WO2019038786A1 - Ensemble et procédé de fabrication automatisée d'anneaux - Google Patents

Ensemble et procédé de fabrication automatisée d'anneaux Download PDF

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Publication number
WO2019038786A1
WO2019038786A1 PCT/IN2018/050541 IN2018050541W WO2019038786A1 WO 2019038786 A1 WO2019038786 A1 WO 2019038786A1 IN 2018050541 W IN2018050541 W IN 2018050541W WO 2019038786 A1 WO2019038786 A1 WO 2019038786A1
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WO
WIPO (PCT)
Prior art keywords
ring
wound
ejection
assembly
forging
Prior art date
Application number
PCT/IN2018/050541
Other languages
English (en)
Inventor
Shrikant LOKHANDE
Original Assignee
Lokhande Shrikant
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Lokhande Shrikant filed Critical Lokhande Shrikant
Publication of WO2019038786A1 publication Critical patent/WO2019038786A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21F—WORKING OR PROCESSING OF METAL WIRE
    • B21F37/00—Manufacture of rings from wire
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D53/00—Making other particular articles
    • B21D53/16—Making other particular articles rings, e.g. barrel hoops
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K1/00—Making machine elements
    • B21K1/76—Making machine elements elements not mentioned in one of the preceding groups
    • B21K1/761—Making machine elements elements not mentioned in one of the preceding groups rings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K27/00—Handling devices, e.g. for feeding, aligning, discharging, Cutting-off means; Arrangement thereof

Definitions

  • the present disclosure relates to an assembly and process for automated manufacturing of rings.
  • the term 'ring' for the purpose of the present disclosure, is to be interpreted as a tool for attachment to multifarious articles of utility including but not limited to keys, inhalers, flashlights, compasses, calculators, penknives, discount cards, bottle openers, security tokens and USB flash drives.
  • the term 'mechanical power press' for the purpose of the present disclosure, is to be interpreted as a machine used in the manufacturing industry to give shape to an article of manufacture by the application of pressure.
  • 'wound piece' for the purpose of the present disclosure, is to be interpreted as a unit which is used as a precursor for manufacturing rings, which is obtained by winding a cord and cutting the stray ends in accordance with certain preset standards, wherein the cord is made up of any raw material typically used for manufacturing rings.
  • the term 'ram' for the purpose of the present disclosure, is to be interpreted as a component, having reciprocating, up and down movement, that is responsible for the process of forging of the article of manufacture.
  • An upper die or upper punch is attached to the lower surface of the ram.
  • the term 'total traveling distance' is used multiple times in the present disclosure with respect to the ram.
  • the term 'total traveling distance' is to be interpreted, for the purpose of the present disclosure, to mean the total distance traversed by the ram, in one direction, during the reciprocating, up and down movement thereof.
  • the term 'crankshaft' for the purpose of the present disclosure, is to be interpreted as the rod connecting the two vertical sides of the frame of the mechanical power press and is responsible for the conversion of the rotary movement of the motor to the reciprocating movement of the ram.
  • the crankshaft may also be referred to as the main shaft.
  • the term 'frame' for the purpose of the present disclosure, is to be interpreted as the main support structure or skeleton of the mechanical power press, over which the press components such as ram, crankshaft and the control mechanisms are mounted.
  • the frame of a mechanical power press has a C - shape.
  • the term 'press bed' for the purpose of the present disclosure, is to be interpreted as the platform on which a lower die is mounted.
  • the press bed is parallel to the floor on which the mechanical power press rests.
  • the term 'lower die' for the purpose of the present disclosure, is to be interpreted as the component holding the article of manufacture (to be given the desired shape), during the process of forging. Particularly, the article of manufacture gets the desired shape due to the cumulative impact of the upper die and the lower die, with the article of manufacture resting on the lower die.
  • the lower die may also be referred to as the lower punch.
  • rings have been manufactured by processes that require significant human intervention. This, besides making the whole process time consuming and causing a decrease in the production rate, causes a towering increase in the incidence of accidents among the machine operators. Furthermore, as the dependency on the operators is tremendous, chances of manual errors are on the rise.
  • the inventor of the present disclosure has envisaged an assembly and a process for manufacturing rings that mitigates the afore- stated problems.
  • the present disclosure provides an assembly (10) and a process for the automated manufacturing of rings.
  • the assembly (10) is to be installed in a conventional mechanical power press (100).
  • the assembly (10) of the present disclosure comprises a conveyor mechanism for facilitating the conveyance of at least one wound piece from a wound pieces' reservoir to at least one ring forging cum ejection mechanism; an entry regulating mechanism for regulating the timing of entry of said wound piece(s) into said ring forging cum ejection mechanism; and a ring forging cum ejection mechanism for facilitating forging of ring(s) from said wound piece(s), followed by immediate ejection thereof away from the assembly (10).
  • the components of the assembly (10) are driven by the movement of and position of the ram and the crankshaft (104) in said mechanical power press (100).
  • Figure 1 illustrates a non-limiting embodiment of the ring of the present disclosure
  • Figure 2 illustrates the assembly of the present disclosure after installation in a mechanical power press
  • Figure 3 illustrates a perspective view of the assembly of the present disclosure after installation in a mechanical power press, focusing on the ring ejection setup of the ring forging cum ejection mechanism;
  • Figure 4 illustrates the front view of the assembly of the present disclosure after installation in a mechanical power press, focusing on the conveyer mechanism, entry regulating mechanism and lower die unit of the ring forging cum ejection mechanism;
  • Figure 5a illustrates the position of the components of the assembly, just before the wound piece is forged to form a ring; and Figure 5b illustrates the position of the components of the assembly, after the ring is forged and just before it is ejected away from the assembly.
  • the inventor of the present disclosure provides an assembly (10) and process for automated manufacturing of rings.
  • the conventional technique for the manufacturing of rings typically includes steps such as winding a cord, cutting the cord to separate out wound pieces, placing the wound piece on the die of a power press, causing the ram (102) of the power press to hammer on the wound piece and separating the resulting ring from the working area to a collection area - steps that are all carried out manually.
  • Human intervention forms the crux of the conventional techniques.
  • the conventional techniques are fraught with industrial hazards such as increased time and cost of production, increased incidences of injuries to machine operators, decreased safety of workers, increased percentages of error and the like.
  • the assembly (10) and process of the present disclosure addresses the afore-stated concerns.
  • the inventor of the present disclosure in accordance with one aspect, provides an assembly (10) for the automated manufacturing of rings.
  • the assembly (10) of the present disclosure is to be installed in a conventional mechanical power press (100) as demonstrated in Figure 2 and comprises a conveyor mechanism; an entry regulating mechanism and a ring forging cum ejection mechanism.
  • the conveyor mechanism is for facilitating the conveyance of at least one wound piece from a wound pieces' reservoir to at least one ring forging cum ejection mechanism.
  • the conveyor mechanism comprises at least one shoot (12) that linearly transfers the wound pieces from the reservoir.
  • the horizontal plane of the shoot (12) is maintained at a predetermined angle with respect to the plane of the press bed (106) of the mechanical power press (100).
  • the pre-determined angle is decreased with an increase in the specific weight of the material of the wound pieces.
  • the pre-determined angle is increased with a decrease in the specific weight of the material of the wound pieces.
  • the entry regulating mechanism is for regulating the timing of entry of the wound piece(s) lined up in the shoot (12), into the ring forging cum ejection mechanism, such that only one wound piece slides into the ring forging cum ejection mechanism for forging.
  • the entry regulating mechanism of the present disclosure comprises at least two wires affixed to the ram (102), wherein the first wire is a straight stopper wire (14) and the second wire is a U-shaped stopper wire (16).
  • the inventor of the present disclosure after extensive experimentation, has found that the maximum horizontal distance between the two wires should be 30 to 66 % of the internal diameter of the ring or l/3 rd for best results.
  • the length of the straight wire is determined on the basis of the time required by the wound piece first in cue to land and stabilize on the stationary die component (20) of the lower die unit.
  • the entry regulating mechanism is driven by the movement of and position of the ram (102) in the mechanical power press (100), as explained in detail in subsequent parts of the present disclosure.
  • the ring forging cum ejection mechanism is for facilitating forging of ring(s) from the wound piece(s), followed by immediate ejection thereof away from the assembly (10) - all without human intervention.
  • the ring forging cum ejection mechanism comprises at least one lower die unit, adapted to receive the wound piece from the shoot (12) for forging and at least one ring ejection setup adapted to cause actuation of the sleeve element (22a) to facilitate ejection of the forged ring away from the assembly.
  • the lower die unit (representations seen in Figures 4, 5a and 5b) comprises at least one lower die base (18), at least one stationary die component (20) and at least one moving die component (22).
  • the lower die base (18) is mounted on the press bed (106) and is adapted to hold and support the stationary die component (20) and the moving die component (22).
  • the stationary die component (20) is mounted on the base (18), coaxial to the ram (102) of the mechanical power press (100) and is adapted to hold the wound piece conveyed from the shoot (12) and give shape thereto after impact from the upper die (108) of the mechanical power press (100) to form a ring.
  • the moving die component (22) is mounted coaxially around the stationary die component (20) on the base (18) and comprises at least one sleeve element (22a) and at least one spring element (22b).
  • the sleeve element (22a) is adapted to hold the wound piece at the site of impact and is further adapted to expose the forged ring to at least one air blower (24) to eject the forged ring away from the assembly (10) upon actuation by the ring ejection setup.
  • the spring element (22b) is adapted to facilitate the exposure of the forged ring to the air blower (24).
  • the ring ejection setup (representations seen in Figures 3 and 4) comprises at least one cam (26), at least one vertical element (28), at least one vertical element supporting frame (34), at least one horizontal element (30) , at least one stopper bolt (36), at least one binding element (32), at least one sliding element (38), at least one reciprocating switch (40), at least one air blower actuator (42) and at least one air blower (24).
  • the cam (26) is affixed to the crankshaft (104) of the mechanical power press (100), besides the press brake and is adapted to mirror the movement of the rotating crankshaft (104) and exert pressure on the ring ejection setup to trigger the downward motion of the vertical element (28).
  • the vertical element (28) is parallel to the frame of the mechanical power press (100) and is adapted to accept the trigger provided by the cam (26) and displace downwards and cause the horizontal element (30) to displace downwards.
  • the vertical element (28) comprises a first end (28a) having a roller facing and being under intermittent influence of the cam (26) and a second end irreversibly inserted in at least one binding element (32), thereby influencing the movement of the horizontal element (30) which is also engaged in the binding element (32).
  • the vertical element supporting frame (34) is affixed to the frame of the mechanical power press (100) and is adapted to hold and support the vertical element (28).
  • the horizontal element (30) pierces through the frame of the mechanical power press (100) in parallel to the press bed (106) of the mechanical power press (100) and is adapted to receive the trigger provided by the vertical element (28) and displace downwards to cause the sleeve element (22a) to displace downwards and expose the forged ring to the air blower (24).
  • the horizontal element (30) comprises a first end (30a) engaged in the binding element (32) and a second end resting onto the sleeve element (22a).
  • the stopper bolt (36) is affixed on the horizontal element (30) and adapted to maintain a pre-determined distance between the top surfaces of the stationary die component (20) and the sleeve element (22a) for best results.
  • the binding element (32) is adapted to bind together the second end (28b) of the vertical element (28) and the first end (30a) of the horizontal element (30) to facilitate transferability of stimulus or pressure between the vertical (28) and horizontal (30) elements and to preclude the elements from getting damaged.
  • the end of the horizontal element (30b) receiving the trigger from the vertical element (28) and the end triggering the downward movement of the sleeve (22a) are on the opposite sides of the frame (110) of the press (100), there are high chances of the horizontal element (30) getting bent which is prevented by the specific design of the binding element (32).
  • the sliding element (38) is affixed to the first end (30a) of the horizontal element (30), adjacent to the binding element (32), at one end and to the frame of the power press (100) at the other end.
  • the sliding element (38) is adapted to cause the sleeve element (22a), the horizontal element (30), the binding element (32) and the vertical element (28) to displace upwards and resume original position.
  • the sliding element (38) is a spring.
  • the reciprocating switch (40) is affixed to the frame of the power press and adapted to maintain the axis and strength of motion of the vertical element (28). As the distance between the vertical element (28) and the sleeve element (22a) is more and as both the said components are connected indirectly, the power of the vertical element (28) cannot be sufficiently harnessed to influence the downward movement of the sleeve element (22a), leading to outward displacement of the vertical element (28) with respect to the frame (110) of the press (100).
  • the reciprocating switch (40) is included in the present setup to prevent the afore- stated undesirable side effect.
  • the air blower actuator (42) is affixed to the binding element (32) and is adapted to open the valve of an air pipe (44) leading up to the air blower (24), when the crankshaft (104) traverses a pre-determined distance; thereby actuating the cam (26).
  • the air blower (24) being the outlet of the air pipe (44) and being affixed on the upper surface of the sleeve (22a), is adapted to eject the forged ring away from the assembly (10) upon actuation by the air blower actuator (42).
  • the wound piece is forged to form a ring.
  • the cam (26) while mirroring the crankshaft's (104) movement, triggers the downward movement of the vertical element (28), which in turn triggers the downward movement of the horizontal element, which in turn causes the sleeve element (22a) to displace downwards and expose the forged ring to the air blower (24).
  • the cam (26) actuates the air blower actuator (42) which opens the air pipe (44) causing the air blower (24) to blow on the exposed ring and eject the forged ring away from the assembly.
  • the ring forging cum ejection mechanism is driven by the movement of and position of the ram (102) and the crankshaft (104) in the mechanical power press (100).
  • the components of the assembly (10) are affixed, connected, coupled and mounted, as applicable by using convention methods such as welding, bolting and the like.
  • the inventor of the present disclosure in accordance with another aspect, provides a process for automated manufacturing rings using the aforementioned assembly (10).
  • the process of the present disclosure comprises transferring a plurality of wound pieces from a wound pieces' reservoir to at least one ring forging cum ejection mechanism by a conveying mechanism; regulating the timing of entry of the wound pieces into the ring forging cum ejection mechanism by an entry regulating mechanism and forging of wound pieces to form rings, followed by immediate ejection thereof away from the assembly (10) hosting the process, by means of said ring forging cum ejection mechanism.
  • the step of transferring a plurality of wound pieces comprises transporting a plurality of wound pieces from the wound pieces' reservoir to the ring forging cum ejection mechanism by means of the shoot (12).
  • the step of regulating the timing of entry of the wound pieces into the ring forging cum ejection mechanism ensures the reaching of only one wound piece into the ring forging cum ejection mechanism for forging.
  • the step of regulating the timing of entry is carried out in multiple sub-steps depending upon the movement of and position of ram (102) of the mechanical power press (100) as demonstrated herein below.
  • the blocked wound piece second in cue in the shoot (12) is allowed to slide down due to gravity and become the new wound piece first in cue in the shoot (12).
  • the straight stopper wire (14) also engages with the new wound piece first in cue, blocking the latter further.
  • the new wound piece first in cue remains blocked due to engagement with both the afore- stated stopper wires during the time taken for the ram (102) to travel from 17% to 30 % of the total traveling distance from the topmost position.
  • the U-shaped stopper wire (16) disengages from the new wound piece first in cue, however, the straight stopper wire (14) continues to block the new wound piece first in cue.
  • the straight stopper wire (14) continues to block the new wound piece first in cue singularly till the ram (102) reaches the bottommost position and also during the time required by the ram (102) to ascend from the bottommost position to reach 80- 85% of the total traveling distance.
  • the U-shaped stopper wire (16) blocks the wound piece next in cue to the new wound piece first in cue.
  • the step of forging of wound pieces to form rings, followed by immediate ejection thereof away from the assembly (10) is driven by the movement of and position of the ram (102) as well as the crankshaft (104) of said mechanical power press (100).
  • the wound piece at the stationary die component (20) is hammered on by the upper die (108) of the mechanical power press (100) to form a ring.
  • the wound piece is held at the desired site of impact by the sleeve element (22a) being in the original position, aided by the stopper bolt (36) of the ring ejection setup and supported by the lower die base (18).
  • One full rotation of the crankshaft (104) is taken to be from 0° to 360° and the values mentioned in degrees herein are derived using said equation.
  • the air pipe (44) leading up to the air blower (24) is opened up by at least one air blower actuator (42) (after getting actuated by the cam (26)), causing ejection of the forged ring away from the assembly.
  • the sliding element (38) of the ring ejection setup of the ring forging cum ejection mechanism relaxes, and facilitates the horizontal element (30), the vertical element (28) and the binding element (32) of the ring ejection setup to displace upwards and resume the original position. Consequently, the spring element (22b) of the moving die component (22) also relaxes causing the sleeve element (22a) to resume the original position.
  • the step of forging of the wound piece includes giving the ring a predetermined shape.
  • the ring of the present disclosure is a flat ring (illustrated in Figure 1).
  • the afore-stated steps are carried out repeatedly to render forged rings using the assembly (10) of the present disclosure. It is crucial to note that the inventor of the present disclosure, after systematic research and trials over multiple years has designed the assembly (10) and process of the present disclosure, wherein the entry regulating mechanism is driven by the movement of and position of the ram (102) in the mechanical power press (100) and the ring forging cum ejection mechanism is driven by the movement of and position of the ram (102) and the crankshaft (104) in the mechanical power press (100).
  • the afore-mentioned feature has been designed with the specific purpose of assigning the control of the assembly (10) and the process of manufacturing rings to the components of the press and to remove the control of the same from the workers operating the assembly; thereby making the assembly (10) and process safer, more efficient and highly productive without compromising on the product specifications.
  • Example 1A Manufacturing rings by the conventional process
  • Example IB Manufacturing rings by the assembly (10) and process of the present disclosure
  • the assembly (10) of the present disclosure was installed in the conventional mechanical power press (100) as shown in the Figures 2 to 5b.
  • a plurality of wound pieces was transferred from the wound pieces' reservoir to the lower die unit by the conveying mechanism described herein above.
  • the timing of entry of the wound pieces into the stationary die component (20) was regulated by the entry regulating mechanism described herein above.
  • the wound piece in the stationary die component (20) was forged to form a ring and immediately ejected away from the assembly (10) by the ring forging cum ejection mechanism descried herein above.
  • the assembly (10) of the present disclosure (10) the production rate was found to be over 95 pieces per minute.
  • the embodiments described herein above are non-limiting.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Forging (AREA)

Abstract

La présente invention concerne un ensemble (10) et un procédé de fabrication automatisée d'anneaux. L'ensemble (10) comprend un mécanisme de transport pour faciliter le transport d'au moins une pièce enroulée depuis un réservoir de pièces enroulées vers au moins un mécanisme d'éjection de bague de forgeage ; un mécanisme de régulation d'entrée pour réguler le moment de l'entrée de la pièce enroulée dans le mécanisme d'éjection de bague de forgeage ; un mécanisme d'éjection de bague de forgeage pour faciliter le forgeage d'un anneau à partir de la pièce enroulée, puis pour éjecter immédiatement celui-ci hors de l'ensemble (10). Les éléments de l'ensemble (10) sont entraînés par le mouvement et la position du vérin (102) et du vilebrequin (104) dans la presse mécanique (100), afin d'assurer la sécurité et de maintenir une productivité élevée, sans compromettre les spécifications du produit.
PCT/IN2018/050541 2017-08-23 2018-08-22 Ensemble et procédé de fabrication automatisée d'anneaux WO2019038786A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IN201721029858 2017-08-23
IN201721029858 2017-08-23

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WO2019038786A1 true WO2019038786A1 (fr) 2019-02-28

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Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE1118137B (de) * 1955-07-07 1961-11-30 Nat Standard Company Ltd Vorrichtung zum Herstellen geschlossener Drahtschlaufen
US3570300A (en) * 1967-11-09 1971-03-16 Kieserling & Albrecht Apparatus for ejecting articles in cold forming presses or the like
US3848444A (en) * 1971-12-28 1974-11-19 Taylor & Challen Ltd Feed mechanisms
US4014203A (en) * 1975-06-20 1977-03-29 Peltzer & Ehlers Ejector mechanism for ejecting pressed parts from the bottom die of press
US4741196A (en) * 1987-02-09 1988-05-03 Formatec Tooling Systems, Inc. Air conveyor and method for removing parts from a high speed forming press
US20050092052A1 (en) * 2003-11-05 2005-05-05 Paul Stone Forging apparatus and conveyor for forming complex articles

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE1118137B (de) * 1955-07-07 1961-11-30 Nat Standard Company Ltd Vorrichtung zum Herstellen geschlossener Drahtschlaufen
US3570300A (en) * 1967-11-09 1971-03-16 Kieserling & Albrecht Apparatus for ejecting articles in cold forming presses or the like
US3848444A (en) * 1971-12-28 1974-11-19 Taylor & Challen Ltd Feed mechanisms
US4014203A (en) * 1975-06-20 1977-03-29 Peltzer & Ehlers Ejector mechanism for ejecting pressed parts from the bottom die of press
US4741196A (en) * 1987-02-09 1988-05-03 Formatec Tooling Systems, Inc. Air conveyor and method for removing parts from a high speed forming press
US20050092052A1 (en) * 2003-11-05 2005-05-05 Paul Stone Forging apparatus and conveyor for forming complex articles

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