HARRELSON DARRELL B (US)
CLAIMS WE CLAIM: 1. A linear-actuated press machine for forming a part, comprising: a moveable press ram for holding a tool that forms the part; an first actuator for moving the moveable press ram by use of a first male-female thread mechanism for producing a linear movement of the moveable press ram, the first actuator including at least one first actuator sprocket for driving the first actuator, the at least one first actuator sprocket being coupled to the first male-female thread mechanism for rotating the first male-female thread mechanism; a first motor system for producing a low-speed high-force linear movement to the moveable press ram via the first actuator, the first motor system including a first motor, a first clutch operationally coupled to the first motor, a first motor sprocket operationally coupled to the first clutch, a first belt system coupling the first motor sprocket to the at least one first actuator sprocket; a second motor system for producing a high-speed low-force linear movement to the moveable press ram via the first actuator, the second motor system including a second motor, a second motor sprocket operationally coupled to the second motor, and a second belt system coupling the second motor sprocket to the at least one first actuator sprocket; an second actuator for moving the moveable press ram by use of a second male- female thread mechanism for producing the linear movement of the moveable press ram, the second actuator including at least one second actuator sprocket for driving the second actuator, the at least one second actuator sprocket being coupled to the second male-female thread mechanism for rotating the second male-female thread mechanism; a third motor system for producing, in conjunction with the first motor system, the low-speed high-force linear movement to the moveable press ram, the third motor system being coupled to the second actuator, the third motor system including a third motor, a second clutch operationally coupled to the third motor, a third motor sprocket operationally coupled to the second clutch, and a third belt system coupling the third motor sprocket to the at least one second actuator sprocket; and wherein, during the high-speed low-force linear movement of the second motor system to advance or retract the press ram relative to the part, (i) the first clutch is at least partially disengaged from the first motor to maintain a rotational speed of the first motor below a limit to reduce possible damage to the first motor, and (ii) the second clutch is at least partially disengaged from the third motor to maintain a rotational speed of the third motor below a limit to reduce possible damage to the third motor; and wherein, during the low-speed high-force linear movement of the first motor system and third motor system to form the part, (i) the first clutch is operationally engaged to transfer high torque from the first motor to the first linear actuator, and (ii) the second clutch is operationally engaged to transfer high torque from the third motor to the second linear actuator. 2. The press machine of claim 1, wherein the linear velocity for the press ram is at least about 400 inches per minute when advancing the press ram toward the to-be-formed part by use of the second motor system. 3. The press machine of claim 2, wherein the low-speed high-force linear movement of the first motor system and the third motor system provides at least 200 tons of force to the press ram for forming the part. 4. The press machine of claim 3, wherein the linear velocity of the press ram during the advancement with the second motor system is greater than 5 times the linear velocity of the press ram when forming the part with the first motor system and third motor system. 5. The press machine of claim 1, wherein the at least one first actuator sprocket includes two actuator sprockets, the first belt system couples the first motor sprocket to a first one of the two actuator sprockets, the second belt system couples the second motor sprocket to a second one of the two sprockets. 6. The press machine of claim 5, wherein the second belt system includes a single belt that engages the second one of the two sprockets and the second motor sprocket. 7. The press machine of claim 5, wherein the first motor system further includes an intermediate shaft on which the first clutch is mounted, the first belt system includes a plurality of belts, a first one of the plurality of belts couples the first motor sprocket to the intermediate shaft, a second one of the plurality of belts is coupled to the first one of the two sprockets. 8. The press machine of claim 7, wherein the first clutch is a bi-directional clutch which limits the rotational speed of the first motor in a first direction when the second motor system is advancing the press ram toward the part, and in a second direction when the second motor system is retracting the press ram away from the part. 9. The press machine of claim 1, wherein the male-female thread mechanism includes an actuator screw that rotates but remains linearly stationary and a nut that moves along the actuator screw, the press ram moves with the nut as the nut moves along the actuator screw as the actuator screw rotates. 10. The press machine of claim 1, further including a fourth motor system coupled to the second actuator that, in conjunction with the second motor system, delivers the high-speed low-force linear movement to the press ram for advancing the press ram toward the part and retracting the press ram from the part. 11. The press machine of claim 1, wherein the first and second clutches are bi- directional clutches that limit the rotational speeds of the first motor and the third motor in a first direction when the second motor system is advancing the press ram toward the part, and in a second direction when the second motor system is retracting the press ram away from the part. 12. A press system for forming a part, comprising: a first linear actuator having a first male-female screw arrangement and a first actuator rod that is coupled to the first male-female screw arrangement, the first actuator rod undergoing linear movement in response to rotational movement of the first male-female screw arrangement; a second linear actuator having a second male-female screw arrangement and a second actuator rod that is coupled to the second male-female screw arrangement the second actuator rod undergoing linear movement in response to rotational movement of the second male-female screw arrangement; a press ram that is coupled to the first actuator rod and the second actuator rod, the press ram for receiving a tool for forming the part, the press ram configured to undergo movement toward and away from the part in response to the corresponding linear movement of the first and second actuator rods; a high-speed motor coupled to the first male-female screw arrangement of the first linear actuator for providing a high-speed and low-force condition on the press ram, the high-speed motor for advancing the press ram toward the part and retracting the press ram from the part; a first high-torque motor coupled to the first male-female screw arrangement of the first linear actuator; a second high-torque motor coupled to the second male-female screw arrangement of the second linear actuator, the first and second high-torque motors for providing a low-speed and high-force condition on the press ram for forming the part; a first clutch that is operatively coupled to the first high-torque motor; a second clutch that is operatively coupled to the second high-torque motor; and wherein, while the high-speed motor is providing a high-speed and low-force condition on the press ram, the first and second clutches are partially or fully disengaging so as to reduce the rotational movement on the first and second high-torque motors. 13. The press machine of claim 12, wherein, in the low-speed and high-force condition, the press ram delivers in excess of 200 tons of force. 14. The press machine of claim 12, wherein the first and second clutches are bi- directional clutches which limit the rotational speed of the first and second high-torque motors in a first direction when advancing the press ram toward the part, and in a second direction when retracting the press ram away from the part. 15. The press machine of claim 12, further including a second high-speed motor coupled to the second male female screw arrangement for assisting with advancing the press ram toward the part and retracting the press ram from the part. 16. The press machine of claim 12, wherein each of the first and second male-female thread mechanisms includes an actuator screw that rotates but remains linearly stationary and a nut that moves along the actuator screw as the actuator screw rotates, the first and second actuator rods being coupled to a corresponding one of the nuts. 17. The press machine of claim 12, wherein the first clutch is located on a first intermediate shaft that is positioned away from a drive shaft of the first actuator and a drive shaft of the first high-torque motor, the second clutch is located on a second intermediate shaft that is positioned away from a drive shaft of the second actuator and a drive shaft of the second high-torque motor. 18. The press machine of claim 17, further including a first plurality of belts for coupling the first actuator, the first high-torque motor, and the first clutch, and further including a second plurality of belts for coupling the second actuator, the second high-torque motor, and the second clutch. 19. A press system for forming a part, comprising: a first linear actuator having a first male-female screw arrangement and a first actuator rod that is coupled to the first male-female screw arrangement, the first male-female thread mechanism includes a first actuator screw that rotates but remains linearly stationary and a first nut that moves along the first actuator screw as the first actuator screw rotates, the first actuator rod being coupled to the first nut, the first actuator rod undergoing linear movement in response to rotational movement of the first actuator screw; a second linear actuator having a second male-female screw arrangement and a second actuator rod that is coupled to the second male-female screw arrangement, the second male-female thread mechanism includes a second actuator screw that rotates but remains linearly stationary and a second nut that moves along the second actuator screw as the second actuator screw rotates, the second actuator rod being coupled to the second nut the second actuator rod undergoing linear movement in response to rotational movement of the second actuator screw; a press ram that is coupled to the first actuator rod and the second actuator rod, the press ram for receiving a tool for forming the part, the press ram configured to undergo movement toward and away from the part in response to the corresponding linear movement of the first and second actuator rods; a high-speed motor coupled to the first male-female screw arrangement of the first linear actuator for providing a high-speed and low-force condition on the press ram, the high-speed motor for advancing the press ram toward the part and retracting the press ram from the part; a first high-torque motor coupled to the first male-female screw arrangement of the first linear actuator; a second high-torque motor coupled to the second male-female screw arrangement of the second linear actuator, the first and second high-torque motors for providing a low-speed and high-force condition on the press ram for forming the part; a first clutch that is operatively coupled to the first high-torque motor, the first clutch being a bi-directional clutch which limits the rotational speed of the first high-torque motor in a first direction when the press ram advances toward the part, and in a second direction when the press ram retracts away from the part; a second clutch that is operatively coupled to the second high-torque motor, the second clutch being a bi-directional clutch which limits the rotational speed of the second high-torque motor in the first direction when the press ram advances toward the part, and in the second direction when the press ram retracts away from the part; and wherein, while the high-speed motor is providing a high-speed and low- force condition with a velocity of at least 400 inches per minute to the press ram, the first and second clutches are partially or fully disengaging so as to limit the rotational movement on the first and second high-torque motors; and wherein the first and second high-torque motors produce at least 200 tons of force for the press ram for forming the part. 20 The press machine of claim 19 further including a second high speed motor coupled to the second male-female screw arrangement for assisting with advancing the press ram toward the part and retracting the press ram from the part. 21. A method of operating a linear-actuated press machine for forming a part, the press machine comprises a first motor, a second motor, a linear actuator having a male-female thread mechanism, a press ram coupled to linear actuator and for holding a tool, and a clutch coupled to the first motor, the method comprising: driving the linear actuator with the second motor to advance the press ram toward the part in a low-force and high-linear-speed condition; while advancing the press ram toward the part in the low-force and high-linear- speed condition, partially or fully disengaging the clutch so as to reduce the rotational movement on the first motor; driving the linear actuator with the first motor to form the part with the tool in a high-force and low-linear-speed condition; after the part has been formed by the tool, retracting the tool from the part by use of at least the second motor; and while retracting the press ram from the part in a second low-force and high-linear- speed condition, partially or fully disengaging the clutch so as to reduce the rotational movement on the first motor. 22. The method of claim 21, wherein the clutch is a bi-directional clutch that reduces the rotational movement of the first motor in a first direction when the press ram is advancing toward the part and in a second direction when the press ram is retracting from the part. 23. The method of claim 21, wherein the driving the linear actuator with the first motor includes transferring torque via a first belt system, the first belt system including a first belt coupling the first motor and the clutch. 24. The method of claim 23, wherein the first belt system further includes at least a second belt for coupling the clutch to the linear actuator. 25. The method of claim 21, wherein the high-force and low-linear-speed condition delivers at least about 100 tons of force to form the part. 26. The method of claim 21, wherein the male-female thread mechanism includes an actuator screw that rotates but remains linearly stationary, the press ram is coupled to a nut that moves along the actuator screw as the actuator screw rotates. 27. A method of operating a linear-actuated press machine for forming a part, the press machine comprises a first motor, a second motor, a linear actuator having a male-female thread mechanism, a press ram coupled to linear actuator and for holding a tool, and a clutch coupled to the first motor, the method comprising: driving the linear actuator with the second motor to advance the press ram toward the part in a first low-force and high-linear-speed condition, the clutch being partially or fully disengaged so as to reduce the rotational movement on the first motor while the press ram is advancing toward the part in the first low-force and high-linear-speed condition; in response to the press ram being a distance “X” from the part, (i) reducing the rotational drive speed at the linear actuator provided by the second motor to reduce the linear velocity of the press ram and (ii) monitoring the rotational drive speed at the linear actuator with a second sensor; during the reducing and while the clutch remains partially or fully disengaged, operating the first motor and sensing a first motor rotational speed with a first sensor; in response to the first motor rotational speed being a value that should provide approximately the same rotational drive speed at the linear actuator as the rotational drive speed measured by the second sensor, engaging the clutch to provide a high-force and low-linear-speed condition to the press ram from the first motor; forming the part with the tool in the high-force and low-linear-speed condition; after the forming of the part, retracting the tool from the part by use of at least one of the first motor and the second motor; subsequent to the retracting, (i) increasing the velocity of the press ram in a direction away from the formed part by use of the second motor to create a second low-force and high-linear-speed condition, and (ii) partially or fully disengaging the clutch so as to limit the rotational movement on the first motor during the second low-force and high-linear-speed condition. 28. The method of claim 27, wherein at least one of the first low-force and high-linear- speed condition and the second low-force and high-linear-speed condition moves the press ram at greater than 400 inches per minute. 29. The method of claim 27, wherein the high-force and low-linear-speed condition causes at least 100 tons of force on the press ram. 30. The method of claim 28, wherein the second motor remains operational and contributes a portion of the overall force in the high-force and low-linear-speed condition. 31. The method of claim 27, wherein the second sensor is a second encoder. 32. The method of claim 31, wherein the second encoder is directly coupled to the second motor. 33. The method of claim 31, wherein the second encoder is associated with the linear actuator. 34. The method of claim 27, wherein the second sensor is a linear-movement sensor. 35. The method of claim 34, wherein the linear-movement sensor is associated with the linear actuator. 36. The method of claim 31, wherein the first sensor is a first encoder. 37. The method of claim 36, wherein the first encoder is directly coupled to the first motor. 38. A press system for forming a part, comprising: a first linear actuator having a first male-female screw arrangement and a first actuator rod that is coupled to the first male-female screw arrangement, the first actuator rod undergoing linear movement in response to rotational movement of the first male-female screw arrangement; a second linear actuator having a second male female screw arrangement and a second actuator rod that is coupled to the second male-female screw arrangement, the second actuator rod undergoing linear movement in response to rotational movement of the second male-female screw arrangement; a third linear actuator having a third male-female screw arrangement and a third actuator rod that is coupled to the third male-female screw arrangement, the third actuator rod undergoing linear movement in response to rotational movement of the third male-female screw arrangement; a press ram that is coupled to the first actuator rod, the second actuator rod, and the third actuator rod, the press ram for receiving a tool for forming the part, the press ram configured to undergo movement toward and away from the part in response to being driven by the first, second, and third actuator rods; a first motor coupled to the first male-female screw arrangement of the first linear actuator; a second motor coupled to the second male-female screw arrangement of the second linear actuator, the first and second motors are for providing a low-speed and high-force condition on the press ram for forming the part; a third motor coupled to the third male-female screw arrangement of the third linear actuator for providing a high-speed and low-force condition on the press ram, the third motor for advancing the press ram toward the part and retracting the press ram from the part; a first clutch that is operatively coupled to the first motor; a second clutch that is operatively coupled to the second motor; and wherein, while the third motor is providing a high-speed and low-force condition on the press ram, the first and second clutches are partially or fully disengaging so as to limit the rotational movement on the first and second motors, and wherein, during the low-speed and high-force condition from the first and second motors for forming the part, (i) the first clutch is operationally engaged to transfer high torque from the first motor to the first linear actuator, and (ii) the second clutch is operationally engaged to transfer high torque from the second motor to the second linear actuator. 39. The method of claim 38, wherein the high-speed and low-force condition moves the press ram at greater than 400 inches per minute. 40. The method of claim 39, wherein the low-speed and high-force condition causes at least 200 tons of force on the press ram. 41. A linear-actuated press machine for forming a part, comprising: a moveable press ram for holding a tool that forms the part; an actuator for moving the moveable press ram by use of a male-female thread mechanism for producing a linear movement of the moveable press ram, the actuator including at least one sprocket for driving the actuator, the at least one sprocket being coupled to the male-female thread mechanism for rotating the male-female thread mechanism; a first motor system for producing a low-speed high-force linear movement to the moveable press ram via the actuator, the first motor system including a first motor, a clutch operationally coupled to the first motor, and a first motor sprocket operationally coupled to the clutch; a second motor system for producing a high-speed low-force linear movement to the moveable press ram via the actuator, the second motor system including a second motor and a second motor sprocket operationally coupled to the second motor; a belt system for coupling the at least one actuator sprocket, the first motor sprocket, and the second motor sprocket; and wherein, during the high-speed low-force linear movement of the second motor system to advance or retract the press ram relative to the part, the clutch is at least partially disengaged from the first motor to maintain a rotational speed of the first motor below a limit to reduce possible damage to the first motor; and wherein, during the low-speed high-force linear movement of the first motor system to form the part, the clutch is operationally engaged to transfer high torque from the first motor to the linear actuator via the belt system. 42. The press machine of claim 41, wherein the linear velocity for the press ram is at least about 400 inches per minute when advancing the press ram toward the to be formed part by use of the second motor system. 43. The press machine of claim 42, wherein the low-speed high-force linear movement of the first motor system provides at least 100 tons of force via the press ram. 44. The press machine of claim 43, wherein the linear velocity of the press ram during the advancement with the second motor system is greater than 5 times the linear velocity of the press ram when forming the part with the first motor system. 45. The press machine of claim 41, wherein the belt system includes a single belt that engages the actuator sprocket, the first motor sprocket, and the second motor sprocket. 46. The press machine of claim 41, wherein the at least one actuator sprocket includes a first actuator sprocket and a second actuator sprocket, the belt system includes a first belt system that couples the first actuator sprocket and the first motor sprocket, and a second belt system that couples the second actuator sprocket and the second motor sprocket. 47. The press machine of claim 46, wherein the first belt system includes first and second intermediate sprockets that rotate on an intermediate shaft and a plurality of belts, the clutch being mounted on the intermediate shaft. 48. The press machine of claim 47, wherein the clutch is a bi-directional clutch which limits the rotational speed of the first motor in a first direction when the second motor system is advancing the press ram toward the part, and in a second direction when the second motor system is retracting the press ram away from the part. 49. The press machine of claim 46, wherein the male-female thread mechanism includes an actuator screw that rotates but remains linearly stationary, the press ram being coupled to a nut that moves along the actuator screw as the actuator screw rotates. 50. The press machine of claim 41, wherein the clutch is a bi-directional clutch which limits the rotational speed of the first motor in a first direction when the second motor system is advancing the press ram toward the part, and in a second direction when the second motor system is retracting the press ram away from the part 51. A linear-actuated press machine for forming a part, comprising: a moveable press ram for holding a tool that forms the part; an actuator for moving the moveable press ram by use of a male-female thread mechanism for producing a linear movement of the moveable press ram, the actuator including first and second actuator sprockets coupled to the male-female thread mechanism for rotating the male-female thread mechanism; a first motor drive system for producing a low-speed high-force linear movement to the moveable press ram via the actuator, the first motor drive system including a first motor for directly driving a first motor sprocket, a clutch located on an intermediate shaft that is positioned away from the first motor and the actuator, a first belt coupling the first motor sprocket to the intermediate shaft, and a second belt coupling the intermediate shaft to the first actuator sprocket; a second motor drive system for producing a high-speed low-force linear movement to the moveable press ram via the actuator, the second motor drive system including a second motor for directly driving a second motor sprocket and a third belt coupling the second motor sprocket to the second actuator sprocket; and wherein, in response to the high-speed low-force linear movement of the second motor drive system to advance or retract the press ram relative to the part, (i) the first actuator sprocket drives the second belt at a high rotational speed, and (ii) the clutch at least partially disengages the first motor to maintain a rotational speed of the first motor below a limit to reduce possible damage to the first motor; and wherein, in response to the low-speed high-force linear movement of the first motor system to form the part, the clutch is operationally engaged to transfer torque from the first motor to the first actuator sprocket of the linear actuator via the first and second belts. 52. The press machine of claim 51, wherein the linear velocity for the press ram is at least about 500 inches per minute when advancing the press ram toward the to-be-formed part by use of the second drive motor system 53. The press machine of claim 52, wherein the low-speed high-force linear movement of the first drive motor system provides at least 100 tons of force to the part. 54. The press machine of claim 53, wherein the linear velocity of the press ram during the advancement with the second drive motor system is greater than 5 times the linear velocity of the press ram when forming the part with the first drive motor system. 55. The press machine of claim 51, wherein the first motor drive system increases the torque output from the first motor to the actuator by a factor in the range of 3 to 7. 56. The press machine of claim 51, wherein the first actuator sprocket and the second actuator sprocket are adjacent to each other and mounted around an actuator input shaft. 57. The press machine of claim 56, wherein the first actuator sprocket has a larger diameter than the second actuator sprocket. 58. The press machine of claim 57, further including a mounting platform, the first and second motors being mounted to the mounting platform, the first actuator sprocket and the second actuator sprocket being on one side of the mounting platform and the moveable press ram being on the other side of the mounting platform. 59. The press machine of claim 51, wherein the male-female thread mechanism includes an actuator screw that rotates but remains linearly stationary, the press ram being coupled to a nut that moves along the actuator screw as the actuator screw rotates. 60. The press machine of claim 51, wherein the clutch is a bi-directional clutch that limits the rotational speed of the first motor (i) in a first direction when the second motor system is advancing the press ram toward the part and (ii) in a second direction when the second motor system is retracting the press ram away from the part. 61. A linear-actuated press machine for forming a part, comprising: a moveable press ram for holding a tool that forms the part; an actuator including an actuator rod and a male female thread mechanism the male-female thread mechanism including a rotatable screw and a nut that translates vertically along the rotatable screw, the actuator rod being coupled to the nut and to the moveable press ram, the actuator rod producing a linear movement of the moveable press ram, the actuator further including at least one actuator sprocket for driving the rotatable screw; a first motor drive system for producing a low-speed high-force linear movement to the moveable press ram via the actuator, the low-speed high-force linear movement causing greater than 100 tons of force to be delivered by the tool to the part, the first motor drive system including a first motor for directly driving a first motor sprocket, a bi-directional clutch located on an intermediate shaft that is positioned away from the first motor and the actuator, a first belt coupling the first motor sprocket to the intermediate shaft, and a second belt coupling the intermediate shaft to the at least one actuator sprocket; a second motor drive system for producing a high-speed low-force linear movement to the moveable press ram via the actuator, the second motor drive system including a second motor for directly driving a second motor sprocket and a third belt coupling the at least one actuator sprocket to the second actuator sprocket; and wherein, in response to the high-speed low-force linear movement of the second motor drive system advancing the press ram toward the part, (i) the at least one actuator sprocket drives the second belt at a high rotational speed in a first direction, and (ii) the bi-directional clutch at least partially disengages the first motor to maintain a rotational speed of the first motor below a limit to reduce possible damage to the first motor; wherein, in response to the low-speed high-force linear movement of the first motor system to form the part, the bi-directional clutch is operationally engaged to transfer torque from the first motor to the at least one actuator sprocket of the linear actuator via the first and second belts; wherein, in response to the high-speed low-force linear movement of the second motor drive system retracting the press ram from the part after the part has been formed, (i) the at least one actuator sprocket drives the second belt at a high rotational speed in a second direction that is opposite to the first direction, and (ii) the clutch at least partially disengages the first motor to maintain a rotational speed of the first motor below a limit to reduce possible damage to the first motor. 62. The press machine of claim 61, wherein the linear velocity for the press ram is at least about 500 inches per minute when advancing the press ram toward the to-be-formed part by use of the second motor drive system. 63. The press machine of claim 62, wherein the linear velocity of the press ram during the advancement with the second motor drive system is greater than 5 times the linear velocity of the press ram when forming the part with the first motor drive system. 64. The press machine of claim 61, wherein the first motor drive system increases the torque output from the first motor to the actuator by a factor in the range of 3 to 7. 65. The press machine of claim 61, wherein the at least one actuator sprocket includes a first actuator sprocket and a second actuator sprocket, the first actuator sprocket being coupled to the second belt, the second actuator sprocket being coupled to the third belt. 66. The press machine of claim 65, wherein the first actuator sprocket has a larger diameter than the second actuator sprocket. 67. The press machine of claim 65, wherein the first actuator sprocket and the second actuator sprocket are adjacent to each other and located at a first end of the actuator, the actuator rod moving away from a second end of the actuator and toward the part, the second end being opposite to the first end. 68. The press machine of claim 65, further including a mounting platform, the first and second motors being mounted to the mounting platform, the first actuator sprocket and the second actuator sprocket being on one side of the mounting platform and the moveable press ram being on the other side of the mounting platform. 69. The press machine of claim 65, further including a plurality of posts, the moving press ram moving along and being guided by the plurality of posts 70. A method of operating a linear-actuated press machine for forming a part, the press machine comprises a first motor, a second motor, a linear actuator having a male-female thread mechanism with a rotatable screw and a nut that moves along the rotatable screw, a press ram holding a tool and being coupled to the linear actuator via an actuator rod, the actuator rod being coupled to the nut, the method comprising: (i) driving the linear actuator with the second motor to advance the press ram toward the part in a low-force and high-linear-speed condition; (ii) while advancing the press ram toward the part in the low-force and high-linear- speed condition of the second motor, partially or fully disengaging a clutch so as to reduce the rotational movement on the first motor, the clutch being located on an intermediate shaft that is positioned away from the first motor and the linear actuator; (iii) subsequent to acts (i) and (ii), engaging the clutch to drive the linear actuator with the first motor to form the part with the tool in a low-speed and high-force linear movement condition, the low-speed and high-force linear movement condition causing greater than 100 tons of force to be delivered by the tool to the part; (iv) after the part has been formed by the tool, retracting the press ram from the part by use of the second motor; and (v) while retracting the press ram by use of the second motor, partially or fully disengaging the clutch so as to reduce the rotational movement on the first motor. 71. A press machine for forming a part, comprising: a moveable press ram for holding a tool that forms the part; an actuator for moving the moveable press ram, the actuator including a first male- female thread mechanism for producing a first linear movement of the moveable tool and a second male-female thread mechanism for producing a second linear movement of the movable press ram, the first linear movement being a high-force linear movement condition and the second linear movement being a high-speed linear movement condition; a first motor for driving the first male-female thread mechanism to produce the first linear movement; and a second motor for driving the second male-female thread mechanism to produce the second linear movement. 72. The press machine of claim 71, wherein the second motor is coupled to the press ram and moves with the moveable press ram. 73. The press machine of claim 72, further including a stationary press crown, the first motor is coupled to the stationary press crown. 74. The press machine of claim 71, wherein the actuator includes a first tube and a second tube that telescopically mate together to provide the linear movement to the moveable press ram. 75. The press machine of claim 74, wherein the second tube moves relative to the first tube when the second motor is in operation. 76. The press machine of claim 75, wherein the first tube and the second tube move together when the first motor is in operation. 77. The press machine of claim 71, wherein the first male-female thread mechanism includes a first threaded screw and a first roller nut, the first threaded screw rotates in response to the operation of the first motor and remains in the same location while rotating, the first roller nut linearly moves along the first threaded screw while the first threaded screw rotates. 78. The press machine of claim 77, wherein the second male-female thread mechanism includes a second threaded screw and a second roller nut, the second roller nut rotates in response to the operation of the second first motor, the second roller nut linearly moves along the second threaded screw while the second roller nut rotates. 79. The press machine of claim 78, wherein the second threaded screw is fixed to a structure connected to the first roller nut such that the second threaded screw linearly moves with the first roller nut while the first threaded screw rotates. 80 The press machine of claim 79 wherein the structure is a first tubular structure the first tubular structure telescopically slides along a second tube structure associated with the second roller nut. 81. A press machine for forming a part, comprising: a moveable press ram for holding a tool that assists in forming the part; an actuator for moving the moveable press ram by use of at least one male-female thread mechanism for producing a linear movement of the moveable press ram; a first motor for driving the actuator to produce a high-force linear movement condition to the moveable press ram; a second motor for driving the actuator to produce a high-speed linear movement condition to the moveable press ram; and wherein the first motor and the second motor linearly moves away from each other when the first motor is operational. 82. The press machine of claim 81, wherein the actuator includes a first tube and a second tube that telescopically mate together to provide the linear movement to the moveable press ram. 83. The press machine of claim 82, wherein the second tube moves relative to the first tube when the second motor is in operation. 84. The press machine of claim 83, wherein the first tube and the second tube move together when the first motor is in operation. 85. The press machine of claim 81, wherein the first male-female thread mechanism includes a first threaded screw and a first roller nut, the first threaded screw rotates in response to the operation of the first motor and remains in the same location while rotating, the first roller nut linearly moves along the first threaded screw while the first threaded screw rotates. 86. The press machine of claim 81, wherein the second motor is coupled to the press ram and moves with the moveable press ram. 87 The press machine of claim 86 further including a stationary press crown the first motor is coupled to the stationary press crown. 88. A method of operating a linear-actuated press machine for forming a part, the press machine comprises a first motor, a second motor, a linear actuator having a male-female thread mechanism, a tool coupled to the linear actuator, and a belt system coupling the first motor, the second motor, and the male-female thread mechanism, the method comprising: by use of the second motor and the belt system, advancing the tool toward the part in a low-force and high-linear-speed condition; while advancing the tool in the low-force and high-linear-speed condition, partially or fully disengaging the first motor from rotational movement caused by the belt system; by use of the first motor and the belt system, forming the part with the tool in a high-force and low-linear-speed condition; and after the part has been formed by the tool, retracting the tool from the part by use of at least one of the first motor and the second motor. 89. The method of claim 88, wherein the belt system includes a first motor sprocket, a second motor sprocket, and an actuator sprocket. 90. The method of claim 88, wherein the actuator includes a first tube and a second tube that telescopically mate together to provide the linear movement to the moveable press ram, the male-female thread mechanism includes a threaded screw and a roller nut, the first threaded screw rotates in response to the operation of the first motor and remains in the same location while rotating, the first roller nut linearly moves along the first threaded screw while the first threaded screw rotates. |
[0111] From the table above, with the overall force being constant at about 125 tons for all three press configurations, the additional power provided by the first and second motors 712 and 714 in the Press 2 and Press 3 configurations is used to increase the velocity of the actuator rod 722, especially when advancing the tool toward the to-be-formed part or retracting the tool from the formed part. Consequently, the efficiency of the press increases because less time is needed during the advancement and retraction of the actuator rod 722. The larger motors and reduced gear reduction result in faster travel speeds for the actuator rod 722. This enhances production rates by reducing travel time of the actuator for a given press stroke. [0112] As such, in one embodiment, the present invention contemplates a press with a single actuator configured that delivers in excess of 100 tons of force and has an actuator rod (and a press ram/tool) traveling at between 300-700 inches per minute during advancement and retraction. In another embodiment, when the actuator 720 of FIGS.11-13 delivers in excess of 100 tons of force to the press ram and has a total reduction factor (via gears and sprockets/belts) for the first motor 712 between 10 and 50, and a total reduction factor (via gears and sprockets/belts) for the second motor 714 between 1 and 8. In another embodiment, the press delivers in excess of 100 tons of force, has an actuator rod (and a press ram/tool) traveling at between 300-700 inches per minute during advancement and retraction, has a total reduction factor (via gears and sprockets/belts) for the first motor 712 between 10 and 50, and a total reduction factor (via gears and sprockets/belts) for the second motor 714 between 1 and 8. [0113] Like the actuator 320 from FIG.7, the actuator 720 can be used in various types of press machines (e.g., gib-style presses) and other metal bending machines, such as press brake machines and metal bending machines, in which a high-forces (e.g. +100 tons) are required. Furthermore, like the actuator 320 from FIG. 7, the actuator 720 can be used in multiple actuator arrangements, such as those shown in FIGS.9-10 and 14A-14B. [0114] FIGS 14A and 14B illustrate a gib-style press 900 that can deliver in excess of 200 tons of force (e.g., 250 tons) to the press ram 932 using a pair of actuators 720a and 720b. FIG. 14A illustrates the various pieces of the housing of the press 900 and also the upper enclosures 780a, 780b that protects the drive systems for the actuators 720a, 720b. FIG. 14A also illustrates an input/output device 935 associated with the control system for the press 900. The input/output device 935 includes hard keys and/or touch keys allowing the operator to input parameters for operation of the press 900, and a display for displaying information about the operation and diagnostics of the press 900. [0115] FIG. 14B illustrates the press 900 with the housing pieces removed and the upper enclosures 780a, 780b removed. The lower caps 760a are mounted to an intermediate press crown structure 937 in the press 900, while the lower part of the actuator rods 722a, 722b are coupled to the press ram 932. The left actuator 720a is arranged in an opposite fashion compared to the right actuator 720b. Thus, the fluid reservoirs 782a, 782b are on the outside of the actuators 720a, 720b, while the first motors 712a, 712b are directly adjacent to each other. This is different from the embodiment of FIGS.9A-9B in which the two actuators 320 have the same configuration, but are rotated 180 degrees from each other. [0116] FIG.15 illustrates a flow diagram of the operation of the press by use of the first encoder 772 and the second encoder 774 (FIG.11A). Based on information related to the to-be-formed part, the location of the to-be-formed part relative to the press ram (and the tool on the press ram) is known. During operation, the press ram/tool initially moves downwardly at a high rate of speed (e.g., 300-700 inches per minute) during the advancement stroke as it moves toward the part under the drive force of the second motor 714 (Step 1010). The second encoder 774 is used for detecting the linear position of the press ram/tool relative to the part by knowing the rotational positon of the second motor 714 (Step 1020). The first actuator sprocket 731 and the belt 743 associated with drive system of the first motor 712 are still being driven at a high rate of speed due by the second motor 714. During this high speed advancement, the clutch 726 is disengaged such that the belt 741 (FIG.11D) is not driving the first motor 712. [0117] In response to the press ram/tool being a known distance “X” from the to-be-formed part as detected by the second encoder 774, the second motor 714 decelerates from its high- speed condition (e.g., 400 inches per minute at the press ram/tool) to a speed that moves the press ram/tool at a linear speed that is associated with the operation of the first motor 712 (e.g., 75 inches per minute) (Step 1030). After or during this deceleration process of the second motor 714, the first motor 712 begins operation at a rotational velocity, as measured by the first encoder 772 that, but for the fact that the clutch 726 is disengaged, would normally result in a linear speed at the press ram/tool (eg 75 inches per minute) that is used to form the part with high force (e.g. in excess of 100 tons or 200 tons) (Step 1040). When the rotational speed on the intermediate shaft 738 from both drive sources (i.e., as driven by the belt 743 and the second motor 714 via the first actuator sprocket 731; and as driven by belt 741 and the first motor 712) is approximately the same, the clutch 726 engages so that the first actuator sprocket 731 is now receiving high-torque from the first motor 712. (Step 1050). This results in a smooth transition to the high-torque condition. At this point, the press ram/tool is a known distance “Y” relative to the part, as measured by the second encoder 774, wherein “Y” is less than “X”. The difference between “X” and “Y” relates to the amount of time it takes for the second motor 714 to decelerate from the high rate of speed to the rotational speed at which the first motor 712 is to operate. It should be noted again that, without a clutch 726 in the drive system associated with the first motor 712, the first motor 712 would be driven by the second motor 714 at a rate of speed (as dictated by the total reduction due to the pulleys and gear box) that would exceed the maximum rotational speed of the first motor and damage the first motor 712. [0118] By use of the second encoder 774, the press ram/tool are and are further advanced by a known distance “Z” that is needed to fully form the part (Step 1060). When forming the part, the first motor 712 is providing the majority of the force, but the second motor 714 may still be operational to help provide a smaller amount of force. In this preferred embodiment, the second motor 714 delivers less than 10% of the overall force to the press ram/tool, such as between 5% and 10% (i.e., the first motor 712 delivers greater than 90%, such as between 90% and 95%). When the press ram/tool has advanced the full distance “Z” to form the part, the first motor 712 and the second motor 714 are reversed to starting retracting the press ram/tool from the now-formed part. It should be noted that the velocity of the press ram/tool during the forming process preferably decrease at some point along the distance “Z” so that the advancement velocity is low (preferably near 0 inches per minute) at distance “Z” so that another smooth transition may occur as the press ram/tool is retracted. [0119] For at least some distance “A” during the retraction mode as measured by the first encoder 772 and/or the second encoder 772, the first motor 712 is preferably operational to ensure any contact-engagement force between the now-formed part and the tool is overcome by the high force provided by the first motor 712. (Step 1070). At a point at which the formed part is disengaged from the press-ram/tool, the clutch 726 is disengaged such that only the second motor 714 is driving the actuator 720. (Step 1080). The second motor 714 then accelerates to quickly retract the press-ram/tool from the now-formed part to its initial positon (Step 1090). When the clutch 726 is disengaged, the first motor 712 can move to a non- operational mode to reduce the power consumption of the system Alternatively the first motor 712 may continue to rotate as it waits for the next part to be formed. [0120] When the second motor 714 retracts the press-ram/tool, the formed part can be removed from the press and a new to-be-formed part is placed in the press (Step 1100). The process then repeats itself and, thus, when the press ram/tool is the known distance “X” from the next to-be-formed part as detected by the second encoder 774, the second motor 714 decelerates to a rate of speed that moves the press ram/tool at a linear speed associated with the operation of the first motor 712. The first motor 712 begins operation and the clutch 726 engages to allow the first motor 712 to apply the high force to the part. [0121] In this embodiment described relative to FIG. 15, the second encoder 774 associated with the second motor 714 is used for controlling the linear speed and location of the press- ram/tool, even when the first motor 712 is providing the high force condition and forming the part. On the other hand, the first encoder 772 is used to ensure that the first motor 712 is driving at the proper speed when the clutch 726 is engaged to provide a smooth transition when first motor 712 becomes operational to form the part. Because the second motor 714 is always rotating with the actuator shaft 730 (i.e., the second motor 714 is directly coupled to the actuator 720 via the belt 745), the second encoder 774 is used as the master encoder for the press machine. Further, because of the direct coupling of the actuator 720 and the second motor 714, there are less opportunities for tolerance issues in the drive system for the second motor 714 to cause errors in measuring the linear position (and, thus, the linear speed) of the actuator rod 720 via the second encoder 774. [0122] Though the methodology for driving the press ram in FIG.15 has been described using the second encoder 774 as the master sensor for determining the position (and, thus, the velocity of the press ram/tool), it should be understood that other sensors could be used as well. For example, a linear transducer or similar device may determine the position of the press ram directly from, the press ram, the actuator, or the actuator rod. Alternatively, an encoder could be used in conjunction with the screw or nut of the male-female connection within the actuator. Like the second encoder 774, all of these types of sensors provide a scalable digital output for determining the position of the press ram/tool. Further, these optional sensors would help to determine the rotational velocity of the shaft associated with the clutch 726 to dictate the rotational velocity that should be sensed by the first encoder 772 being the clutch 726 is engaged to ensure the drive speed at the actuator provided by the first motor 712 is approximately the same as the drive speed at the actuator provided by the second motor 714. [0123] FIG.16 illustrates an alternative linear actuated press system 1110 using three actuator arrangements each of which has a motor and a linear actuator A pair of first motors 1112a 1112b provides the low-speed/high force conditions and a second motor 1114 provides the high-speed/low-force conditions. In the first actuator arrangements, the first motors 1112a, 1112b are driving first linear actuators 1123a, 1123b by use of belts and sprockets. The first linear actuators 1123a, 1123b have male-female thread mechanisms (e.g., threaded screw-nut engagement used in the prior embodiments) for forming the part with a press ram 1132 and an upper tool 1142. In the second actuator arrangement, the second motor 1114 drives a second linear actuator 1127 having the male-female thread mechanism of the prior embodiments, thereby providing the high-speed/low-force condition to the press ram 1132 and the upper tool 1142 when advancing and retracting the press ram 1132 relative to the part. [0124] The second actuator 1127 is coupled to the second motor 1114 via a gear and/or sprocket system 1119, which is sized to provide enough force to advance the press ram 1132 upwardly and downwardly in a high-speed/low-force condition. In that high-speed/low-force condition, the pair of first motors 1112a, 1112b are still coupled to the press ram 1132 via the first linear actuators 1123a, 1123b, which are still operating at a high speed along with the press ram 1132. To minimize the potentially detrimental effects of the high-speed condition on the pair of first motors 1112a, 1112b, each of the first motors 1112a, 1112b includes a corresponding clutch 1126a, 1126b between the drive shaft of the first motors 1112a, 1112b and the drive shaft of the first linear actuators 1123a, 1123b. As shown in FIG. 16, the corresponding clutches 1126a, 1126b are coupled to the drive shaft of the first motors 1112a, 1112b, but they could also be placed on the shafts of the first linear actuators 1123a, 1123b. [0125] When high force is required as the press ram 1132 and tool 1142 closely approach or engage the to-be-formed part, the clutches 1126a, 1126b can be engaged to provide the high- force conditions from the pair of first motors 1112a, 1112b. During the high-force condition of the press cycle, the second motor 1114 and the second actuator 1127 may optionally be active and contribute to the total force applied to the upper tool 1142 within the press ram 1132. Thus, the embodiment of FIG. 16 is a three-actuator system in which the clutches 1126 are used to reduce the speed at which the low-speed/high-force actuators 1123 drives the pair of first motors 1112 when the press ram 132 is moving quickly in the advancement or retraction mode due to the second motor 1114. [0126] The alternative press system 1110 of FIG.16 is advantageous when multiple high-force actuators are needed to provide a high press force output to the press ram 1132. For example, if the press system 1110 is required to generate in excess of 400 tons of force to the press ram 1132 to form the part, the press system 1110 can include four of the first motors 1112 (and four first actuators 1123) to produce at least 400 tons of force (each first motor 1112 delivering at least 100 tons). However, the press system 1110 would only need a single second motor 1114 and corresponding second actuator 1127 to provide the high-speed advancement and retraction of the press ram 1132 (i.e., five total motors for the press system 1110). If the mass of the press ram 1132 is high, then an additional second motor 1114 may be added to provide the high- speed advancement and retraction of the press ram 1132 (i.e., six total motors for the press system 1110). The clutches 1126 associated with the first motors 1112 limit the rotational speed of the first motors 1112 to acceptable RPMs despite the male-female threaded mechanism of the first linear actuators 1123 rotating at high RPMs during the high-speed advancement and retraction of the press ram 1132 caused by the second motor 1114. [0127] In the press machines with the multi-speed linear actuators in accordance to the previous embodiments of FIGS.1-16, the downward force can result in 75 tons, 100 tons, 125 tons, 150 tons, 175 tons, 200 tons or more than 200 tons of force on the part in the working stroke driven by the first motor(s). In one embodiment, the force provided by the linear actuators of the press machine is at least 50 tons, but preferably more than 100 tons. Press machine systems using multiple actuators (e.g., FIGS.9 and 10) can deliver in excess 200 tons, 300 tons, 400 tons, or 500 tons by adding additional actuators with high-torque, low-speed motor systems. Further, the linear press machines will provide a linear velocity of the press ram (and upper tool) via the actuator typically in the range of 300 to 700 inches per minute in the advancement and retraction strokes driven by the second motor(s). In one embodiment, the velocity of the actuator is at least 250 inches per minute, is preferably greater than 400 inches per minute, is preferably greater than 500 inches per minute, and is most preferably greater than 750 inches per minute (such as 800 or 900 inches per minute) in the advancement and retraction strokes. In these embodiments, the linear velocity of the linear actuator and, hence, the press ram in the advancement stroke is: greater than about 4 times the linear velocity in the working stroke when the part is being formed, greater than about 5 times the linear velocity in the working stroke when the part is being formed, greater than about 6 times the linear velocity in the working stroke when the part is being formed, greater than about 7 times the linear velocity in the working stroke when the part is being formed, greater than about 8 times the linear velocity in the working stroke when the part is being formed, greater than about 9 times the linear velocity in the working stroke when the part is being formed, or greater than about 10 times the linear velocity in the working stroke when the part is being formed. [0128] In the previous embodiments, the pulleys and belts can be interchanged with gears or other drive systems. Similarly, the sprockets and belts can be interchanged with gears or other drive systems [0129] As shown in the figures, the multi-speed linear actuators of the present invention are contemplated for use on the press machines in which the press ram slides along posts, such as a four-post press (all four posts can be seen, for example, in FIG. 8) or a two-post press. Furthermore, the present invention is also contemplated for use on the press machines in which the press ram moves along gibs (e.g., wedge-shaped gibs) in the frame that guide the reciprocating motion of the press ram, such as those shown in FIGS.9 and 14. [0130] In the embodiments above, the high-speed motor system causes the press ram to move at a high velocity during the advancement stroke toward the to-be-formed part, and/or the retraction stroke from the now-formed part. However, because the high-force motor system(s) that is needed to form the part is still coupled to the same press ram via the same actuator used by the high-speed motor system or a parallel actuator that is also coupled to the press ram, the high velocity of the press ram in the advancement and/or retraction stroke would cause the high-force motors (via the sprockets, belts, gears) to rotate at rotational speeds that exceed their limits and would damage them. The use of the clutches and specific locations within the high- force motor system(s) allow those motors to disengage and limit their rotational speeds in the advancement and/or retraction strokes. [0131] These embodiments and obvious variations thereof is contemplated as falling within the spirit and scope of the claimed invention, which is set forth in the following claims. Moreover, the present concepts expressly include any and all combinations and subcombinations of the preceding elements and aspects.
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