging the metal components, and at least one motor for moving the at least one part handling rail and the at least one gripper between the die stations.

[0006] Another aspect of the disclosure provides a die stamping system. The die stamping system includes a press; a plurality of die stations disposed in the press; and at least one transfer system for conveying components from one of the die stations to another one of the die stations. The transfer system includes at least one part handling rail, at least one gripper attached to the at least one part handling rail for engaging the metal components, and at least one motor for moving the at least one part handling rail and the at least one gripper between the die stations.

[0007] Another aspect of the disclosure provides a method of manufacturing metal components. The method includes conveying a coil of metal to a plurality of die stations of a die stamping system, forming a metal component from the coil at a first one of the die stations, and transferring the metal component from the first die station to a second one of the die stations using at least one transfer system. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Other advantages of the present invention will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawing wherein:

[0009] Figures 1 and 2 illustrate a die stamping process including a micro-transfer system according to example embodiments;

[0010] Figures 3 and 4 illustrate a standard die stamping process without a micro-transfer system;

[0011] Figure 5 illustrates a conventional progressive die stamping system compared to a die stamping system including a micro-transfer system according to an example embodiment;

[0012] Figures 6-8 show the micro-transfer system according to example embodiments;

[0013] Figures 9A-9F illustrate the motion of part handling rails and grippers of the micro-transfer system during operation of the system according to example embodiments; and

[0014] Figure 10 illustrates the amount of metal used in a conventional progressive die stamping system with metal carriers compared to the amount of metal used in the die stamping process disclosed herein according to other example embodiments.

DESCRIPTION OF EXAMPLE EMBODIMENTS

[0015] One aspect of the invention provides a die stamping system 10 for manufacturing metal components 12, for example steel parts for vehicles, with less scrap and potentially fewer die stations 14, compared to conventional progressive die stamping systems. The die stamping system 10 disclosed herein is similar to conventional progressive die stamping systems. However, unlike conventional progressive die stamping systems, the die stamping system 10 disclosed here includes a micro-transfer system 16 for conveying the metal components 12 from one die station 14 to the next die station 14. Thus, webs and carriers formed from the metal coil are not needed to move the metal components 12 through the die stamping system 10. Also, due to the flexibility of the micro-transfer system 16, particularly the deployment flexibility or flexibility of travel of the micro-transfer system 16 along 3 axes (pitch, drive, lift), the microtransfer system 16 can be dedicated to the die stamping system 10 or moved to different tools.

[0016] Examples of the die stamping system 10 are shown in Figures 1 and 2. A standard die stamping system without the micro-transfer system 16 is shown in Figures 3 and 4. A comparison between the typical progressive die stamping system and the die stamping system 10 including the micro-transfer system 16 is shown in Figure 5. Like typical progressive die stamping systems, the die stamping system 10 disclosed herein includes the plurality of die stations 14 disposed in a press. A coil of the metal is used to form the metal components 12. The metal coil is fed and conveyed through the die stamping system 10.

[0017] As shown in Figure 5, the die stamping system 10 typically includes a coil storage station 18, a coil decoiler station 20, a coil straightener station 22, and a coil feeder 24 which feeds the coil to the die stations 14. The die stations 14 are disposed on a die shoe. Each die station 14 includes a lower die and an upper die to shape the metal components 12. The upper die moves upward and downward along with the press. The die stations 14 of the die stamping system 10 may be the same as those used in a conventional progressive die stamping system, or may be modified slightly to accommodate the micro-transfer system 16.

[0018] The micro-transfer system 16 is located on the same die shoe and adjacent the die stations 14 to move the metal components 12 through the die stamping system 10 from one die station 14 to the next. Typically, two of the micro-transfer systems 16 are used in connection with each die stamping system 10. The two micro-transfer systems 16 are independent but work in unison to carry the metal components 12 from one die station 14 to the next in the forward and reverse direction. Examples of the micro-transfer system 16 are shown in Figures 1-5. Additional perspective views of the micro-transfer system 16 are shown in Figures 6-9F.

[0019] The micro-transfer system 16 may include a base plate 26 for mounting the micro-transfer system 16 on the same die shoe as the die stations 14. Mounting all components on the same base plate 26 can provide for ease of die mounting and ensures the micro-transfer system 16 is enclosed in one envelope. Alternatively, the micro-transfer system 16 can be mounted using another type of base, or can be mounted on the die shoe directly. The microtransfer system 16 is mounted to a component of the die stamping system 10 only and is independent from the press, besides electrical and controls connections. Thus, the micro-transfer system 16 can be transferred and used in other presses.

[0020] The micro-transfer system 16 includes a main electrical panel 28 for powering and controlling the micro-transfer system 16. The micro-transfer system 16 further includes grippers 30 attached to a part handling assembly, which is preferably part handling rails 32.

[0021] The micro-transfer system 16 also includes at least one motor 34 and at least one guide 36, but typically a plurality of motors 34 and a plurality of guides 36 to drive the part handling rails 32 and grippers 30 and thus move the metal components 12 from one die station 14 to the next quickly and efficiently. The motors 34 can be servo-motors, stepper motors, hydraulic and pneumatic drives, or another type of motor or motion device. The guides 34 can be linear actuators or another type of guide. The motors 34 ensure proper weight distribution of the micro-transfer system 16. Additional guides 36 can be added if the micro-transfer system 16 is too heavy. The guides 36 of the example embodiment are pre-engineered ball screw linear actuators 36. [0022] According to the example embodiments, two sets of motors 34 and guides 36 drive the part handling rails 32 and grippers 30 in and out relative to the die stations 14. These motors 34 and guides 36 also lift the metal components 12 up and down. One motor 34 and guide 36 is used to “pitch” the metal components 12 from die station 14 to die station 14. The motors 34 are able to move the part handling rails 32 and grippers 30 in various directions, so that the grippers 30 can engage each metal component 12.

[0023] The main electrical panel 28 includes controls which allow for each axis, including a drive, lift, and pitch axis, to be independently controlled. Thus, the main electrical panel 28 controls the movement of the motors 34 and the part handling rails 32. The controls are also connected to the press so that the micro-transfer system 16 stays in sync with the press. The controls further allow for each drive axis to be independently controlled.

[0024] During operation of the die stamping system 10, the metal coil is straightened and fed toward a first die station 14. The press opens and closes, along with the upper die, at the first die station 14 to stamp the metal coil and thus form one or more of the metal components 12. A single metal component 12 separated from other metal components 12 is formed at the first die station 14. In the example embodiments, the metal component 12 includes a pair of parts, specifically splash shields or pillars, which are connected to one another. Alternatively, the metal component 12 could include a single part. The shape of the metal component 12 after being stamped at the first die station 14 is far from the shape of the finished metal component 12. The shape of the finished metal component 12 is achieved progressively by stamping at the additional die stations 14, as in a conventional progressive die stamping process.

[0025] According to the example embodiment, after the metal component 12 is formed at the first die station 14, the micro-transfer system 16 transfers the metal component 12 to the second die station 14 and to subsequent die stations 14, until the metal component 12 reaches the final die station 14. The metal component 12 can go through a series of progressive stamping stations (die stations 14) until it is separated from the coil strip. The number of die stations 12 which form the metal component 12 before the micro-transfer system takes over is dependent on the type of component to be formed. The transfer motion begins when the press begins to open, immediately after stamping the metal component 12 at the first die station 14. The part handling rails 32 are moved toward the center of the first die station 14, and the grippers 30 and part handling rails 32 together lift the metal component 12 to be transferred. Lifting of the metal component 12 clears obstructions from the lower die. As the press reaches the top of its stroke, the micro-transfer system 16 moves the metal component 12 to the second die station 14. The grippers 30 continue to engage the metal component 12 during the transfer. As the press closes, the micro-transfer system 16 drops the metal component 12 on the second die station 14. The part handling rails 32 are then retracted back from the center of the second die station 14 and return to the original position while the upper die stamps the metal component 12 at the second die station 14. The movement of the part handling rails 32 is preferably synched to the press strokes. After the metal component 12 is stamped at the second die station 14, the part handling rails 32 move toward the center of the second die station 14, and the micro-transfer system 16 lifts and moves the metal component 12 to a third die station 14. The die stamping process continues, and micro-transfer system 16 continues to move the metal component 12 from one die station 14 to the next until the metal component 12 reaches the final die station 14. Figures 9A- 9F illustrate the motion of the part handling rails 32 and grippers 30 during operation of the micro-transfer system 16 according to example embodiments. The metal components 12 formed by the die stamping system 10 can vary. For example, the metal components 12 could be used as a pillar or splash shield.

[0026] The die stamping system 10, die stamping method, the micro-transfer system 16 used in the die stamping system 10, as disclosed herein, provides number advantages. First, the amount of scrap created during the die stamping process is significantly reduced compared to the amount of scrap created during a conventional progressive die stamping process which requires the metal carriers or webs to connect the metal components 12. The metal carriers and webs are scrap at the end of the process. The die stamping system 10 disclosed herein can also allow for nesting of the metal components 12. The reduction in metal required to form the metal components 12 and the reduction in the amount of scrap leads to significant material cost savings. Figure 10 illustrates the amount of metal used in the die stamping process including the micro-transfer system 16 compared to the amount of metal used in the conventional progressive die stamping process including the metal carriers according to an example embodiment.

[0027] The micro-transfer system 16 disclosed herein is also compact and can be transported within the die. The micro-transfer system 16 was designed such that it can sit on the die shoe without protruding out from the edges. Thus, micro-transfer system 16 can remain on the die shoe during die transfer and storage. The micro-transfer system 16 can also be used outside of the press for setup, testing, troubleshooting, etc. Due to the compact size of the microtransfer system 16, the micro-transfer system 16 can be easily transported by a forklift.

[0028] The micro-transfer system 16 can also be used on most progressive die stamping systems, since the components of the micro-transfer system 16 provide enough travel and enough power, so no major redesign is required for each die stamping system 10. The micro-transfer system 16 can also be used with difference presses and with different press motion curves, since the motion control is independent of the ram and press motion. This also allows the microtransfer system 16 run outside of the press for setup, testing, and maintenance.

[0029] The motors 34 and guides 36 used to drive the 3 -axes of the micro-transfer system 16 are also beneficial. According to the example embodiment, the servo-motors 34 allow for full motion control of the micro-transfer system 16 independent of the ram and allows for the system to run with faster transfer rates compared to a mechanical mechanism. The pre-engineered ball screw linear actuators 36 allow for easy building and maintenance of the micro-transfer system 16

[0030] Benefits of the micro-transfer system 16 for transferring the metal components from one die station 14 to a following die station 14 in the die stamping system also include the following. As explained above, the micro-transfer system 16 includes the plurality of motors 34 and the part handling assembly, preferably rails 32, that moves parts from station to station. Motion is created by linking to the press position via crank angle or the ram position to prevent collisions and to tailor the motion profile. The micro-transfer system 16 motions can be driven by any mechanical or electrical means. In addition to motors, a stepper, encoders, hydraulic cylinders, gears etc. can be used to drive motions of the micro-transfer system 16.

[0031] The micro-transfer system 16 can be mounted onto the die or the press area. This feature enables ease of setup in a tool room as it can be done offline. It also allows for immediate production start once loaded in the press, increasing OEE (overall equipment effectiveness). Current transfer systems require change of grippers or transfer bars.

[0032] The part handling assembly can be removed from the micro-transfer system 16 for ease of adjustment and changes including all periphery connections (electrical, fluids etc...). This can be accomplished by the use of mechanical fastening solutions, such as dove tails, bolts and screws.

[0033] The micro-transfer system 16 also enables smaller pitch when compared to progressive stampings resulting in large material savings. For example, the micro-transfer system 16 can accommodate pitches from 10mm to 700mm in travel. The micro-transfer system 16 can also maintain SPM ranging from 5 SPM to 50 SPM depending on part geometry; minimize use of outside carriers and/or minimize use of center carriers, and optimize blank nesting and re-nest to improve material utilization.

[0034] The micro-transfer system 16 also enables use of coil fed transfer dies to be run in a progressive die. The micro-transfer system 16 can save cost, redeploy lower capital equipment, and minimize future capital investments. Stamping in the die can be conducted without the need to use the coil to advance the blank from station to station, which improves operational efficiency while running in a progressive press. Finally, multiple micro-transfer systems 16 can be installed in the same die to allow different pitches across stations.

[0035] Obviously, many modifications and variations of the present invention are possible in light of the above teachings and may be practiced otherwise than as specifically described while within the scope of the disclosure and claims.

Claims

CLAIMS What is Claimed is:

1. A transfer system for transferring metal components from a first die station to a second die station, comprising: at least one part handling rail, at least one gripper attached to the at least one part handling rail for engaging the metal components, and at least one motor for moving the at least one part handling rail and the at least one gripper between the die stations.

2. The transfer system of claim 1 further including at least one guide for moving the at least one part handling rail and the at least one gripper between the die stations.

3. The transfer system of claim 2, wherein the at least one guide includes a linear actuator.

4. The transfer system of claim 1, wherein the least one motor moves the at least one part handling rail along three axes.

5. The transfer system of claim 1, wherein the at least one motor includes at least one of a servo-motor, stepper motor, encoder, hydraulic cylinder, pneumatic drive, and gear.

6. The transfer system of claim 1 including a main electrical panel for powering and controlling the at least one motor and the at least one part handling rail.

7. The transfer system of claim 6, wherein the main electrical panel includes controls allowing for three axes to be controlled independently.

8. The transfer system of claim 7, wherein the three axes include a drive, a lift axes, and a pitch axis.

9. The transfer system of claim 7, wherein the controls are connectable to a press so that the transfer system remains in sync with the press.

10. A die stamping system, comprising: a press; a plurality of die stations disposed in the press; and at least one transfer system for conveying components from one of the die stations to another one of the die stations; the transfer system including at least one part handling rail, at least one gripper attached to the at least one part handling rail for engaging the metal components, and at least one motor for moving the at least one part handling rail and the at least one gripper between the die stations.

11. The die stamping system of claim 10 including a coil storage station for containing a coil of metal used to form the metal components, a coil decoder station for decoding the coil, a coil straightener station for straightening the coil, and a coil feeder for feeding the coil to the die stations.

12. The die stamping system of claim 10 including a plurality of the transfer systems, wherein two of the transfer systems are disposed adjacent each one of the die stations.

13. A die stamping system of claim 12, wherein the two transfer systems and the adjacent die station are mounted on a single base plate.

14. A method of manufacturing metal components, comprising the steps of: conveying a coil of metal to a plurality of die stations of a die stamping system, forming a metal component from the coil at a first one of the die stations, transferring the metal component from the first die station to a second one of the die stations using at least one transfer system.

15. The method of claim 14, wherein each of the at least one transfer system includes at least one part handling rail for moving between the die stations, grippers attached to the at least one part handling rail for engaging the metal components, and a least one motor for moving the at least one part handling rails and the at least one gripper between the die stations.

16. The method of claim 14, wherein the metal component is fully separated from the remainder of the coil before transferring the metal component to the second die station.

17. The method of claim 14, wherein the step of transferring the metal component from the first die station to the second die station includes moving the component along three axes.

18. The method of claim 14, wherein the first and second die stations are disposed in a first press, and including the step of moving the transfer system from the first press to a second press which includes a third and fourth die station.

19. The method of claim 14, wherein two of the transfer systems are disposed adjacent to each one of the die stations on opposite sides of the die station, wherein the two transfer systems are independent controlled.

20. The method of claim 14, wherein the step of forming the metal component includes stamping.