Patent Application
20180207702
The present invention relates generally to the field of manufacturing equipment, and more specifically to a linear press assembly for processing sheet material.
The invention is an assembly for use with a linear press. The assembly comprises a tool having opposed first and second ends and a tool support member configured to support the tool such that the first end of the tool projects from the tool support member. A die is configured to receive a portion of the first end of the tool and is supported in a die support. A first sleeve is supported within the tool support member and' a second sleeve supported by the die support member. A first elongate member is positioned within both the first sleeve and the second sleeve to align the tool with the die along a first line.
The invention includes a machine comprising a table to support a work piece and a frame configured to support the table and the assembly described above. A positioning member moves the work piece on the table between the tool support member and die support member. A ram is movable along the frame to align with the tool and to engage the second end of the tool to project the first end of the tool from the tool support member and drive the first end of the work tool toward the work piece.
The present invention is likewise directed to a method for use of the machine described above. The method comprises attaching the die support member to a frame and positioning the tool support member on the frame and above the die support member. The elongate member is positioned within both the first and second sleeves to align the tool and the die on the first line. The die support member and tool support member are then secured to the frame. A work piece is positioned between the first end of the tool and the die on a table supported by the frame. The tool support member and the tool are driven toward the work piece to engage the first end of the tool with the work piece.
Punch presses are an indispensable part of manufacturing operations that require the punching or forming of sheet metal. Whether using a soft-tooling machine or a hard-tooling machine the cost of operation, repair, and maintenance are of considerable concern to manufacturers. Hard-tooling machines use tooling that is configured for one particular purpose. Thus, such machines may experience significant downtime if there is no need to make the specific part for which the hard-tooling machine is designated. Further, malfunction of the hard tooling machine may slow production to a stop.
Soft-tooling machines may be used to overcome some of the disadvantages of hard tooling machines. However, many soft-tooling machines are not as efficient as hard tooling machines and they must be programmed to deliver the sheet metal or the tool to a precise location. Further, the tools and dies in soft-tooling machines are prone to misalignment because they are moved during machine operation. Hard-tooling machines do not generally have this problem as the tool and die are not moved about during operation.
The assembly of the present invention overcomes the drawbacks and disadvantages of hard-tooling and soft-tooling punch machines by providing an assembly that has a plurality of precisely aligned tools and dies and a precision movement assembly configured to move the sheet metal to the location of the tool and die.
Turning now to the Figures and in particular to
The press frame assembly 14 supports a bolster frame 26, and a tool support member frame 28. A plurality of panels 30 having air vents may be spaced around the press frame assembly 14 to permit the flow of air around the machine 10 and through the press frame assembly 14.
The tool support member frame 28 has a first upper support member 32 and a second upper support member 34. Both members 32 and 34 may be constructed of welded plate steel with stiffening members underneath to provide sufficient strength, rigidity, and flatness. A gap is formed between the first and second upper support members 32 and 34 for accommodating groups of processing tools in an array 46, which will be described herein, below. A bridge beam 36 has a first end attached to the first upper support member 32 and an opposing second end attached to the second upper support member 34. The bridge beam 36 may provide additional strength and rigidity to the tool support member frame 28. A gear rack 38 may be attached to the bridge beam 36 to engage with a gear (not shown) used to drive movement of a ram 40 along the bridge beam.
Guide rails 50 and 52 are supported by the press assembly frame 14. The guide rails 50 and 52 are operatively connected to the support struts 55 of the ram 40. The guide rails 50 and 52 help to maintain lateral alignment of the ram 40 with the tooling array 46 and guide the ram along the frame. Thus, the ram 40 is movable along the frame 14 on the bridge beam 36 and the guide rails 50 and 52.
A positioning member 42 is supported on the frame and on the top side of the table 20. The positioning member 42 is used to move the work piece 90 on the table in a gap 44 formed between the tooling array 46 and the die array 48. The positioning member 42 clamps onto the work piece 90 to secure it relative to a reference point in the x,y coordinate system defined by the table. The positioning member 42 may then move the work piece on the table in the plane defined by the table 20.
Referring to
Turning now to
As shown in
The tool assembly 54 may further comprise a third sleeve 78 supported within the tool support member 56 and a fourth sleeve 80 supported by the die support member 58. As shown in
The first, second, third and fourth sleeves 68, 70, 78, and 80 each have opposed first and second ends and a hollow region extending end-to-end. The hollow region of each sleeve has the same uniform cross-sectional dimension from end-to-end. In a preferred embodiment each sleeve comprises a precision bushing constructed from hardened steel and machined to a tolerance of +0.0002 inches, −0.0000 inches, on the inner diameter.
Continuing with
The striper plate 82 is positioned between the tool support member 56 and the die support member 58. The stripper plate 82 is biased away from the tool support member 56 using a plurality of elastic members 88. The elastic members 88 may comprise heavy duty springs that function to separate the first end 62 of the tool 60 from the work piece 90 during operation. Each spring 88 has opposing first and second ends. The first end of each spring 88 is connected to the tool support member 56 and the second end of the spring is connected to the stripper plate 82. The biasing action of the springs 88 drives the stripper plate 82 away from the tool support member 56. This causes the work piece 90 to be driven away from the tool support member 56 and the first end of the tool 60 after the ram has compressed the springs and forced at least one tool 60 into a work piece 90, as shown in
A second elongate member 92 is positioned within both the third sleeve 78 and the fourth sleeve 80 to align the sleeves and second elongate member along a second indexing line 94 that is parallel to the first line 74 and first indexing line 76. Both the first 72 and second 92 elongate members have opposed first and second ends and an outer profile of uniform cross-sectional dimension along their length. Both elongate members 72 and 92 may be constructed from hardened steel rods. Each elongate member 72 and 92 may have a cross-sectional dimension that closely conforms to the maximum cross-sectional dimension of the hollow regions of sleeves 68, 70, 78, and 80. Accordingly, the elongate members are precision ground to 0.001 inches less than the maximum cross-sectional dimension of the hollow regions of the sleeves.
Referring to
Each of the tool and die pairs are configured to perform metal removal or forming of sheet metal. The tool and die pairs may comprise a punch and die set, a form tool and form die set, a roll forming tool and form die set, an etching or marking tool and flat surface die set, or other tooling used in sheet metal fabrication. In addition to different types of tools, the tool array may include a mix and match of any of the above described tool and die pairs and in a variety of sizes.
The first end 62 of the tool 60 comprises a work face 96 that is configured to engage the work piece 90. The second end of the tool 60 is generally covered by an adjustable cap 98. The cap has an open first end and a closed second end. As shown in
With continuing reference to
Next, a machine controller is accessed to move the ram 40 and any other components out of the way to expose the location of installation in the tooling array 46 of the machine. As used herein the machine controller comprises the software, actuators, and processors used to control the function of the machine. The length of the tool and cap combination is adjusted to a desired length by rotating the threaded cap clockwise or counter clockwise until a desired length is obtained. A hold down screw 106 (
Next, a new or replacement light duty spring 104 may be installed in the top portion 102 and the new tool is installed in the tool support member as shown in
A mating stripper plate insert 84 is selected and installed in the stripper plate 82. The tool 60 is then depressed through the installed stripper plate insert 84 and the hold down screw 106 is turned ¼ turn to lock the tool 60, spring 104, and cap 98 in place.
If a die 66 is already installed in the die support member 58 at the location corresponding to the newly installed tool, the old die must be removed from the die support member and a new die installed therein. If, as discussed above, the die is required to be oriented specifically to match the orientation of the toot the operator will align a key (not shown) with a corresponding key way (not shown). Once properly oriented, the die may be dropped into the die support member.
Once the tool 60 and die 66 have been installed in the tool assembly 54 the operator may access a tool array data table for the selected tooling assembly 54 and enter an alphanumeric identifier for the tool assembly to select the desired assembly and then enter a zero (0) value into the “Actual Usage,” “Nominal Applied Load,” and “Last Applied Load” fields for the installed tool. This information is important for tracking usage of the tool and die as discussed herein below. Finally, if any additional tools and dies need to be installed the operator may do so and enter the same information into the tool data array table to reset the values for any newly installed tools and dies.
Once the tool or tools have been installed, the tool assembly may be installed on the frame of the machine. The operator may access the machine controller and command the location for installation of the tool assembly to be exposed. If a tool assembly 54 is already installed in the desired location the operator will first remove the die support member 58 by removing fasteners 110 that are used to secure the die support member to the bolster 27. The fasteners 110 may comprise screws that have a hex shaped head. The fasteners 110 may be removed using a tool 112 that is elongate and able to extend through both the tool support member 56 and the stripper plate 82 into counter bores 114 (
Once the components of the previous tool assembly 54 have been removed the tool support member 56 may be positioned onto the tool support member rail 120. Proper location and orientation of the tool support member is ensured by alignment holes 122 (
Each of the sixteen (16) die support members are attached to a separate bolster frame 27 by threading the fasteners HO into bolster frame 27. The fasteners are threaded in to attach the die support member to the bolster frame 27, but are not initially torqued-down to secure the die support member at this point. Once the die support member 58 is attached to the bolster frame 27, the tool support member 56 is lowered until the striper plate 82 engages the die support member. The first elongate member 72 is inserted into the first sleeve 68 and pushed down until seated through the die support member 58 through the second sleeve 70. The second elongate member 92 is then inserted through the third sleeve 78 and seated in the die support member through the fourth sleeve 80. Insertion of the elongate members as described herein precisely aligns the tool support member 56 and the die support member 58 as well as each tool 60 and die 66 pair supported therein.
With the first and second elongate members in place, the hand tool 112 is used to torque down fasteners 110 to secure the die support member 58 to the bolster frame 27. The elongate members 72 and 92 may be removed from the tool assembly 54 and the tool support member 56 is raised to lift the stripper plate 82 from the surface of the die support member 58. Once the tool assembly has been installed properly, the operator may load data related to the tool assembly into the machine controller's memory to specify the precise location of the tool assembly within the array.
After the tool assembly 54 is installed in the array, a “T#” is assigned to each tool in the tool support member 56. The T# identifies the selected tool and the position of the tool support member 56 in the array. An operator program may be installed on the controller that allows the operator to control many of the machine functions. The operator program may comprise a list of alphanumeric codes developed and assigned by the operator and executed by the controller to cause motion and machine functions to occur. The machine controller identifies the location of the selected tooling assembly 54 in the array and positions the ram 40 at the location on the rails 50 and 52 and bridge beam 38 to utilize the selected tool assembly. Using the number in the T# designation the machine controller can identify the tool and die pair for use and refers to the tool assembly data table to retrieve information relating to the distance from the alignment pin 124 to the first line 74, the total clearance, an appropriate surface for selector 126 to use when the ram engages the tool, and the tool identification. A selector appropriate for use with the machine of the present invention is disclosed in U.S. Pat. No. 6,868,767 entitled “Flexible Manufacturing Process Assembly” issued to Dunn (“the Dunn Patent”), the entire contents of which are incorporated herein by this reference.
The controller uses the T# to determine the location of the selected tool and die pair in the tool assembly and positions the selector 126 using the X to index value from the tool assembly data table for the selected tool number. As used herein, the term “X to index” means the distance from the first line to the alignment pin 124 on the interior end of the tooling support member in the X axis. Using the T#, the controller determines the face of the selector 126 appropriate for the selected tool and rotates the selector 126 to present the correct face to the cap 98.
After the selector is positioned and presented to the cap 98, the controller accesses the tool assembly data table and executes several decisions based on the available data. The controller checks to make sure the total clearance between the first end of the tool and the die is at or near a recommended value for the tool and die pair. If the total clearance is not at or near the recommended value the machine controller alerts the operator to change the tool 60 or modify the value input for the thickness of the work piece 90. In response, the operator may change the tool as described above, alter the material thickness, or override the clearance warning. Once the operator takes one of the preceding actions, the machine controller will execute an evaluation of tool and die pair wear. The machine controller then calculates an offset for the first line 74 of the tool and die pair by combining the offset for X and Y axes to alignment pin 124 from the tool assembly data table.
As discussed hereinafter, the machine controller applies the offset to all X and Y command positions. Finally, the tool support member is clamped to the ram 40 with the selected tool 60 depressed for use. As shown in
When the ram 40 has been clamped to the tool support member 56 the ram, tool support member 56, and tool 60 form a single connected chain that moves in concert when the ram is activated to punch the tool through the work piece 90. Clamping of the ram to the tool support member is the only time the tool is moved down relative to the tool support member within the tool bore.
The components are lowered until the stripper plate 82, attached to the tool support member 56, reaches a preselected distance from the upper surface of the die support member 58. This distance is stored in the data block table at “Hover Height.” Once the predetermined hover height is reached the ram stops lowering. The stripper plate is shown at hover height in
After being clamped together and lowered to the hover height, the ram may be activated to drive the tool and tool support member toward the work piece 90 to engage the first end of the tool with the work piece. As shown in
The ram 40 may be unclamped and raised to cause the selector to disengage the cap 98 when the operator is finished with the selected tool. This permits the tool 60 to move upward relative to the tool support member 56 to the position shown by the unselected tool(s) in
In accordance with the present invention, tool and die wear is monitored by the machine controller. The tool data table is populated with information including the tool identification, amount of usage, recommended usage, nominal peak force, last peak force, and allowed deviation. The machine controller uses this information to control selection and usage of tools positioned within the tool array. For example, when the selected tool reaches a usage number that is greater than the recommended usage, the controller will determine if an alternative identical tool is available in the array. The operator is alerted to change the tool if an alternative identical tool is not available. However, if an identical tool is available in the array the controller will move the ram 40 and selector 126 to the location of the alternative tool and engage use of that tool for further fabrication operations. The controller records every strike of a tool against the work piece 90. When the usage of any tool meets or exceeds the usage or force parameters listed above, the controller will either alert the operator to change the tool and die or select an alternative identical tool and continue operations.
In accordance with the present invention an operation program is disclosed herein to manage operation and usage of the tools in the tooling array 46. The operation program described is described herein to illustrate a preferred use of the machine disclosed herein. The designations and codes used herein are used for purposes of illustration only and are not intended to be limiting in any way.
The operation program may comprise a list of codes executed by the controller in an order of occurrence to cause machine operation and machine function. The codes generally comprise an alphanumeric character followed by a numeric value associated with character. For example the code G# may mean a general instruction to the machine indicating an activity associated with motion or mode of operation of the axes. M# may comprise an instruction to the machine to command execution of machine program control functions such as tool change, ram actions, program pause, stop, or end. X# may be used to indicate position or distance for X axis moves or reference points. The number associated with “X” is typically a real number having four decimal places of precision. Additional axis designations used may be “Y, Z, A, B, and C.” As discussed above “T#” may be used to indicate the selected tool.
The following example is provided to show operation of the machine. The ram punches a hole 6.5 inches from the clamped edge and 4.25 inches from the edge of the work piece 90 nearest the front 134 (
To begin, the code M06 T0218 may be read to select tool 18 in the second tool array. The ram and selector will be engaged to move to the appropriate tool and lock the ram to the tool support member and depress the selected tool. After the selected tool has been clamped, Code M06 may be executed to activate an auto cycle function to monitor axis motion and execute a punch cycle when the work piece is moved by the positioning member 42 to the desired x,y axis location and execute the punch cycle of the ram 40. Next, Code G00 X6.5 Y 4.25 is read to execute axis motion of the positioning member 42 to position the work piece at the desired axis coordinates, centered at the first line 74. During the punch cycle the peak force and one incident of use of the tool are read and recorded in the data table.
Next Code M61 is read to deactivate the punch after the punch cycle. If the tool is finished working, Code M07 is executed to instruct the machine to deselect the tool and unclamp and retract the tool support member 56. Code G28 is executed to return the work piece to a load or unload position. Code M30 is executed to end the program.
It should be appreciated by those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope and spirit of the invention. It is intended that the present invention cover such modifications and variations as come within the scope and spirit of the appended claims and their equivalents.
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 62/192,096 filed on Jul. 14, 2015, the entire contents of which are incorporated herein by reference.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2016/042258 | 7/14/2016 | WO | 00 |
| Number | Date | Country | |
|---|---|---|---|
| 62192096 | Jul 2015 | US |
