Field of Invention

The present invention relates generally to power presses and is particularly useful in transfer presses having servo-driven feed mechanisms.

Power presses are typically designed with the stroke of the press long enough to allow adequate time for the feed mechanism to execute its transfer cycle while the dies of the press are open, i.e., while the press slide is far enougii above the workpieces to permit them to be accessed by the feed mechanism. As the stroke of the press is lengthened, the cost of the press increases not only because of the larger press size required for the longer stroke, but also because the increased torque demand of the longer stroke requires larger and higher-powered clutches and brakes. This also results in an undesirably high impact velocity which, in turn, produces high noise levels and increased die wear rates.

This problem exists not only in transfer presses, which have multiple work stations within a single press, but also in single-station presses operating alone or in a synchronized line of such presses. Each single-station press normally has both a loading mechanism and an unloading mechanism associated with it, and the cycle time of these mechanisms can be even longer than that of the feed

1

-2- mechanism in a transfer press, thereby requiring even longer press strokes.

Summary Of The Invention

It is a primary object of the present invention to provide an improved power press which reduces the size and cost of the press while at the same time providing a very low impact velocity and allowing adequate time for the feed mechanism, or the loading and unloading mechanisms, to operate during the "open" portion of the press cycle. In this connection, a related object of the invention is to provide such an improved press which permits the use of relatively small and less expensive clutches and brakes which consume less power than the clutches and brakes used in comparable presses today.

It is another important object of this invention to provide such an improved press which reduces the noise levels and die wear rates by reducing the impact velocity.

A further object of this invention is to provide such an improved press which offers relatively low overall energy consumption rates for any given amount of work.

Still another object of this invention is to provide such an improved press which has a relatively short stroke length, e.g., a stroke length only half

as long as the stroke of presses currently used for the same purposes.

A still further object of the invention is to provide an improved method of operating power presses, which can be implemented by retrofitting presses already in the field.

Other objects and advantages of the invention will be apparent from the following detailed description and the accompanying drawings.

Brief Description Of Drawings

FIG. 1 is a perspective view of a transfer press with a servo-driven feed mechanism;

FIG. 2 is a diagrammatic illustration of the movement paths of the main press drive shaft and crank and the press slide;

FIG. 3 is a diagrammatic illustration of the path of movement of the transfer feed mechanism;

FIG. 4 is a fragmented perspective view of a transfer feed mechanism for use in the press of FIG. 1, and FIGS. 4A, 4B and 4C are enlargements of the three fragments of the transfer feed mechanism shown in FIG. 4;

FIG. 5 is a section taken generally along line 5-5 in FIG. 4, on an enlarged scale;

FIG. 6 is a side elevation taken generally along line 6-6 in FIG. 5;

FIG. 7 is a section taken generally along line 7-7 in FIG. 5, on an enlarged scale;

FIG. 8 is a section taken generally along line 8-8 in FIG. 6, on an enlarged scale; and

FIG. 9 is a side elevation of a synchronized line of single-station presses each of which has a loading mechanism and an unloading mechanism associated therewith.

Detailed Description Of Preferred Embodiments

While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and will be described in detail herein. It should be understood, however, that it is not intended to limit the invention to the particular forms disclosed, but, on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.

Turning now to the drawings and referring first to FIG. 1, there is shown a power press 10 having a vertically movable slide 11 which is supported by a plurality of columns 12. In operation, the slide 11 carries an upper die 13, and is reciprocated vertically such that the upper die 13 and a stationary lower die 14 are alternately brought into

and out of contact with a workpiece positioned between the two dies . The lower half of the die 14 is supported by a bolster 15 which can be moved transversely in and out of the press slide region.

The press 10 is powered from a large motor- driven flywheel on the crown 16. A clutch and brake interlock mechanism is mounted axially on the flywheel and is adapted to arrest the movement of the slide 11. The flywheel delivers power through a differential drive arrangement to each of the four corners of the slide 11 via a pitman 17. The shaft on which the eccentric is located normally has a rotary transducer positioned on one end to monitor the angular motion of the eccentric and hence the pitman and transduces it into an analog signal which . is directly proportional to the angular position of the eccentric at any given point during the stroke.

A pair of transfer rails 21 and 21' extends longitudinally through the press 10 for transporting workpieces through successive workstations in the press. To accomplish this workpiece movement, the transfer rails 21, 21' can be moved longitudinally (the "X axis"), transversely (the "Y axis"), and vertically (the "Z axis") by a tri-axial transfer drive. Conventional finger units (see FIGS. 4-8) are rigidly attached to the transfer rails 21, 21' for gripping the workpieces.

FIGS. 2 and 3 illustrate one complete operating cycle of a hypothetical press for performing a drawing operation. The top portion of FIG. 2 represents the 360° rotation of the main press drive shaft and crank; the lower portion of FIG. 2 represents the corresponding vertical stroke of the press slide; and FIG. 3 represents the tri-axial movement of the feed mechanism. As indicated by the legends at the top of FIG. 2, the "open" portion of the press cycle begins at the point at which the slide has been raised far enough above its bottom- dead-center (BDC) position to admit the feed mechanism between the dies, and ends at the point at which the upper die (carried on the slide) engages the workpiece. In the illustrative example of FIG. 2, this "open" portion of the press cycle begins at a crank angle of 110° and ends at 274°. The "closed" portion of the press cycle is the remainder of the cycle, and in the illustrative example extends from the crank angle of 110° to 274°.

During the "closed" portion of the cycle, the press slide performs the desired work on the workpiece and then moves upwardly to an elevation sufficiently high to admit the feed mechanism between the workpiece and the die carried on the slide. In the illustrative example, the slide traverses the final 28% of its downstroke and about 55% of its

upstroke during this "closed" portion of the cycle. During the final 28% of the downstroke, a relatively deep draw is produced in the workpiece; during the initial 28% of the upstroke the die carried by the press slide is withdrawn from the workpiece; and during the next 27% of the upstroke, the slide is raised far enough above the workpiece to admit the feed mechanism which transfers the workpieces between successive- stations.

During the "open" portion of the cycle, the press slide traverses the final 45% of its upstroke and the initial 72% of its downstroke. It is during this interval that the feed mechanism picks up the workpieces and transfers them to the succeeding stations.

Before describing the physical structure of the feed mechanism, it will be helpful to refer to FIG. 3 which diagrammatically illustrates a typical transfer cycle. At the end of the "closed" portion of each press cycle, the feed mechanism moves the transfer finger units into the space between the open dies so as to bring the finger units into engagement with the respective workpieces. The feed mechanism dwells at this position, which is identified as position A in FIG. 3, for a brief interval to allow the finger units to securely grip the workpieces. The feed mechanism is then elevated from position A to

position B to lift the workpieces off the lower dies, after which the mechanism is moved both vertically and longitudinally from position B to position C, and then longitudinally to transport the workpieces to the next stations. At position D the feed mechanism begins to descend toward the. lower dies, continuing its longitudinal movement until it reaches position E, and then moving straight down to position F to lower the workpieces onto their respective succeeding lower dies. The feed mechanism again dwells at position F for a brief interval to allow the finger units to be disengaged from the workpieces, after which the mechanism is retracted transversely from position F to position G and then returned longitudinally through positions H and I to its original position J, ready for the next transfer cycle.

The diagrammatic illustration in FIG. 3 does not include a turnover step, but if the finger units are adapted to turn one or more workpieces while they are being transferred from one workstation to the next, the turnover step is carried out during the longitudinal movement from position C to position D.

Turning now to FIGS. 4-8, there is shown a feed mechanism for transferring workpieces sequentially along multiple workstations in the transfer press 10. In order to transfer the various workpieces to

the desired positions and with the desired orientations at each of the multiple stations, the feed mechanism can be moved along any or all of the three different axes referred to as the longitudinal or X axis, the transverse or X axis, and the vertical or Z axis. As will be apparent from the ensuing description, the movement of the feed mechanism along each of these three axes is controlled by one or more independently controllable servo motors.

As can be seen most clearly in FIG. 4, the feed mechanism includes the aforementioned transfer rails 21 and 21' which extend along opposite sides of the multiple workstations. Each of these rails 21 and 21' carries a set of finger units 22a, 22b ... 22n and 22'a, 22'b ... 22'n, respectively, for gripping the workpieces at the respective workstations and transferring them to the next successive workstations. It will be appreciated that a press using a feed mechanism of this type normally has separate loading and unloading mechanisms situated at opposite ends of the press for supplying workpieces to the first pair of finger units 22a, 22'a and removing the finished workpieces from the final pair of finger units 22n, 22'n.

Because the entire mechanism associated with one of the transfer rails 21 and 21' is identical to the mechanism associated with the other rail, the

detailed description to follow will be directed only to the mechanism associated with one of the rails, and corresponding parts associated with the two rails will be identified by identical reference numerals with the addition of a distinguishing prime for those parts associated with the rail 21'.

The illustrative feed mechanism supports the rail 21 on a pair of vertically movable columns 23a and 23b. For vertical movement of the rail 21, a pair of Z-axis servo motors 30a and 30b drive elongated shafts 31a and 31b via successive bevel gear pairs 32a, 33a and 32b, 33b, respectively. The two shafts 31a and 31b carry respective pinions 34a and 34b which mesh with cooperating vertical racks 35a and 35b fastened to the columns 23a and 23b, respectively. As can be seen most clearly in FIG. 4B, the ends of the shafts 31a and 31b are journaled in stationary bearing blocks 36a, 37a and 36b, 37b on the base of the feed mechanism.

Each of the columns 23a and 23b is mounted for vertical sliding movement within two sets of six roller bearings 40a, 41a and 40b, 41b (see Figs. 5 and 6) mounted on housings 42a and 42b, respectively. The roller bearings 40a, 41a and 40b, 41b ride on hardened steel tracks on the vertical side walls of the columns 23a and 23b, thereby guiding the columns along straight vertical paths for

lifting and lowering the rail 21. The vertical position of the rail 21 at any given time, of course, is determined by the positions of the racks 35a and

35b as controlled by the Z-axis drive motors 30a and

30b. The two Z-axis drive motors 30a and 30b are driven in synchronism with each other so that the rail 21 is always maintained in a perfectly horizontal position.

Transverse movement of the rails 21 and 21' is effected and controlled by a pair of Y-axis servo motors 50a and 50b mounted on the stationary base of the feed mechanism. These two drive motors 50a and

50b drive corresponding pinions 51a and 51b via respective pairs of bevel gears 52a and 52b, and the pinions 51a and 51b in turn mesh with parallel pairs of cooperating horizontal racks 53a, 54a and 53b, 54b attached to the respective housings 42a, 42'a and

42b, 42'b. Thus, reciprocating movement of the racks

53a and 53b moves the housings 42a and 42b, and thus the columns 23a and 23b and the rail 21 mounted

_. thereon, back and forth in the transverse (Y-axis) direction. To accommodate this Y-axis movement, each of the housings 42a, 42b is supported and guided by four roller bearing triplets, 55a and 55b respectively, riding on two pairs of stationary transverse rails 56a, 57a and 56b, 57b (see Figs. 4B,

4C, 5 and 6) .

During the traversing movement of the housings 42a and 42b along the transverse rails 56a, 57a and 56b, 57b, the vertical columns 23a, 23b and the racks 35a, 35b mounted thereon, as well as the pinions 34a, 34b meshing therewith, are carried along with the two housings. This traversing movement of the pinions 34a and 34b is effected by respective pairs of bosses 58a and 58b projecting from the housings 42a and 42b or. opposite sides of the pinions. To accommodate this Y-axis movement of the Z-axis drive pinions 34a, 34b, the end portions of the shafts 31a and 31b are splined so that the pinions 34a, 34b can slide back and forth along the splined portions of the shafts 31a, 31b while being simultaneously driven by those shafts. The shafts themselves remain stationary except for their rotational movement, and the bevel gears 33a, 33b which drive the shafts are located between the splined portions of the shafts so that they do not interfere with the Y-axis movement of the Z-axis drive pinions 34a, 34b.

For longitudinal movement of the transfer rail 21, an X-axis servo motor 60 (see Fig. 4A) drives a transverse shaft 61 carrying a pinion 62 meshing with a stationary rack 63 formed on the bottom of a rail 64 fastened to the base of the feed mechanism. The drive motor 60 is fastened to the bottom of a transverse beam 65 supported for smooth sliding X-

axis movement by a pair of linear bearings 66 and 66' sliding on the top and side surfaces of the rails 64 and 64'. The beam 65 is also attached to the ends of the two rails 21 and 21' by a pair of slide blocks 67 and 67' captured in a pair of transverse gibs 68 and 68'. These slide blocks 67, 67' and gibs 68, 68' permit the rails 21, 21' to be moved transversely (in the Y-axis direction) along the beam 65 simultaneously with longitudinal (X-axis) movement of the rails and- the beam 65. Vertical movement of the rails 21 and 21' is also permitted by pivoting links 69 and 69' between the respective slide blocks 67, 67' and the rails 21, 21'.

To permit the rail 21 to move longitudinally relative to the columns 23a and 23b, even while the columns are moving the rails vertically and/or laterally, the rails 21, 21' ride on parallel sets of roller bearings 70a and 70b carried on the tops of the respective columns 23a and 23b. To hold the rails 21, 21' captive on the columns 23a and 23b for vertical and/or lateral movement therewith, the underside of each rail forms a longitudinal channel 71 which receives a set of canted roller bearings 72a and 72b which are also carried on the tops of the respective columns 23a and 23b. These roller bearings 72a and 72b ride on beveled surfaces within the channel 71, thereby holding the rail 21 captive

on the columns while permitting longitudinal movement of the rail relative to the columns.

To permit the workpieces to be turned over while they are being transferred from one work station to the next, each of the finger units 22a ... 22n and 22'a ... 22'n has the construction illustrated in Figs. 7 and 8 for the finger unit 22'b. Thus, the grippers 80 of the finger unit are mounted on a shaft 81 carrying a pinion 82 which meshes with a rack 83. The rack 83 can be driven back and forth in the X-axis direction by means of an air cylinder 84, thereby rotating the gripping fingers 80 about the Y- axis to turn over the workpiece carried by the fingers.

In accordance with one important aspect of the present invention, the press drive shaft is driven at a first, relatively fast angular velocity during the "closed" portion of each cycle of reciprocating movement of the press slide, and is then driven at a second angular velocity slower than the first angular velocity, during the "open" portion of each cycle of reciprocating movement of the press slide; the second angular velocity is sufficiently slow to allow the automatic feed mechanism to execute its transfer cycle during the "open" portion of each cycle.

In the method of this invention, the press drive shaft is decelerated at the beginning of the "open"

portion of the press cycle, preferably as soon as the press slide has been raised to an elevation that permits the feed mechanism to enter the space between the upper and lower dies to remove the workpieces from that space. The drive shaft then continues to be driven at the reduced velocity throughout the "open" portion of the cycle, i.e., until the upper die is about to impact the next workpiece. Thus, the press can have a short stroke with a low impact velocity while at the same time allowing adequate time for the transfer cycle of even the most complex feed mechanism. For example, in the example to be described below, the press stroke is only half as long as the stroke used in current presses for performing the same work (20 inches instead of 40 inches). In general, each inch of stroke length requires an additional three inches of press height, so a 20-inch reduction in stroke length permits a 60- inch reduction in the height of the press.

Furthermore, the impact velocity can be reduced below the lowest levels that are feasible in current long-stroke presses, and this lower impact velocity translates into reduced noise levels, reduced die wear rates, and improved part quality. The clutch and brake can be smaller as a result of the improved mechanical advantage of the shorter stroke, which means they have a lower cost, require less space, and

generally present fewer maintenance problems. The lower inertia of the smaller clutch also provides the benefit of reduced energy consumption in comparison to the alternative long stroke system when that system incorporates a "slow down" to reduce the inherent high impact velocity.

Moreover, the relatively slow velocity of the press during the entire "open" portion of the cycle is a safer mode of operation because the press can be stopped more quickly, and with less damage, in the event of a fault. Most faults occur during the "open" portion of the press cycle when the dies are open so that obstructions, such as a misaligned workpiece or a faulty feed mechanism, can become lodged between the dies. When the dies are closed or in the process of opening, there is little that can go wrong; and these are the only times when the press drive shaft is driven at the higher velocity in the method of this invention.

The following specific example will illustrate how to practice this invention using a conventional eddy current press drive system in a 3200-ton transfer press having the following characteristics:

CRANK RADIUS: 9.00 IN.

PITTMAN LENGTH: 130.00 IN.

BELT RATIO: 4.000 to 1 (MOTOR TO CLUTCH)

GEAR RATIO: 20.000 to 1

(OUTPUT SHAFT TO CRANK)

SLIDE WEIGHT: 200 TONS

MIN. COUNTERBALANCE FORCE; 178.9 TONS

MAX. COUNTERBALANCE FORCE: 221.1 TONS

ROTATING PARTS INERTIA REFL. TO DRIVE SHAFT: 2500 LB-FT ²

FRICTION TORQUE INERTIA REFL. TO DRIVE SHAFT: 0 LB-FT

AIR BRAKE TORQUE INERTIA 0 LB-FT REFL. TO DRIVE SHAFT:

PRESS IS GEARED FOR: 22.50 SPM

Operation of this press was simulated for the following loads:

X (IN. FROM BDC) LOAD (TONS)

18.000 0

5 100 0 5.000 200

4 000 300 3 000 400

2.000 500 1.000 2000 0.500 3200 0.010 3200 0.000 0

using an "eddy current" adjustable speed press drive system with the following characteristics:

"DYNAMATIC" PRESS DRIVE MODEL: 49-63 RUN

PARAMETERS:

CLUTCH DESCR.: CES 49-63 STRKL: 5

MAX. CLUTCH TORQUE 95,000 LBS-FT ICOND: 0.000 MAX. BRAKE TORQUE 475,000 LBS-FT2 HPLL: 16.000 INPUT INERTIA 140,000 LBS-FT2 DELT: 0.010 OUTPUT 10,000 LBS-FT PRINTV: 0.050

OR ID: NEMA D

HP 800

RPM. 1800

SLIP 8%

INERTIA: 350 LBS-FT ²

The simulated set points for the crank velocity were 12.5 SPM from 0° to 100°; 20.0 SPM from 110° to 274°; and 12.5 SPM from 274° to 360°.

A computer-simulated operation of the above press under the above conditions yielded the following results:

CONTROL COOe " CRANK VELOCITY

DPTV* TTPf •• TOP

OPERATING »00K •- CONTINUOUS STROKING π.ir .... CLUTCH-

. IT *HL OISS OISS RF.F ACT. .. rtK SLIOE CRANK

SFC β -4 O HP RPM RP« TO HP TO _ HP SP - SP* vεu POSIT ANGLE TONS TO

0.000 1*_31 2095 676 423 247 60 2 0 1 2 12.4 0.0 18.00 0 0 o.oso 1697 2038 659 424 248 20 1 0 1 2 12.4 3.5 17.99 4 0 62

0.100 1700 1902 642 475 241. 7 0 0 1 2 12.4 7.0 17,93 7 0 124

0. ISO J704 1926 625 426 24S 2 0 0 t 2 !7.4 10.5 17.85 11 0 183

0.700 1707 1-172 609 427 24H 1 0 0 1 2 12.4 14.0 17.72 15 0 239 o.?so 17.0 taiB 592 427 248 0 0 1 2 12.4 17.4 17.57 19 0 290 o. l o 1713 1766 576 428 249 0 0 1 2 12.4 20.-3 17.38 22 0 337

0..50 1716 1714 560 47.9 749 0 0 1 2 12.5 24.2 17.15 26 Ό 377

0.400 1 19 16*3 545 430 750 0 0 1 2 12.5 27.5 16.89 30 0 411

0.450 1722 1614 579 430 750 0 0 1 2 12.5 30.7 t6.60 34 0 438

0.500 1724 1565 514 431 251 0 0 1 2 12.5 33. * 16.28 37 0 457

0.550 1727 151 ^* . 499 437 2SI 0 0 1 7 12.6 36.9 15.93 41 0 468

0. hfO 1729 1471 485 412 252 0 0 1 ? 12.6 39.8 15.54 45 0 471

0.650 17.2 1426 470 433 252 0 0 1 2 12.6 42.6 15.13 49 0 466

- -

0.700 1734 1382 456 434 253 0 -554 -26 12 12.6 45.2 14.69 52 0 .68

'-. ^* -50 1737 1338 443 434 253 0 -4 4 -23 12 12.6 47.5 14.23 56 0 448

0.300 1739 1 96 429 435 253 0 -401 -18 12 12.6 49.7 13.74 60 0 420

0.850 1741 1755 416 435 253 0 -410 -19 12 12. 51.7 13.73 64 0 387 o.ooo 1743 1214 403 436 253 0 -364 -17 12 12.6 53.5 12.71 08 0 346

0.95(1 1745 1175 391 436 253 0 -317 -14 12 12.6 55.1 12.16 71 0 300

1.000 1747 1137 378 437 2« ^* 3 0 -269 -12 17 12.6 5I..5 11.60 75 0 248

1.050 1749 1099 366 437 253 0 -213 -9 12 17.6 57.6 11.03 79 0 191

1.100 1751 1063 355 438 253 0 -154 -6 12 12.6 58.5 10.45 83 0 131

1.150 1753 1028 343 438 751 0 -92 -3 12 12.6 59.1 9.87 37 0 63

1.700 1754 994 332 43 252 0 -34 -1 12 12.6 59.5 9.27 00 0 4 ι.2 ^** -0 175 960 321 439 257 0 -11 0 12 12.6 59.6 8.68 94 0 -57

1.3-10 1758 ^• 928 311 439 252 0 -3 0 12 12.6 59.5 8.08 98 0 -118

1.350 1759 S.96 300 440 252 0 0 12 12.6 59.0 7.49 102 0 -177

1.400 1761 866 290 440 752 0 0 12 17.6 58.3 6.90 105 0 -234

1.450 1762 836 281 441 252 0 0 12 12.6 57.3 6.32 109 0 -786

1. ς*o 1763 812 273 441 252 3707 133 0 20 17.6 56.3 5.76 113 0 -479 i .sat ⁾ 1758 912 306 440 269 3H692 1254 0 0 1 l . ϊ 60.4 5.19 1 11 0 -1778

LC3A0 ZONK -.N KHKO -- START FIN PRINT INTERVAL

1.570 1752 1045 349 438 290 51484 1510 0 20 14.5 64.3 4.94 119 206 -16082 t .580 174H 1127 375 437 301 58775 1521 0 20 15.0 66.1 4.81 119 219 -16670

1.500 1743 1217 404 436 311 61975 1465 0 20 15.6 67.3 4.68 120 212 -17473

1.6 17..8 1309 433 435 123 63609 1356 0 20 16.1 69.6 4.55 121 246 -18205

1.610 1733 1402 463 433 334 64322 1217 0 20 16.7 71.3 4.41 122 260 -I8805

1.620 1728 1494 492 432 345 62000 1024 0 20 17.3 72.7 4.27 123 274 -19470

1.630 172J 1580 5J9 431 35h 57867 826 0 20 17.8 73.7 4.12 124 233 -19976

1.640 1719 1558 543 430 365 57-741 647 0 20 18.3 74.4 3.98 126 303 -20436

1.650 1715 1727 564 479 373 4fr654 1 ^Q 0 20 18.7 74.7 3.83 127 313 -20850

1.660 1712 1785 582 478 380 40133 368 0 20 19.0 74.6 3.68 128 333 -21231 t . 70 1709 1833 597 427 385 33144 269 0 70 19.2 74.1 3.53 129 347 -21574 ι .pa V707 1871 608 427 388 27063 202 0 7.0 11.4 73.2 3.38 130 362 -21917

1. n "Hl 1705 — 1899 617 426 3HO 27283 159 0 70 1''.". 72.0 3.24 131 377 -22762

1.700 1704 1920 623 426 389 1 « 31 t 129 0 20 1f.1 70.6 3.10 132 391 -22590

1.710 1703 1935 628 426 388 1S907 114 0 20 19.4 69.0 2.96 134 405 -22916

1.770 1702 1946 631 476 386 14786 111 0 20 19.3 67.4 2.82 135 419 -23227

1.730 1702 1956 634 425 384 147S0 115 0 20 19.2 65.7 2.69 1 6 432 -21512

1,740 1701 1966 637 425 382 15560 128 0 20 19,1 64.1 2,56 13 445 -23763

1.760 1700 1 0 644 425 379 laβhH lh5 0 20 18.9 60.9 2.31 139 470 -2.131

1.770 1699 2005 649 425 377 20456 185 0 20 18.9 59.4 2.18 141 482 -24235 t.780 ^• 1698 2022 654 424 376 22125 202 0 20 18.3 57.9 2.07 142 494 -24231

1.700 1697 2042 660 474 376 23531 216 0 20 13.8 56.5 1.95 143 578 -27771

1.800 1695 2063 666 424 376 74586 725 0 20 18.8 55.0 1.84 144 746 -34316

1. ^β 10 1694 2085 673 423 375 26135 242 0 20 18.7 53.2 1.73 145 903 -41222

1.870 1692 2110 680 423 373 28483 273 0 20 18.6 51.3 1.63 146 1066 -46998

I .810 1691 2137 688 423 370 31977 372 0 20 13.5 49.4 1.53 147 1218 -52162

1.840 1689 2169 698 422 366 3-.417 390 0 20 18.3 47.4 1.43 148 1364 -56723

1.850 1686 2206 709 422 362 40890 463 0 20 18.1 45.5 1.34 149 1504 -60631

1.860 1684 2249 721 421 358 45520 544 0 20 17.9 43.6 1.25 151 1638 -64063

1.870 1681 2297 735 420 354 49170 615 0 20 17.7 41.7 1.16 152 1767 -66879

1.880 1677 2350 751 419 3S1 52750 688 0 20 17.5 19.9 1.08 153 1890 -69167

1.890 1674 2406 767 418 347 55656 753 0 20 17.4 38.2 1.00 154 2012 -71100

1.900 1670 2464 784 417 344 58358 816 0 20 17.2 16.5 0.93 155 2192 -74t,88

1.910 1666 2525 801 416 341 60U83 876 0 20 17.0 14.8 0.85 156 2364 -77526

1.920 1661 2588 819 415 337 63613 943 0 20 16.9 33.1 0.79 157 2527 -79678

1.930 1657 2653 837 414 314 65606 1001 0 20 16.7 31.4 0.72 1S8 2631 -31173

1.°40 1652 2719 856 413 331 66232 1040 0 20 16.5 29.7 0.66 159 2330 -82042

1."-SO 1647 2784 874 412 327 .-6911 1083 0 20 16.3 28.1 0.60 160 2970 -- ^• 2334

1.9o0 1643 2849 891 411 323 67604 1176 0 20 16.2 26. S 0.55 161 3102 -32035

1.970 1 33 2913 909 409 320 68266 1169 0 20 16.0 25.0 0.49 162 3200 -80676

1.980 1633 2977 926 408 316 68H66 1208 0 20 15.3 23.5 0.45 163 3200 -76686 t .900 1628 3040 943 407 313 60329 1239 0 20 15.7 22.2 0.40 164 1200 -72716

7.000 1624 3102 950 406 311 69405 1250 0 20 15.6 20.9 0.36 164 1200 -6H717

2.010 1619 3163 975 405 311 693«7 1242 0 20 15.5 19.7 0.32 165 1200 -64741

2.070 1614 322 ) 991 403 311 Λ ^Q 07t 1218 0 20 15.5 13.5 0.28 166 3200 -60716

J*'.30 1609 3281 1006 402 312 6»417 1178 0 20 15.6 17.4 0.24 167 3200 -56654

7.040 1604 3337 1020 401 314 67538 1124 0 20 15.7 16.3 0.21 163 3200 -52546

7.050 1600 3391 1033 400 116 6h550 1058 0 20 15.3 15.2 0.18 169 3200 -48182

7.060 tS9 3443 1046 190 320 65226 981 0 20 16.0 14.0 0.15 170 3200 -44154

2.070 1591 3493 lO'-O 39C) 324 63365 800 0 20 16.2 12.3 0.12 171 3200 -39855

2.080 1587 • 3541 1070 397 320 61312 793 0 20 16.4 11.6 0.10 172 3200 -35479

2.090 1533 3535 1081 3 334 59079 694 0 20 16.7 10.3 0.08 173 3200 -31019

2.100 1570 3627 1091 395 340 55853 534 0 20 17.0 9.0 0.06 174 3200 -26471

7.110 1576 - 3665 1100 394 346 ^■" •7231 477 0 20 17.3 7.5 0.04 175 3200 -21832

2.120 1572 3699 1108 391 352 48109 374 0 20 17.6 6.0 0.03 176 3200 -17102

2.130 1570 3729 1115 392 359 43662 280 0 20 17.9 4.4 0.02 177 3200 -12280

2.140 1567 3754 1121 2 365 38349 194 0 20 13.3 2.7 0.01 178 1267 -2921 150 1565 3775 1125 391 172 313*2 117 0 20 18.6 0.9 0.01 179 128 -96

7.160 1564 3789 1129 391 379 22850 53 0 20 18.9 1.0 0.01 131 0 17

^■ 20-

LOAD ZONE rOHPLFTE -- RESUME COARSE PRINT INTERVAL

7-.5 ^* 00 1565 3776 1126 391 390 1909 1 20 19.5 9.0 05 185

2},.25-0 1571 3714 1111 393 391 724 0 20 19.6 19.0 19 191

21,300 1577 3650 1096 394 392 573 0 20 19.6 28.8 42 197

77..350 1533 358b 1081 396 393 491 0 20 19.6 38.3 76 203

21.4^0 1589 3521 1065 397 393 465 0 20 19.7 47.3 19 209

7?..4SO 1594 3456 1049 399 3 ^Q 4 484 0 20 19.7 55.8 71 215

77..50O- 1 00 3390 1033 400 395 470 0 20 19.7 63.7 30 221

7.1550' 1605 3325 1017 401 395 432 1 20 19.8 70.8 2.98 227

7?.jSH)0 ^* 1611 1260 1000 403 196 383 1 20 19.8 77.0 3.72 232 1

27. 1616 3194 981 404 396 328 0 20 19.8 82.4 51 238 1

21.700- 1621 3179 966 405 396 268 0 20 19.8 86.7 36 244 2

21.750 ^* 1627 3063 949 407 397 208 0 20 19.8 90.1 25 250 3

77.J3-00- 1632 2997 932 409 397 145 0 20 19.9 92.4 7.16 256 3

21.330 1637 2932 914 409 397 92 0 20 19.9 93.6 8.09 262 3

21.900 1641 2366 896 410 397 51 0 20 19.9 93.8 9.03 263 3

21.950 1646-. 2801 378 412 397 21 0 20 19.9 92.9 9.96 274 2

3iJ ^* »O 1651 2735 860 413 378 11 0 0 -75326-5421 17 18.9 82.5 10.87 280 3 1 1

3105 ^* 0 1655 2672 842 414 211 2034 7 788 -99350-4016 12 10.6 42.3 11.52 284 348

314:00 1656 2668 841 414 160 30606 1479 16021 -487 12 3.0 36.1 11.90 287 -95

31J-50 1640 2893 903 410 206 65867 2562 -5534 -216 12 10.3 47.6 12.30 290 ^■ 259

31Z0D 1624 3094 957 406 257 18529 525 -8473 -414 12 12.9 54.6 12.81 293 -A7

31J5-0 ^* - l b 34 2 70 9 4 409 245 1818 57 ■1164 ^■ 53 12 12.2 45.7 14 .31 304 υ -47

31Λ00" 1 6 38 2914 909 409 245 1742 54 -381 •17 12 12.3 43.6 14.76 308 0 -50

31,450" 1 642 2357 894 411 246 1212 38 -124 -5 12 12.3 41.3 15.13 312 0 -50

31 500 1647 2797 377 412 247 724 23 -40 -1 12 12.3 38.8 15.58 316 0 -49

3-.. 50- 1 65 1 2735 860 411 247 476 15 -12 0 12 12.4 36.0 15.95 319 0 -48

3 . 600 1 655 2673 843 414 247 417 13 -3 0 12 12 33.1 16.30 323 0 -47

3 . 650 ^* 1 660 2612 826 415 247 433 14 0 12 12 30.1 16.62 327 0 -44

3 . 700 1 664 2551 808 416 247 447 14 0 12 12 77.1 16.90 330 0 -42

3 . 750 1 668 2490 791 417 247 436 14 0 12 12 23.9 17.16 334 0 -38

3. 800 1672 2430 774 418 247 403 13 0 12 12 20.6 17.38 338 0 -34

3, 850 ^* 1 676 2371 757 419 247 358 12 0 12 12 17.3 17.57 341 0 -29

31.900 ^' 1630 2312 740 420 247 308 10 0 12 12 13.9 17.73 345 0 -23

3 . 950 1 68 3 2254 723 421 247 254 8 0 12 12 10.5 17.85 349 0 -18 00. 1 687 2196 706 422 747 198 7 0 12 12 7.0 17.93 353 0 -12

4 ..05 1691- 2138 689 423 247 119 5 0 12 12.4 3.5 17.99 356 0 -6

4.- .1:00; 1694 2081 672 424 247 78 3 0 12 12.4 0.0 18.00 360 0

SUMMΛPϊ (IF STPOKE 3

AVE. STROKING RATE 14.63 SP« P S MOTOR HP. 755.7

AVE. CLUTCH OISS. HP. 172.2

AVF. BRAKE OISS. HP. -162.8

AVF. WORK HP. 383.9

AVE. FLY-HEEL HP. LOSS -3,5

PFLATTVE STABILI ^T Y HAS BEEN REACHED

ANALYSIS CONP fcTE

It can be seen from the above data that the "reference SPM" of the system was set at 12 for the "open" portion of the press cycle, and at 22 for the "closed" portion of the cycle. During a portion of the press downstroke in the "open" portion of the cycle, i.e., within the crank angle range of 52° to 98°, the eddy current brake was energized to maintain the press at the commanded slow speed. When the commanded speed was increased by changing the "reference SPM" to 20, just before the load zone was entered, the eddy current clutch was energized to supply the necessary power to both increase the speed of the press drive and perform the desired work. The "reference SPM" was maintained at 20 through the balance of the downstroke and 89° of the upstroke, and then reduced to 12 again. It can be seen that the brake was again energized, to reduce the press speed, as soon as the "reference SPM" was reduced. With this system, the stroke length was only 18 inches, and yet ample time (2.55 sec.) was allowed for the feed mechanism to access the workstations during the "open" portion of the cycle.

As mentioned previously, the present invention is useful not only in transfer presses, which have multiple workstations within a single press, but also in single-station presses operating alone or in a synchronized line of such presses. An exemplary line of single-station presses is illustrated in Fig. 9, which is similar to the synchronized press lines described in Danly U.S. Patents 3,199,439 and 3,199,443. As described in those patents, such a press line performs successive operations upon a workpiece W, and may be extended to include any desired number of presses. Each individual press includes a base 100 extending below the floor level

101, and an upperly extending frame 102 topped by a crown 103. Recriprocatingly mounted in the press frame is a slide 104 carrying a die 105 for cooperating with a lower die 106 with the slide being driven by a motor 107.

Each of the three presses A, B and C is provided with a loading mechanism 110 for loading workpieces into the working area of the press, and an unloading mechanism 111 for removing workpieces from the work area. These loading and unloading mechanisms are cantilevered from opposite sides of the main frame of the press. Depending from each loading and unloading mechanism 110 and 111 is a transfer arm 112 having a gripper 113 for gripping the workpieces while they are being transferred. The details of these loading and unloading mechanisms are well known in the art and, therefore, need not be described in detail here. The details of how to synchronize such a line of multiple presses are also well known in the art, and one version thereof is described in the aforementioned Danly U.S. Patent 3,199,439.

The reason for describing the synchronized press line here is to illustrate one of the most useful applications of the present invention. It will be appreciated that in a line of multiple presses, each having its own loading and unloading mechanism, a considerable amount of time is required in each cycle to allow the loading and unloading mechanisms to move the workpieces in and out of the workstations of the respective presses. In the past, the necessary cycle time for these operations has been provided by increasing the strokes of all the presses to allow adequate time for the press having the maximum cycle time. In certain situations this has required excessive vertical space or the re-design of the top

portions of the presses in order to reduce their overall height. By applying the present invention to such a press line, however, adequate cycle time can be provided while at the same time reducing the size and cost of each individual press, along with all the other advantages of the invention described above. The resultant overall savings in a multi-press line of the type illustrated in Fig. 9 are quite significant.

The method of this invention can be implemented by retrofitting presses already in the field, particularly those presses equipped with inching drives. An inching drive provides a means to operate the press at a speed much slower than its normal cycle rate, typically providing full tonnage at a speed of one stroke per minute. Inching drives are well known and typically use an inching motor geared to a brake housing mounted on bearings so that the complete brake can be rotated. The housing is connected to an auxiliary brake which keeps the housing in a fixed position during normal operation of the press. For inching, the clutch is de- energized, the main brake is engaged, and the inching motor drives the press (at a reduced speed) through the main brake.

To inplement the present invention via an inching drive, a variable speed drive motor can be substituted for the conventional fixed speed inching drive motor.