Patent Application
20110265544
This application claims the priority of German Application No. 10 2010 019 324.0-14 filed May 3, 2010.
The invention relates to a hydraulic cylinder for a hydraulic drawing cushion of a deep draw press.
During the drawing process, the drawing press clamps a metal sheet between an upper tool part and a lower tool part. By a relative movement between the upper tool part and the lower tool part, the metal sheet is pulled over a lower die and pressed between two die parts. The metal sheet retaining force required for the drawing is provided by the drawing cushion.
A drawing cushion for a drawing press is described, for example, in EP 0069 201 A2. The drawing cushion includes a cylinder which comprises three operating chambers. Two of the operating chambers operate pneumatically while the third operating chamber is in the form of a hydraulic operating chamber. The hydraulic operating chamber provides for the blocking of the drawing cushion in the lower end position and the controlling of the upward movement of the piston rod. The two pneumatic operating chambers are separated from each other by a differential piston. During the upward movement of the piston rod the two pneumatic operating chambers are placed in communications with each other, so that surface area difference of the differential piston becomes effective and moves the piston upwardly for the ejection of the formed metal part. This movement can be controlled by the oppositely acting hydraulic pressure in the hydraulic operating chamber.
Based hereon, it is the object of the invention to provide a compact hydraulic cylinder for a drawing cushion by which the position of the piston rod as well as the force provided by the piston rod can be controlled.
The present invention provides a hydraulic cylinder that comprises a cylinder housing with several operating chambers. In the cylinder housing, a piston rod is slidably supported which, at one front end projects from the cylinder housing. At the outer free end of the piston rod a floating plate is attached on which a metal sheet support ring is disposed. The metal sheet support ring applies during the drawing procedure the required drawing force to the metal sheet part to be deformed.
The hydraulic cylinder includes three hydraulically separated operating chambers. The first and second operating chambers are delimited each by a first and, respectively, a second piston surface area. Preferably, the two operating chambers are separated from each other by an annular piston. The first and second operating chambers have only a small volume and serve to bring the piston rod and, together therewith, the floating plate of the lower tool part into a desired position. In particular, with the hydraulic pressurization of the first and the second operating chamber, the movement and/or the position of the piston rod can be controlled. Because of the small first and second piston surface areas only a small fluid volume is required herefor.
In the cylinder housing preferably at the inner front of the piston rod, a third piston surface area is provided which is substantially larger than the first piston surface area and the second piston surface area. The third piston surface area may be larger than the two other piston surface areas by a factor of 3 to 10. The third piston surface area delimits a third operating chamber via which a metal sheet holding force is adjusted which is transmitted by the piston rod to the metal sheet holding ring. To this end, the hydraulic pressure in the third operating chamber is controlled to a predetermined desired pressure valve.
By means of the hydraulic operating chambers, the position and/or the movement of the piston rod and also the metal sheet holding force can be very accurately adjusted because the hydraulic medium is incompressible in contrast to gas media. Herein the position or, respectively the movement control of the piston rod and the control of the sheet metal holding force is assigned to different operating chambers. The piston surface area or, respectively, the chamber volume of the three operating chambers is therefore adapted to the functions assigned to the operating chambers. In this way a compact design of the hydraulic cylinder with a small diameter is achieved. An economical operation of the drawing cushion is ensured.
Preferably, the inner cylinder space of the cylinder housing which accommodates the piston rod is divided into two coaxially arranged cylindrical sections which join via an annular step. The first cylindrical section of the inner space has a larger diameter than the adjacent second cylindrical section. Preferably, the annular piston is arranged in the upper cylindrical section and divides the upper cylindrical section into the first and the second operating chamber. In the lower cylindrical section, the piston rod may delimit the third operating chamber. With such a design, the piston rod is a cylindrical component which can be manufactured very easily. Also, the two cylindrical sections can be formed in the cylinder housing by co-axial bores with little expenditures. Since all the operating chambers use the same hydraulic medium, small leakage flows between the operating chambers as they may occur, for example, after a longer operating time by a certain wear of the piston seals can be tolerated.
The third operating chamber is preferably hydraulically connected to a suction check valve which is arranged in particular parallel to a pressure control arrangement. Via the suction check valve, a volume increase of the third operating chamber during upward movement of the piston rod hydraulic medium is supplied to the third chamber with a small operating pressure of, for example, 5 to 15 bar so as not to inhibit the movement of the piston rod. The suction check valve blocks when the pressure in the third chamber increases or its volume is reduced so that, then, automatically, the parallel circuited pressure control arrangement becomes effective. With the suction check valve blocked, the pressure in the third operating chamber increases substantially over the intake operating pressure.
A deep draw press provided with the hydraulic cylinder according to the invention can operate very efficiently because for the movement of the piston rod only small hydraulic volume changes in the first and the second operating chambers are required. The large forces required for the engagement of the metal sheet are provided by the piston area of the third chamber. The pressure needed herefor in the third operating chamber is automatically generated by the inward movement of the piston rod. The floating plate of the drawing press may be supported by several of the hydraulic cylinders according to the invention. The position and/or the movement of the piston rods and/or the hydraulic pressure in the third operating chamber can be controlled in the various hydraulic cylinders independently of one another.
Advantageous features of the invention are apparent from the drawings exemplary of the invention, in which:
In the operating direction A spaced from the upper tool part, a lower tool part 15 is disposed on a press table of the press frame 16.
Below the press table 16, the drawing press includes a hydraulic drawing cushion 20. The hydraulic cushion comprises a floating plate 21 which is supported on a cylinder arrangement 22 consisting of one or more hydraulic cylinders 23 so as to be displaceable in the operating direction A. At the side of the floating plate 21 opposite the cylinder arrangement 22, the floating plate 21 is connected to a metal sheet support ring 25 by way of pressure rods 24. The metal sheet support ring 25 can therefore be moved together with the pressure rods and the floating plate 24 by pressurizing the cylinder arrangement 22. Each hydraulic cylinder 23 of the cylinder arrangement 22 is in communication with the hydraulic circuit by way of a first hydraulic line 26, a second hydraulic line 27 and a third hydraulic line 28, so that hydraulic medium can be supplied to the hydraulic cylinder 23 and released from the hydraulic cylinder 22.
One of the hydraulic cylinders 23 of the drawing cushion 20 as well as a highly simplified schematic representation of the connected hydraulic circuit 29 is shown in
The internal cylindrical space 31 includes adjacent the cylindrical opening 32 a first cylindrical section 40 with a first diameter D1. Following the first cylindrical section 40 there is a second cylindrical section 41 with a second diameter D2. The second diameter D2 is smaller than the first diameter D1. In the preferred exemplary embodiment, the second diameter D2 corresponds to the diameter of the cylindrical opening 32. Preferably, the piston rod 33 has, at least in the axial sections of the cylindrical opening 32 and of the second cylindrical section 41, a diameter which except for the necessary play, a diameter corresponding to the diameter D2.
The two cylindrical sections 40, 41 are joined via an annular step 42. Both cylindrical sections 40, 41 are arranged co-axial with the longitudinal axis of the piston rod 33. Next to the annular step 42, there is a second seal arrangement 43 in the inner wall of the second cylindrical section 41 which abuts the piston rod 33 in a fluid-sealing manner.
In the first cylindrical section 40, an annular piston 45 is attached to the piston rod 33. The annular piston 45 includes a piston seal 46 which sealingly abuts the inner wall of the first cylindrical section 40, whereby the first cylindrical section 40 is divided fluidically into a first operating chamber 47 and a second operating chamber 48. By axial movement of the annular piston 45 the volumes of the two operating chambers 47, 48 can be changed wherein however the sum of these volumes remains constant.
Adjacent the first operating chamber 47, the annular piston 45 has a first piston surface 49 and, adjacent the second operating chamber 48 a second piston surface 50. The first and the second piston surfaces have the same size.
In the second cylindrical section 41, a third operating chamber 53 is provided. The front face at the end of the piston rod 33 in the cylinder housing 30 forms a third piston surface 54 which delimits the third operating chamber 53. The surface area of the third piston surface 54 is larger than the surface area of the first and the second piston surfaces 49, 50. In the exemplary embodiment, the third piston surface 54 is three to ten and preferably five times as large as the first piston surface 49 or the second piston surface 50. The width d of the annular piston 45 in radial direction corresponds to the difference of the two diameters D1 (annular piston) and D2 (piston rod).
The first operating chamber 47 is connected to the hydraulic circuit via a first hydraulic line 26, the second operating chamber 48 via the second hydraulic line 27 and the third operating chamber 53 via the third hydraulic line 28. With the first and the second operating chamber 47, 48, a first hydraulic circuit 55 and with the third operating chamber, a second hydraulic circuit 56 is hydraulically connected. The two hydraulic circuits 55, 56 are fluidically completely separated from each other in the exemplary embodiment described here.
The first hydraulic circuit 55 includes a storage container 57 from which a motor-pump unit 58 sucks in hydraulic fluid and provides it via a pressure line 59. Connected to pressure line 59 is a pressure store 60 so that in the pressure line 59 there is always a sufficient amount of pressurized hydraulic medium available. Via an electrically controllable control valve 61, the pressure line 59 can be selectively connected to the first hydraulic line 26 or the second hydraulic line 27. Correspondingly, a return line 62 extending from the control valve 61 to the storage container 57 can be hydraulically connected via the control valve 61 selectively to the first or the second hydraulic line 26 or, respectively, 27. The second hydraulic line 27 is additionally connected to the storage container 57 via a pressure control valve 63. When the pressure in the second operating chamber 48 and, consequently, in the second hydraulic line 27 exceeds a predetermined threshold value, the pressure control valve 63 opens so that hydraulic medium can flow from the second operating chamber 48 to the storage container 57.
In the exemplary embodiment the control valve 61 is in the form of a 4/3 way valve. It may also be replaced by other arrangements such as, for example, two-way valves.
In a first switching position I, the first operating chamber 47 is connected to the pressure line 59 via the first hydraulic line 26 whereas the second operating chamber 48 is connected to the return line 62 via the second hydraulic line 27. In a second switching position II, the control valve 61 blocks the pressure line 59 and the branch connection 27a to the second hydraulic line 27 and connects the first hydraulic line 26 to the return line 62. The third switching position III provides for a hydraulic connection between the first operating chamber 47 and the return line 62 and between the second operating chamber 48 and the pressure line 59.
The second hydraulic circuit 56 includes a hydraulic reservoir 65 which is connected to the third hydraulic line 28 and which maybe in the form of a low pressure storage container. Via the hydraulic reservoir 65, the hydraulic medium is made available under a low pressure of about 5 to 15 bar. The hydraulic reservoir 65 is fluidically connected to the third hydraulic line 28 via a check valve 66. The check valve 66 permits in a suction operation, a fluid flow from the hydraulic reservoir 65 to the third operating chamber 53. In the opposite direction, the check valve 66 blocks during controlled pressure operation. Parallel to the check valve, an electrically controllable pressure control arrangement 67 is connected to the hydraulic line 28 via which the pressure in the third operating chamber 53 can be controlled during controlled pressure operation. The pressure control arrangement 67 may connect the third hydraulic line 28 to a storage container 69 via a return line 68. For controlling the pressure control arrangement 67 and the control valve 61 as well as the motor pump unit 58, a control unit 70 is provided.
In a modified exemplary embodiment, other than shown in
Via the first partial hydraulic circuit 55, the position and/or the movement are controlled, for example, the position and/or the speed and/or the acceleration of the piston rod 33. In the first switching position I, the first operating chamber 47 is connected to the pressure line 59 whereas the second operating chamber 48 is connected to storage container 57 and therefore is not pressurized. Because of the pressure difference at the opposite sides of the annular piston 45, a force is effective on the piston rod 33 which causes the piston rod 33 to move into the cylinder 23. In order to make the inward movement of the piston rod 33 possible, the third operating chamber 53 is connected, by means of the controllable pressure control arrangement 67, to the storage container 69 so that hydraulic medium can flow out of the third operating chamber 53.
In the third switching position III of the control valve 61, the piston rod 33 is caused to move out of the cylinder 23. The pressure in the second operating chamber 48 which exceeds that in the first operating chamber 47 generates a force on the annular piston 45 and consequently the piston rod 33 which causes outward movement of the piston rod 33. In the process, the volume of the third operating chamber 53 is increased and hydraulic medium flows into the third operating chamber 53 via the third hydraulic line 28 and the check valve 66 out of the hydraulic reservoir 65 in order not to prevent the movement of the piston rod 33 (supply suction operation). Because the first and the second piston surfaces 49, 50 are small also the volume flows to the first operating chamber 47 and out of the second operating chamber 48 or, respectively, vice versa are very small. The position and movement control of the piston rod 33 can therefore be achieved in a very efficient manner. By means of the control valve 61 and the first hydraulic circuit 55, for example, pre-accelerations of the metal sheet support ring 25 can be provided in order to reduce the relative speeds between the upper tool part 15 and the metal sheet support ring 25 before they meet. Also, an ejection movement of the formed metal part can be achieved by way of the first hydraulic circuit 55 and the first two operating chambers 47, 48.
During the drawing procedure, the sheet metal part B to be formed needs to be clamped between the metal sheet support ring 25 and the upper tool part 14 with a predetermined sheet metal holding force. In this clamped condition, the sheet metal part B is pulled by a continuous movement of the plunger 12 toward the lower tool part 15 over the shape of the lower tool part 15 and at the same time formed by the essentially complementary shape of the upper tool part 14. The sheet metal holding force needs to be maintained herein in order to ensure the quality of the part formed in the process. With an excessive holding force, the sheet metal may rupture. On the other hand, with an insufficiently large holding force folds may occur during the forming procedure.
The adjustment of the desired and required sheet metal holding force is achieved by the second holding circuit 56 and the third operating chamber 53 of the hydraulic cylinder 23. First, the cylinder 23 of the cylinder arrangement 22 are brought to their start-out positions. This occurs by movement of the annular piston 45 by supplying hydraulic medium to or from the first and the second hydraulic chambers 47, 48. The drawing cushion 20 is operated by position and/or movement control. Shortly before the upper tool part 14 abuts the metal sheet B disposed on the metal sheet support ring 25, an inward movement of the piston rod 33 can be initiated in order to reduce the relative speed between the plunger 12 and the metal sheet support ring 25.
As soon as the upper tool part 14 is disposed on the sheet metal part B the hydraulic drawing cushion 20 is switched over for a control of the metal sheet clamping force. To this end, the control valve 61 is moved to its second switching position II in which the first operating chamber 47 is connected to the return line 62 so that it is pressure free. The branch connection 27a from the second hydraulic line 27 to the control valve 61 is blocked, so that the second operating chamber 48 is connected via the pressure control valve 63 to the storage container 57. The press drive 13 tries to move the upper tool part 14 in the operating direction A toward the lower tool part 15. In the process, the pressure in the second and third operating chambers 48, 53 increases. Because of this pressure increase, the pressure control valve 63 opens so that hydraulic medium can flow out of the second operating chamber 48 to the storage container 57. The sheet metal holding force is controlled by the pressure control arrangement 67 in the second hydraulic circuit 56. The control arrangement 67 is controlled by the control unit 70 in such a way that a desired pressure is obtained in the operating chamber 53 which results in the setting of the desired metal sheet holding force. In this way, the metal sheet holding force remains constant also with a continuing inward movement of the piston rod 33. This means that during the forming of the metal part B the metal sheet holding force generated between the upper tool part 14 and the lower tool part 15 is always provided by the sheet metal support ring 25.
In a modified embodiment, in the second switching position II the first hydraulic line 26 or, respectively, the first operating chamber 47 may be blocked. In this embodiment the pressure in the second operating chamber 48 is controlled by the pressure control valve 63. Then a suction inlet line needs to be connected to the first operating chamber to make a piston rod movement possible.
When the forming procedure is completed, the upper tool part 14 can again move away from the lower tool part 15. The drawing cushion 20 or, respectively, the hydraulic cylinder 23 is then no longer controlled for an adjustment of the desired metal sheet holding force, but is again operated under position control. The first control valve 61 switches either to the first switching position I for causing a return movement of the piston rod or to the third switching position for performing an ejection movement. Wherein the piston rod 33 is moved outwardly and the hydraulic medium is sucked into the third operating chamber 53. For a sufficient suction movement only a small suction pressure in the range of 5 to 15 bar is needed in the second hydraulic circuit 56. In contrast, the pressure store 60 of the first hydraulic circuit 55 provides for the movement of the piston rod 33 a pressure in the area of 200 bar, which permits a rapid piston road movement.
The second hydraulic circuit 56 may include its own motor pump unit 72 for replenishing the hydraulic reservoir 65. The pressure control arrangement 67 is, in the exemplary embodiment of
The inlet check valve 66 is preferably a pressure-controlled safety valve 74. Via an inlet 81, the pressure of the hydraulic reservoir 65 is effective on the stem 75 of the safety valve 74. An outlet 76 of the safety valve 74 is connected to the third hydraulic line 28. The hydraulic pressure effective at the outlet 76 is transmitted, via a control line 77 to a control chamber 78, which is delimited by a control surface 79 of a piston 80 connected to the stem 75. The control surface 79 is substantially larger than the front face of the stem 75 associated with the inlet 81. If the pressure in the control line 77 and consequently at the outlet 76 is sufficiently large, the stem is moved by the pressure in the control chamber 78 in a closed position whereby the inlet 81 is separated from the outlet 76 of the safety valve 74. When the pressure in the control line 77 drops, the stem 75 opens a communication path between the inlet 81 and the outlet 76 so that a pressurized hydraulic medium can flow from the reservoir 65 via the inlet 81 and the outlet 76 to the third hydraulic line 28. When subsequently, the pressure at the outlet 76 and consequently in the control line 77 has sufficiently increased, the safety valve 74 closes again. In this way the intake of hydraulic fluid into the third operating chamber during outward movement of the piston rod 33 is achieved. During the pressure control, the hydraulic pressure in the third operating chamber 53 is sufficiently large to keep the safety valve 74 in the closed position. Hydraulic fluid can then flow out of the second hydraulic line 28 only via the pressure control arrangement 77 and, for example, the 2/2 way valve 73.
With the connection between the motor pump unit 72 and the supply line 83 established, hydraulic medium can be supplied to the hydraulic reservoir 65 for pressure storage therein. From the third operating chamber 53, hydraulic fluid cannot flow out via the third hydraulic line 28 since the return line 68 is blocked and the safety valve 74 does not permit a hydraulic medium return flow. In the other switch position, the connection of the motor-pump unit 72 to the hydraulic reservoir 65 and the safety valve 74 is interrupted and hydraulic medium can return to the storage container 69 for pressure reduction in the third operating chamber 53 via the third hydraulic line 28, the return line 68 and the pump of the motor-pump unit 72. In this way, the returning hydraulic medium drives the pump. The electric motor can then be operated in a generator mode wherein it produces electricity which can, for example, be stored in a battery. In this way, the energy efficiency of the drawing cushion 20 or, respectively, the drawing press is further improved.
In a modification of the embodiment shown in
If the cylinder arrangement 22 of the drawing cushion 20 includes several hydraulic cylinders 23, they can be controlled independently of one another. This offers the possibility to control the cylinders, so that at different locations of the sheet metal support ring 25 different positions and/or movements and/or metal sheet clamping forces can be obtained. This may be necessary in connection with complex forming processes, for example, in connection with vehicle body parts in the automotive industry.
In
Optionally, an additional multi-way valve 92 may be arranged parallel to the pressure limiting valve 89 which valve 92 is controlled by the control unit 70. This multi-way valve 92 is in the preferred embodiment according to
The invention resides in a hydraulic cylinder 23 for a hydraulic drawing cushion 20 of a drawing press 10. The hydraulic cylinder 23 includes a first operating chamber 47, a second operating chamber 48, and a third operating chamber 53. An annular piston 45 with a first piston surface area 49 and a second piston surface area 50 separates the first operating chamber 47 from the second operating chamber 48. The first and the second piston surfaces 49, 50 have the same size. A front surface of the piston rod 33 forms a third piston surface 54 which is larger than the first and second piston surfaces. The third piston surface 54 delimits the third operating chamber 53 of the hydraulic cylinder 23. The first and the second operating chambers 47, 48 are provided for controlling the position and/or the movement of the piston rod 33. The third operating chamber 53 serves to control the metal sheet clamping force of the drawing press via the piston rod 33. The metal sheet clamping force is adjusted by controlling the hydraulic pressure in the third operating chamber 53. Herewith a compact hydraulic cylinder 23 is provided with two operating chambers 47, 48 for the position and/or movement control of the piston rod 33 and with a pressure-controlled further operating chamber 53 for the adjustment of a metal sheet clamping force. All functions of the drawing cushion 20 are therefore combined in one hydraulic cylinder and are realized in simple and economical manner by the separation into different operating chambers 47, 48, 53.
| Number | Date | Country | Kind |
|---|---|---|---|
| 102010019324.0-14 | May 2010 | DE | national |
