Patent Application
20220126382
The present application claims priority under 35 U.S.C. § 119 to Japanese Patent Application No. 2020-177866 filed on Oct. 23, 2020. The above application is hereby expressly incorporated by reference, in its entirety, into the present application.
The present invention relates to a scrap cutter, and more particularly to a scrap cutter capable of cutting scrap material fed from a press machine with high efficiency and high speed.
The types of scrap cutters include: a scrap cutter which cuts scrap materials between a fixed blade and a moving blade (cutter blade) which is reciprocated in the vertical direction by a crank mechanism or the like; and a scrap cutter having a structure in which a cutter blade is directly attached to a lower end of a connecting rod connected to a crankshaft and is pin-guided in the vertical direction toward the vicinity of the cutter part.
Furthermore, some cutter blades have a shear angle of 0 degrees and other cutter blades have a certain shear angle. Here, the shear angle is an angle formed by the moving blade and the fixed blade.
In a case where the shear angle is 0 degrees or as the shear angle becomes small, a greater press capacity is required at the time of cutting. This requires a greater mechanical rigidity of the cutter apparatus itself and also increases the inertia of the drive unit. Therefore, this structure is not suitable for high speed operation. In contrast, as the shear angle becomes larger, the stroke of the moving blade from a start to an end of cutting increases. Because this increases the apparatus size, the structure is not suitable for high speed operation.
On the other hand, Japanese Patent Application Laid-Open No. 2009-107096 proposes a cutting machine that drives a cutter blade by a link mechanism.
The cutting machine according to Japanese Patent Application Laid-Open No. 2009-107096 is a cutting machine that cuts a thin work by causing a moving blade facing a fixed blade to cross the fixed blade. The cutting machine is configured as a four-link mechanism in which the moving blade (blade holder) is pivotally supported by two swing arms and suspended from a machine base. One of the two swing arms swings by a crank mechanism. The moving blade descends while swinging, and the moving blade diagonally crosses the fixed blade while gradually reducing the cutting angle (shear angle) of the moving blade, thereby sequentially performing pull-cut of the work from one end to the other end.
In the cutting machine according to Japanese Patent Application Laid-Open No. 2009-107096, the moving blade descends while being swung by the four-link mechanism so that the moving blade diagonally crosses the fixed blade while gradually reducing the cutting angle of the moving blade, thereby sequentially performing pull-cut of the work from one end to the other end. However, because the blade holder including the moving blade swings, left-right vibration is generated and the machine is not suitable for high speed operation.
In addition, the cutting machine according to Japanese Patent Application Laid-Open No. 2009-107096 gradually reduces the cutting angle (shear angle) of the moving blade by swinging the moving blade at the time of cutting the work. As a result, it can eliminate or reduce breakage of the cut section of the work at the final stage of cutting to make the cut surface uniform and fine. However, the reason why the shear angle is gradually reduced is not in consideration of the press capacity at the time of cutting.
The present invention has been made in view of such circumstances, and aims to provide a scrap cutter capable of cutting a scrap material fed from a press machine with high efficiency and high speed.
In order to achieving the above object, an invention according to a first aspect is a scrap cutter provided in a subsequent stage of a press machine and configured to cut a scrap material fed from the press machine, the scrap cutter including: a slide configured to be driven to reciprocate in the vertical direction by a crank mechanism; an upper blade attached to the slide; and a lower blade attached to a fixed part and configured to cut the scrap material in cooperation with the upper blade, wherein a shear angle formed by the upper blade and the lower blade has an angle which gradually decreases from a start of cutting of the scrap material toward an end of cutting of the scrap material, and allows a driving torque of a crankshaft of the crank mechanism to be constant from the start of cutting to the end of cutting in a case where a scrap material of a cutting capacity limit is cut.
According to the first aspect of the present invention, the shear angle has an angle which gradually decreases from the start of cutting the scrap material toward the end of cutting the scrap material, and allows the driving torque of the crankshaft of the crank mechanism that drives the slide having an upper blade attached thereto to reciprocate in the vertical direction to be constant, particularly in a case where the scrap material of the cutting capacity limit is cut. Therefore, it is possible to minimize the driving torque of the crankshaft in cutting the scrap material of the cutting capacity limit, minimize the inertia, stroke and vibration, and downsize the scrap cutter. As a result, the scrap material can be cut with high efficiency and high speed.
In the scrap cutter according to a second aspect of the present invention, the scrap material of the cutting capacity limit is determined by a thickness and a shear resistance of a material.
Because the shear angle is determined based on the scrap material of the cutting capacity limit, the scrap cutter according to the present invention can naturally cut scrap materials within the cutting capacity limit with high efficiency and high speed.
In the scrap cutter according to a third aspect of the present invention, the tangential force F in a tangential direction of the crankshaft is expressed by the following expression
F=T/r
where T represents the driving torque applied to the crankshaft of the crank mechanism, and r represents the crank radius of the crankshaft,
a pushing force P by the upper blade is expressed by the following expression
P=F/(sin θ*n*s)=T/(r*sin θ*n*s)
where θ represents a rotation angle from the top dead center of the crankshaft, n equals 1 for an asymmetrically inclined blade and equals 2 for a symmetrically inclined blade, and s represents a safety factor, and
the shear angle α is expressed by the following expression
α=−tan−1(Kfc*t2/2P)=−tan−1(Kfc*t2*n*s*r*sin θ/2T)
where t represents a thickness of the scrap material of the cutting capacity limit, and Kfc represents a shear resistance of the scrap material of the cutting capacity limit. The sign * in the above expressions means multiplication.
In the scrap cutter according to a fourth aspect of the present invention, in an xy coordinate system in which an x-axis is a longitudinal direction of a cutter blade which is at least one of the upper blade and the lower blade, and a y-axis is a direction orthogonal to the x-axis, a coordinate (x, y) on a cutting edge of the cutter blade is expressed by the following expressions
x=(r/A)*(η−θ), and
y=−r(1+cos θ)
where A=Kfc*C*n*s*r/2T.
In a case where the blade shape of the cutter blade is represented by the coordinates (x, y) on the cutting edge of the cutter blade in the xy coordinate system and the other blade has a horizontal shape, the upper blade and the lower blade form the above-described shear angle α.
In the scrap cutter according to a fifth aspect of the present invention, the crank mechanism is preferably a Scotch yoke mechanism.
In the scrap cutter according to a sixth aspect of the present invention, at least one of the upper blade and the lower blade is a cutter blade having an asymmetrically inclined blade that is asymmetric with respect to a center of the cutter blade, or a symmetrically inclined blade that is symmetrical with respect to the center of the cutter blade.
The cutter blade may be an asymmetrically inclined blade (single-edged blade), or may be a symmetrically inclined blade (double-edged blade). The single-edged blade has an inclination angle different from that of the double-edged blade. However, The single-edged blade has the same height of the blade, as the double-edged blade.
According to the present invention, the shear angle formed by the upper blade and lower blade is optimized so that the scrap material fed from the press machine can be cut with high efficiency and high speed.
Preferred embodiments of scrap cutters according to the present invention is to be described below in detail with reference to the accompanying drawings.
The press line shown in
The uncoiler 10 is a material supply apparatus that unwinds a material wound around a drum in a coil shape (coil material) and supplies the unwound coil material while controlling the bending of the coil material.
The leveler 20 is arranged between the uncoiler 10 and the feeder 30. The leveler 20 holds (sandwiches) the coil material between a plurality of alternately arranged rolls, and alternately deforms the coil material in the vertical direction to remove the strain from the coil material having curl.
The feeder 30 is a material feeding apparatus that feeds the coil material into the die of the press machine 40 at regular intervals.
The press machine 40 performs operation such as cutting-out the outer shapes of the products from the coil material.
The scrap cutter 50 is provided in the subsequent stage of the press machine 40. The scrap cutter 50 cuts a scrap material (punching scrap of the coil material) fed from the press machine 40 into a size that is easy to handle, and discharges the cut scrap material to the waste material conveyor 60. The scrap cutter 50 of the example is operated in synchronization with the press machine 40.
As shown in
The Scotch yoke mechanism 57 according to the example includes: a slider 58; and a crankshaft 59. The slide 58 is provided so as to be movable in the left-right direction, in a rectangular opening MA formed in the slide 54. Here, the left-right direction is a direction orthogonal to the vertical direction, and the vertical direction is the moving direction of the slide 54. To the crankshaft 59, rotational driving force is transmitted from a servomotor (not shown), and an eccentric part 59A of the crankshaft 59 is rotatably inserted into the slider 58 via a bearing.
In the Scotch yoke mechanism 57, one rotation of the crankshaft 59 once reciprocates the slider 58 in the vertical direction and in the left-right direction, depending on the amount of eccentricity (crank radius) of the eccentric part 59A. The movement of the slider 58 in the left-right direction is not transmitted to the slide 54 by the opening 54A formed in the slide 54, and only the movement of the slider 58 in the vertical direction is transmitted to the slide 54, so that the slide 54 is driven to reciprocate in the vertical direction.
Because the Scotch yoke mechanism 57 is used as the crank mechanism, the motion of the upper blade 55, which is the moving blade, turns into a sine motion. In addition, because the driving force is transmitted only in the vertical direction to the slide 54 to which the upper blade 55 is attached, it is possible to suppress the left-right vibration.
The scrap material fed from the press machine 40 is set between the upper blade 55 and the lower blade 56 of the scrap cutter 50 during a period when there is a gap between the upper blade 55 and the lower blade 56 (for example, the period in the range of ±90 degrees where 0 degree represents the rotation angle of the crankshaft 59 when the slide 54 is located at the top dead center), and then, the scrap material is cut with the descending upper blade 55 which works in cooperation with the lower blade 56.
Next, description is to be made on the blade shape of cutter blade which is at least one of the upper blade 55 and the lower blade 56. Here, the blade shape of the cutter blade described below is for the blade shape of the upper blade 55.
The scrap cutter 50 cuts various scrap materials having various materials, plate thicknesses, and the like. The scrap cutter according to the present example has a shear angle formed by the upper blade 55 and the lower blade 56 designed as shown below so as to highly efficiently cut a scrap material of an allowable limit of the cutting capacity (a scrap material of a cutting capacity limit).
The shear angle formed by the upper blade 55 and the lower blade 56 is applied to the scrap cutter 50. The shear angle gradually decreases from a start of cutting of the scrap material toward an end of cutting so as to allow the driving torque of the crankshaft of the crank mechanism to be constant from the start of cutting to the end of cutting in a case where the scrap material of the cutting capacity limit is cut.
With reference to
F=T/r
wherein:
T represents the driving torque applied to the crankshaft; and
r represents the crank radius.
Furthermore, the pushing force P by the cutter blade is expressed by the following expression
P=F/(sin θ*n*s)=T/(r*sin θ*n*s) [Expression 1]
wherein:
θ represents a rotation angle from the top dead center of the crankshaft;
n is 1 for an asymmetrically inclined blade, and 2 for a symmetrically inclined blade; and
s represents a safety factor.
The cutter blade shown in
The cutter blade shown in
Part (A) shows the position of the upper blade 55 when the rotation angle of the crankshaft is an angle θa. The position of the upper blade 55 shown in Part (A) is the position when the upper blade 55 first comes into contact with the scrap material 70 after the upper blade 55 descends as the crankshaft rotates. Cutting of the scrap material 70 starts from this position of the upper blade 55.
Part (C) shows the position of the upper blade 55 when the rotation angle of the crankshaft is an angle θc.
The position of the upper blade 55 shown in Part (C) indicates the position when the uppermost point of the upper blade 55 (center of the upper blade 55) reaches the upper surface of the scrap material 70 after the upper blade 55 further descends.
Part (B) shows the position of the upper blade 55 when the rotation angle of the crankshaft is between the angle θa and the angle θc, where a part of the upper blade 55 reaches the lower surface of the scrap material 70. Here in Part (B), the reference signs 70A and 70B designate shear surfaces that can be sheared by the pushing force applied to the upper blade 55 at this position.
While the upper blade 55 moves from the position shown in Part (A) to the position shown in Part (C), the shear angle formed by the upper blade 55 and the lower blade 56 gradually decreases with the stroke of the upper blade 55. This allows the driving torque of the crankshaft of the crank mechanism to be constant in cutting the scrap material of the cutting capacity limit.
In addition, the stroke length k of the upper blade 55 from the position shown in Part (A) to the position shown in Part (C) (from the crankshaft angle θa to the crankshaft angle θc) is equal to a gap k created by the shear angle of the upper blade 55 between the uppermost point of the upper blade 55 and the upper surface of the scrap material 70 when the upper blade 55 is in the position shown in Part (A).
Part (E) shows the position of the upper blade 55 when the rotation angle of the crankshaft reaches the angle θe (the slide 54 is at the bottom dead center). When the upper blade 55 reaches the position shown in Part (E), the cutting of the scrap material 70 ends.
The stroke length of the upper blade 55 from the position shown in Part (C) to the position shown in Part (E) (crankshaft angle θc to angle θe) is the same as the plate thickness t of the scrap material 70.
Part (D) shows the position of the upper blade 55 when the rotation angle of the crankshaft is between the angle θc and the angle θe.
As the upper blade 55 descends from the position shown in Part (C) to the position shown in Part (E), the uncut part of the scrap material 70 gradually decreases in the height and width as shown in Part (C). Therefore, the pushing force of the upper blade 55 required for cutting the scrap material 70 between the position shown in Part (C) and the position shown in Part (E) also gradually decreases with the stroke of the upper blade 55, so that the crankshaft torque is sufficient therethrough.
In
S=P/Kfc=t
2/(2 tan α) [Expression 2]
wherein:
(−α) represents the shear angle corresponding to the inclination angle of the cutter blade;
t represents the plate thickness [mm] of the scrap material 70; and
Kfc represents a shear resistance [N/mm2].
By substituting [Expression 1] for P in [Expression 2] and converting the expression with respect to the shear angle α, the shear angle α can be expressed by the following expression.
α=−tan−1(Kfc*t2/2P)=−tan−1(Kfc*t2*n*s*r*sin θ/2T) [Expression 3]
The shear angle α indicated in [Expression 3] is an angle that gradually decreases from the start of cutting of the scrap material toward the end of cutting (with the rotation angle θ of the crankshaft being a variable). In addition, this shear angle α is an angle at which the scrap material can be cut with a constant driving torque T of the crankshaft (in a state where the maximum torque is output) from the start of cutting to the end of cutting, in cutting the scrap material of the cutting capacity limit which is determined by the plate thickness t and shear resistance Kfc.
The scrap cutter 50 having the above configuration can reduce the crankshaft driving torque T (rated torque of the servomotor that drives the crankshaft) required for cutting the scrap material of the cutting capacity limit. In addition, the scrap cutter 50 can reduce the inertia of the part including the slide 54 and the upper blade 55, that reciprocates in the vertical direction. Therefore, it is possible to cut the scrap material fed from the press machine with high efficiency and high speed.
Next, description is to be made on a case in which the blade shape of the cutter blade, which has an inclination corresponding to the shear angle α shown in [Expression 3], is defined in a two-dimensional coordinate. Here, the blade shape of the cutter blade is defined in an xy coordinate system in which the x-axis direction represents the longitudinal direction of the cutter blade and the y-axis direction represents the moving direction of the cutter blade.
[Expression 3] can be converted to the following expression.
α=−tan−1(A*sin θ)
∴ tan α=−A*sin θ [Expression 4]
wherein A represents Kfc*t2*n*s*r/2T in [Expression 3].
The inclination dy/dx of the cutting edge of the cutter blade in the xy coordinate system can be expressed by the following expression based on [Expression 4].
dy/dx=tan α=−A*sin θ [Expression 5]
On the other hand, the y coordinate on the cutting edge of the cutter blade is expressed by the following expression using the rotation angle θ of the crankshaft and the crank radius r.
y=−r(1+cos θ) [Expression 6]
When [Expression 6] is differentiated by θ, the result can be expressed by the following expression.
dy/dθ=r*sin θ [Expression 7]
From [Expression 5] and [Expression 7], the following expression is established.
dx/dθ=(dy/dθ)/(dy/dx)=(r*sin θ)/(−A*sin θ)=−r/A [Expression 8]
By integrating [Expression 8] by θ, the x coordinate on the cutting edge of the cutter blade can be expressed by the following expression.
x=−(r/A)*θ+C=−(r/A)*θ+(r/A)*π=(r/A)*(π−θ) [Expression 9]
wherein:
C represents integration constant; and
A=Kfc*t
2
*n*s*r/2T.
Therefore, the coordinates (x, y) on the cutting edge of the cutter blade can be expressed by the following expressions from [Expression 6] and [Expression 9].
x=(r/A)(π−θ)
y=−r(1+cos θ) [Expression 10]
wherein:
A=Kfc*t
2
*n*s*r/2T; and
θ varies from 0 to π
In addition, if y=−r(1+cos θ)=h, then
cos θ=−h/r−1
∴θ=cos−1(−h/r−1)
wherein h0≤h≤h1, h0 is the cutting end height, and h1 is the cutting start height.
Therefore, [Expression 10] can be converted to the following expression.
x=(r/A){π−cos−1(−h/r−1)}
y=h [Expression 11]
wherein A=Kfc*t2*n*s*r/2T.
The blade shape of the cutter blade can be calculated, for example, by appropriately giving constants and the variable h in [Expression 11]. The details are to be described below.
As shown in
Next, the x coordinate corresponding to each of the y coordinates on the cutting edge of the cutter blade is calculated under the condition that the constants shown below are entered into [Expression 11], and then the difference (h1−h0=6 [mm]) between the cutting start height h1 and the cutting end height h0 of the cutter blade is divided into 50 equal parts.
<Constants>
The driving torque T of the crankshaft: 70 [Nm]
The crank radius r: 12.5 [mm]
The shear resistance Kfc of the scrap material: 637 [N/mm2]
The plate thickness t of the scrap material: 0.3 [mm]
The blade shape (number of cuts) n: 2 (1 for the single-edged blade, 2 for the double-edged blade)
The cutting end height h0: 0 [mm]
The cutting start height h1: 6 [mm]
The safety factor s: 2
Y coordinates are obtained for 51 points on the cutting edge of the cutter blade in a case where the height of the cutter blade (difference between the cutting start height and the cutting end height) is divided into 50 equal parts. X coordinates corresponding to each of the y coordinates can be obtained by calculation.
In addition,
The graph in
[Others]
In the embodiment, a continuously changing inclination is provided to the upper blade (moving blade) without providing an inclination to the lower blade (fixed blade), so as to continuously change the shear angle α formed by the fixed blade and the moving blade from the start of cutting of the scrap material to the end of cutting. On the contrary, a continuously changing inclination may be provided to the fixed blade without providing an inclination to the moving blade, so as to continuously change the shear angle α formed by the fixed blade and the moving blade from the start of cutting of the scrap material to the end of cutting.
Furthermore, in the embodiment, the Scotch yoke mechanism is used as the crank mechanism for driving the upper blade (moving blade) to reciprocate in the vertical direction, but the present invention is not limited to this configuration. For example, a slide-crank mechanism in which the eccentric part of the crankshaft is connected to the slide with a connecting rod, may be applied. In a case where the conrod stroke ratio (connecting rod length/crank radius) of the slide-crank mechanism is large to some extent, the movement of the slide becomes substantially sinusoidal motion, so that the calculation expression used in the Scotch yoke mechanism can be used as it is. Note that a large conrod stroke ratio is suitable for high speed operation.
Furthermore, the present invention is not limited to the above-described embodiment. Needless to say, various modifications can be made without departing from the spirit of the present invention.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2020-177866 | Oct 2020 | JP | national |
