FORM 2
The Patents Act 1970
(39 of 1970)
&
The Patent Rules 2003
COMPLETE SPECIFICATION
(See Section 10 and rule 13)
TITLE OF THE INVENTION:
PUSHER ASSEMBLY FOR COIL/STRIP IN PRESS
TOOL ASSEMBLY


APPLICANT: LARSEN & TOUBRO LIMITED
L&T House, Ballard Estate, P.O. Box No. 278,
Mumbai, 400 001, Maharashtra INDIA.
PREAMBLE OF THE DESCRIPTION:

THE FOLLOWING SPECIFICATION PARTICULARLY DESCRIBES THE INVENTION AND THE MANNER IN WHICH IT IS TO BE PERFORMED


A) TECHNICAL FIELD
[0001] The present invention generally relates to a press tool assembly and particularly to the press tools used for processing coils or strips in progressive punching operations executed during the manufacturing process of sheet metal components used in applications such as electrical/electronic products, automobiles, watches etc. The present invention more particularly relates to a pusher assembly to align a strip /coil to a common reference surface for punching of holes in the strip/coil and to maintain consistency in the position of holes with respect to one end of the component during the progressive punching operation.
B) BACKGROUND OF THE INVENTION
[0002] Press working is one of the major processing techniques for converting a sheet metal into the sheet metal parts of different shapes. The sheet metal parts are required for different applications such as electrical/ electronic products, automobiles, watches etc. The sheet metal is punched between two parts called punch and die. The die profile is the female profile intentionally kept bigger than the punch profile by a uniform gap called cutting clearance.
[0003] The press tool mainly consists of two halves, namely fixed bottom half and moving top half. The fixed bottom half is secured to the stationary bolster plate of mechanical press. The bottom half comprises an arrangement to guide the

strip/coil, die cavities, guide pillars for alignment of both halves etc. The top moving half is clamped to the moving ram of the mechanical press and it comprises a number of circular and non circular cutting and non cutting elements called punches. The punches move up and down along with the moving ram of the mechanical press and they are guided in cavities made in a plate called Stripper plate. During the downward movement, the punches penetrate the sheet metal and enter the die cavity thereby pushing the sheet metal scrap displaced by the cutting punch into the lower half of the tool. One downward and return upward movement of the top half of press tool is called as a stroke of press tool. The surrounding metal clings to the body of cutting punches during the downward stroke. The same is stripped off by the stripper plate during the upward stroke of the punches.
[0004] The press tools are of multi-station type or single station type. In a multi¬station tool, the strip moves from one end of the strip guides to the other end. It moves progressively by a fixed distance called pitch after every stroke of the mechanical press. At each stage during the movement of strip, different punching operations are carried out on the strip / coil leading to the completion of the stamping profile in the last stage. The stripper in the press tools is designed to move as the press ram reaches the bottom of its stroke. Usually the strippers are of two types such as a fixed stripper and a floating stripper. The fixed stripper is fixed to the bottom half of the press tool and the floating stripper is fixed to the top half of the press tool to hold down the stock during the stamping operation and strip the stock.
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[0005] Many times the nominal width of coil or strip is equal to maximum width of stamping to reduce the generation of scrap. The stampings have circular and non circular holes placed symmetrically with respect to the width of the stamping. The gap in the strip guides is always kept bigger than the maximum size of strip/coil width for ease of strip/coil feeding. It is not possible to ensure that the strip moves exactly at the middle of the gap between strip guides. The strip would move randomly and the position of the punched holes with respect to edges of coil width will vary randomly. This will not allow the maintenance of the symmetry of holes with respect to the strip/coil width leading to rejection of stampings by quality control department.
[0006] In conventional press tools, the coil / strip width is more than the component width and the edges of the component were formed by notching operations. Hence an extra material is punched by notching punches to form outer edges of the component. However, this resulted in loss of material in the form of scrap generated by the notching punches. Many times, the width of the coil/strip is kept the same as the maximum size of the stamping to save material. In such cases, it is not possible to maintain symmetry of holes with respect to coil / strip edges.
[0007] The stampings have circular and non circular holes placed in such a way that the distance between the hole centre with respect to one edge of the component is very important and it is a critical to quality dimension irrespective of variation in the size of coil or strip. More over there was no consistency in positioning of the
holes with respect to one edge of component to be punched.
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[0008] Hence there is a need to provide a constant reference for punching of holes during the progressive punching operation and to maintain consistency in the position of holes with respect to one edge of the component.
[0009] The above mentioned shortcomings, disadvantages and problems are addressed herein and which will be understood by reading and studying the following specification.
C) OBJECTS OF THE INVENTION
[0010] The primary object of the present invention is to provide a pusher assembly at one or more location in the press tool assembly to align the strip or coil in press tools with respect to one edge of the component to be punched and to provide a constant reference for punching of holes.
[0011] Another object of the present invention is to provide a pusher assembly for coil/strip in press tool assembly to maintain consistency in the positioning of holes with respect to one edge of the component.
[0012] Yet another object of the present invention is to provide a pusher assembly which is easy to assemble and which requires less maintenance.
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[0013] Yet another object of the present invention is to provide a pusher assembly to take care of the variation in strip / coil width and clearance in the guiding slot and maintain the consistency in the positioning of holes with respect to one edge of the component.
[0014] These and other objects and advantages of the present invention will become readily apparent from the following detailed description taken in conjunction with the accompanying drawings.
D) SUMMARY OF THE INVENTION
[0015] The various embodiments of the present invention provide a pusher assembly for coil/strip in press tool assembly at one or more location in the press tool assembly to align the strip or coil in the press tools with respect to one edge of the component to be punched and to provide a constant reference for punching of holes.
[0016] According to one embodiment of the present invention, a pusher assembly for coil/strip in a press tool assembly has at least one pusher element provided in a stripper plate included in a press tool assembly. A sleeve is provided above the pusher element. A spring is arranged around the sleeve. A fastener is provided to secure the sleeve with the pusher element. A first washer is provided between the Allen screw and the sleeve. A second washer is provided between the sleeve and the pusher element. The pusher element has a tapered surface at the end to come in contact with the coil/strip to exert wedge effect on the coil/strip from one side to

ensure that the coil/strip is not moved randomly and is kept aligned to one common surface. The tapered surface at the end is made to come in contact with the vertical edges of the coil/strip to exert a wedge effect on the coil /strip from one side to force coil/strip to butt against the guiding surface of the stripper plate irrespective of the size of the coil/strip to ensure that the coil/strip is not moved randomly and is kept aligned to one edge during the punch process.
[0017] Pluralities of the pusher elements are used in the press tool assembly, when the pitch is larger than the stamping size. The pitch is the preset distance travelled by the strip during each stroke of the press tool. The pusher element is guided through a hole in the stripper plate. The pluralities of the pusher element punches are arranged on one side of the coil/strip at the entry point of the coil/strip before any punching station provided in the press tool assembly. The height of all the pusher element punches are identical, when pluralities of the pusher element punches are used in the press tool assembly. The taper angle of the taper surface provided at the pusher element punches is identical, when pluralities of the pusher element punches are used in the press tool assembly. The point at which the taper surface starts in all the pusher element punches is identical, when pluralities of the pusher element punches are used in the press tool assembly.
[0018] The spring has a height based on the stroke required for the punch, shut height of the press tool and the thickness of the coil/strip material. The two washers are arranged to provide resting surface for both the Allen screw and the pusher elements with the respective plates in the press tool assembly. The load of the spring

is designed in such a manner to prevent the formation of dent marks on the edges of the coil/strip. The pusher elements are arranged on the opposite side of the strip guiding surface of the stripper plate to push the strip to butt against the guiding surface of the stripper plate. According to one embodiment the fastener is an Allen screw.
[0019] According to embodiment of the present invention, the press tool assembly comprises of a top plate, base plate, a die plate clamped to the base plate, a strip or coil to be guided on the die plate, a strip guide edge, a stripper plate with a cavity at the centre mounted on the die plate, holder plate clamped to the top plate, a pusher to be guided in stripper cavity, a pair of washers, an Allen screw, a spring and a sleeve.
[0020] According to embodiment of the present invention, the pusher is a floating punch which is rectangular in shape and is guided in stripper plate. The pushers are provided to provide constant reference for positioning of the holes and to maintain consistency in the positioning of holes with respect to one edge of the component. The pusher is located on one side of coil at the entry of strip or coil before any punching station in the press tool. The pusher includes a taper surface at the bottom and a spring above it, the complete assembly is held in the punch holder plate of the press tool.
[0021] The sleeve is provided above the pusher. The washers are provided
between the Allen screw and the sleeve and between pusher and sleeve. The washer
provides resting surface for both Allen screw and the pusher. The spring is provided
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around the sleeve. The spring provided above the pusher is in the pre compressed condition. The height of the spring is maintained based on the stroke required for the pusher unit, shut height of the press tool and the material thickness. The sleeve also ensures that the spring is not over tightened beyond the required length and force. When the fixed distance travelled by strip during each stroke of press tool is larger than the stamping size, more number of pushers are provided in the press tool at a suitable location.
[0022] When the stroke on the press tool is in fully upward direction there is no gap between the top plate and the washer. Hence the pushers and the punch will not come in contact with the strip or coil. When the stroke on press tool is in fully downward direction and when the tapered surfaces of the pusher come in contact with the vertical edges of strip or coil, the spring above the pusher is compressed and a wedge effect is exerted on the strip or coil from one side. The wedge effect forces the strip or coil to butt against the guiding surface of the stripper or guiding plates irrespective of the size of the strip or coil width. This ensures that the strip or coil would not move randomly and will be aligned to one common surface. Any extra downward movement of top half of press tool is compensated by the deflection of the spring above pusher. The strip guide edge is provided to support the strip or coil towards one end and to select the required hole or profile distance from the edge of the component.
[0023] Accordingly, the pushers are provided at one or more locations in the press
tool assembly to align the strip or coils in the press tools and to provide a constant
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reference for positioning of the holes. It ensures consistency in the positioning of holes with respect to one edge of the component. The pushers are designed such that it takes care of the variation in the strip or coil width. It takes care of the extra clearance in strip guides. The assembling and maintenance of the pusher is very easy.
E) BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The other objects, features and advantages will occur to those skilled in the art from the following description of the preferred embodiment and the accompanying drawings in which:
[0025] FIG.l shows a sectional view of a typical press tool assembly provided with a pusher assembly according to one embodiment of the present invention.
[0026] FIG. 2 shows a sectional view of the press tool assembly provided with a pusher assembly during the downward stroke, according to one embodiment of the present invention.
[0027] FIG. 3 shows a bottom half plan view of the pusher assembly for strip/coil in press tool assembly, according to one embodiment of the present invention.
[0028] FIG. 4 shows a top half plan view of the pusher assembly for strip/coil in press tool assembly, according to one embodiment of the present invention.
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[0029] FIG. 5 shows a side sectional view of a pusher element in pusher assembly for strip/coil in press tool assembly, according to one embodiment of the present invention.
[0030] FIG. 6 shows a sectional view of a sleeve in a pusher assembly for strip/coil in press tool assembly, according to one embodiment of the present invention.
[0031] Although specific features of the present invention are shown in some drawings and not in others. This is done for convenience only as each feature may be combined with any or all of the other features in accordance with the present invention.
F) DETAILED DESCRIPTION OF THE INVENTION
[0032] In the following detailed description, reference is made to the accompanying drawings that form a part hereof, and in which the specific embodiments that may be practiced is shown by way of illustration. These embodiments are described in sufficient detail to enable those skilled in the art to practice the embodiments and it is to be understood that the logical, mechanical and other changes may be made without departing from the scope of the embodiments. The following detailed description is therefore not to be taken in a limiting sense.

[0033] The various embodiments of the present invention provide pushers at one or more location in the press tool assembly to align the strip or coil in press tools with respect to one edge of the component to be punched and to provide a constant reference for punching of holes.
[0034] According to one embodiment of the present invention, a pusher assembly for coil/strip in a press tool assembly has at least one pusher element provided in a stripper plate included in a press tool assembly. A sleeve is provided above the pusher element. A spring is arranged around the sleeve. A fastener is provided to secure the sleeve with the pusher element. A first washer is provided between the Allen screw and the sleeve. A second washer is provided between the sleeve and the pusher element. The pusher element has a tapered surface at the end to come in contact with the coil/strip to exert wedge effect on the coil/strip from one side to ensure that the coil/strip is not moved randomly and is kept aligned to one common surface. The tapered surface at the end is made to come in contact with the vertical edges of the coil/strip to exert a wedge effect on the coil /strip from one side to force coil/strip to butt against the guiding surface of the stripper plate irrespective of the size of the coil/strip to ensure that the coil/strip is not moved randomly and is kept centralized during the punch process.
[0035] Pluralities of the pusher elements are used in the press tool assembly,
when the pitch is larger than the stamping size. The pitch is the preset distance
travelled by the strip during each stroke of the press tool. The pusher element is
guided through a hole in the stripper plate. The pluralities of the pusher element
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punches are arranged on one side of the coil/strip at the entry point of the coil/strip before any punching station provided in the press tool assembly. The height of all the pusher element punches is identical, when pluralities of the pusher element punches are used in the press tool assembly. The taper angle of the taper surface provided at the pusher element punches is identical, when pluralities of the pusher element punches are used in the press tool assembly. The point at which the taper surface starts in all the pusher element punches is identical, when pluralities of the pusher element punches are used in the press tool assembly.
[0036] The spring has a height based on the stroke required for the punch, shut height of the press tool and the thickness of the coil/strip material. The two washers are arranged to provide a resting surface for both the Allen screw and the pusher elements with the respective plates in the press tool assembly. The load of the spring is designed in such a manner to prevent the formation of dent marks on the edges of the coil/strip. The pusher elements are arranged on the opposite side of the strip guiding surface of the stripper plate to push the strip to butt against the guiding surface of the stripper plate. According to one embodiment the fastener is an Allen screw.
[0037] According to embodiment of the present invention, the press tool assembly comprises of a top plate and a base plate. A die plate is clamped to the base plate. A strip or coil is guided through a cavity in the die plate. A stripper plate with a cavity at the centre is mounted on the die plate. A holder plate is clamped to the top plate. A
pusher is guided in stripper cavity. Two washers are provided above and below the
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sleeve. A spring is arranged around the sleeve. The sleeve is secured to the pusher element through a fastener such as an Allen screw.
[0038] According to embodiment of the present invention, the pusher is a floating punch which is rectangular in shape and is guided in stripper plate. The pushers are provided to provide constant reference for the positioning of the holes and to maintain consistency in the positioning of holes with respect to one edge of the component.
[0039] The pusher is located on one side of coil at the entry of strip or coil before any punching station in the press tool. The pusher includes a taper surface at the bottom and a spring above it, the complete assembly is held in the punch holder plate of the press tool. The sleeve is provided above the pusher. The washers are provided between the Allen screw and the sleeve and between pusher and sleeve. The washer provides resting surface for both Allen screw and the pusher. The spring is provided around the sleeve. The spring provided above the pusher is in the pre compressed condition. The height of the spring is maintained based on the stroke required for the pusher unit, shut height of the press tool and the material thickness. The sleeve also ensures that the spring is not over tightened beyond the required length and force. When the fixed distance travelled by strip during each stroke of press tool is larger than the stamping size, more number of pushers are provided in the press tool at a suitable location.
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[0040] By using pushers, the component feature or component dimension from one edge is achieved by butting the strip against one fixed reference surface or one side of the strip guiding surface. The holes and profiles such as punches and dies are positioned, considering this as the reference. The Pushers provided on the opposite side of the reference surface pushes the material and makes it butt against the reference surface. The difference in taper angle and spring load on the pushers will not affect the component accuracy.
[0041] The guiding slot machined on one side of the guiding surface is maintained perfectly to achieve the component features. The relief for feeding is provided only on one side on which pushers are placed. The tapered profile on the pusher is maintained in such a manner that any slight increase or decrease in the strip width should not affect the functioning of the press tool and the working of the pusher mechanism. The variation in the strip thickness will also not affect the working of the press tool and the working of the pusher mechanism.
[0042] When the stroke on the press tool is in fully upward direction there is no
gap between the top plate and the washer. Hence the pushers and the punch will not
come in contact with the strip or coil. When the stroke on press tool is in fully
downward direction and when the tapered surfaces of the pusher come in contact
with the vertical edges of strip or coil, the spring above the pusher is compressed and
a wedge effect is exerted on the strip or coil from one side. The wedge effect forces
the strip or coil to butt against the guiding surface of the stripper or guiding plates
irrespective of the size of the strip or coil width. This ensures that the strip or coil
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would not move randomly and will be aligned to one common surface. Any extra downward movement of top half of press tool is compensated by the deflection of the spring above pusher. The strip guide edge is provided to support the strip or coil towards one end and to select the required hole or profile distance from the edge of the component.
[0043] Accordingly, the pushers are provided at one or more locations in the press tool assembly to align the strip or coils in the press tools and to provide a constant reference for positioning of the holes. It ensures consistency in the positioning of holes with respect to one edge of the component. The pushers are designed such that it takes care of the variation in the strip or coil width. It takes care of the extra clearance in strip guides. The assembling and maintenance of the pusher is very easy.
[0044] FIG. 1 shows a sectional view of a typical press tool assembly provided with a pusher assembly according to one embodiment of the present invention. With respect to FIG. 1, the press tool assembly mainly consists of two halves, namely fixed bottom half and moving top half. The fixed bottom half is secured to the stationary bolster plate of mechanical press. It comprises of an arrangement to guide the strip/coil, die cavities, guide pillars for alignment of both halves etc. The top moving half is clamped to the moving ram of the mechanical press and it comprises a number of circular and non circular cutting and non cutting elements called punches 8. The base plate 2 is clamped to the fixed bottom part. The die plate 3 is clamped on the base plate 2 with the strip or coil to be punched is guided on the die plate 3. The
stripper plate 5 is clamped to the die plate 3. The top plate 1 is clamped to the
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moving top half. The holder plate 6 is clamped to the top plate 1. The holder plate holds the punches 8. The punches 8 move up and down along with the moving ram of the mechanical press and they are guided in cavities made in a plate called stripper plate 5. During downward movement, the punches 8 penetrate the sheet metal and enter the die cavity thus pushing the sheet metal scrap displaced by the cutting punch into the lower half of the tool. The surrounding metal clings to the body of cutting punches during downward stroke. The same is stripped off by the stripper plate 5 during upward stroke of the punches 8.
[0045] FIG. 2 shows a sectional view of the press tool assembly provided with a
pusher assembly during the downward stroke, according to one embodiment of the
present invention. With respect to FIG. 2, the gap between the top plate 1 and the
washer 10 is increased during the downward stroke. Simultaneously the distance
between the holder plate 6 and the stripper plate 5 is decreased. The spring 12 will be
compressed, during this condition and the cutting punch will be inside the stripper
plate 5. The cutting punch is proceeded towards the strip or coil 4 and is about to
pierce the strip or coil 4. At the same time, the distance between the top plate 1 and
the base plate 2 is also decreased. When the stroke on press tool is in fully downward
direction, the spring 12 above the pusher 7 is compressed and the tapered surfaces of
the pusher 7 come in contact with the vertical edges of strip or coil 4 to exert a
wedge effect on the strip or coil 4 from one side. The strip guide edge 14 supports
the strip or coil 4 towards one end and also helps to select the required hole or profile
distance from the edge of the component for punching operation. The wedge effect
forces the strip or coil 4 to butt against the guiding surface of the stripper or guiding
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plates irrespective of the size of the strip or coil width. This ensures that the strip or coil 4 would not move randomly and will be aligned to one common surface. Any extra downward movement of top half is compensated by the deflection of the spring above pusher 7.
[0046] FIG. 3 shows a bottom half plan view of the pusher assembly for strip/coil in press tool assembly, according to one embodiment of the present invention. With respect to FIG. 3, the cavities 40 are provided on the die plate to receive the pusher, when the stroke on press tool is fully downward.
[0047] FIG. 4 shows a top half plan view of the pusher assembly for strip/coil in press tool assembly, according to one embodiment of the present invention. With respect to FIG. 4, pushers 50 are provided on the top half of the die plate. By using the pushers 50, the component feature or component dimension from one edge is achieved by butting the strip against one fixed reference surface or one side of the strip guiding surface. The holes and profiles such as punches and dies are positioned, considering this as the reference. The Pushers provided on the opposite side of the reference surface pushes the material or component and makes it butt against the reference surface.
[0048] FIG. 5 shows a side sectional view of a pusher element in pusher assembly
for strip/coil in press tool assembly, according to one embodiment of the present
invention. With respect to FIG. 5, a pusher 7 is an elongated element with a tapered
profile at the end. The height of all the pushers 7 used in the press tool assembly is
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identical. The taper angle on all the pushers 7 and the point at which the taper starts are identical for all pushers 7.
[0049] FIG. 6 shows a sectional view of a sleeve in a pusher assembly for strip/coil in press tool assembly, according to one embodiment of the present invention. With respect to FIG. 6, the sleeve 11 is a cylindrical member. The Sleeve 11 is provided above the pusher. The sleeve 11 is provided to reduce the pressure on the spring during fully downward stroke. The height of the spring is maintained based on the stroke required for the pusher, shut height of the press tool and the material thickness. The sleeve also ensures that the spring is not over tightened beyond the required length and force.
G) ADVANTAGES OF THE INVENTION
[0050] The various embodiments of the present invention provide pushers at one or more location in the press tool assembly to align the strip or coil in press tools with respect to one edge of the component to be punched and to provide a constant reference for punching of holes. It ensures consistency in the positioning of holes with respect to one edge of the component. The pushers are designed such that it takes care of the variation in the strip or coil width. It also takes care of the extra clearance in strip guides. The assembling and maintenance of the pusher is very easy. Tapered profile on pusher is maintained in such a manner that any slight increase or decrease in the strip width, does not affect the functioning of the press tool and the
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working of the pusher mechanism. The variation in the strip thickness will also not affect the working of the press tool and the working of the pusher mechanism.
[0051] Although the invention is described with various specific embodiments, it will be obvious for a person skilled in the art to practice the invention with modifications. However, all such modifications are deemed to be within the scope of the claims.
[0052] It is also to be understood that the following claims are intended to cover all of the generic and specific features of the present invention described herein and all the statements of the scope of the invention which as a matter of language might be said to fall there between.

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CLAIMS
What is claimed is:
1. A pusher assembly for coil/strip in a press tool assembly comprising:
At least one pusher element provided in a stripper plate included in a press
tool assembly;
A sleeve provided above the pusher element;
A spring arranged around the sleeve;
A fastener provided to secure the sleeve with the pusher element;
A first washer provided between the Allen screw and the sleeve; and
A second washer provided between the sleeve and the pusher element;
Wherein the pusher element has a tapered surface at the end to come in
contact with the coil/strip to exert wedge effect on the coil/strip from one side
to ensure that the coil/strip is not moved randomly and is kept aligned to one
common surface.
2. The assembly according to claim 1, wherein the tapered surface at the end is
made to come in contact with the vertical edges of the coil/strip to exert a
wedge effect on the coil /strip from one side to force coil/strip to butt against
the guiding surface of the stripper plate irrespective of the size of the
coil/strip to ensure that the coil/strip is not moved randomly and is kept
aligned to one edge during the punch process.
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3. The assembly according to claim 1, wherein pluralities of the pusher elements are used in the press tool assembly, when the pitch is larger than the stamping size.
4. The assembly according to claim 1, wherein the pitch is the preset distance travelled by the strip during each stroke of the press tool.
5. The assembly according to claim 1, wherein the pusher element is guided through a hole in the stripper plate.
6. The assembly according to claim 1, wherein the pluralities of the pusher element punches are arranged on one side of the coil/strip at the entry point of the coil/strip before any punching station provided in the press tool assembly.
7. The assembly according to claim 1, wherein the height of the all the pusher element punches are identical, when pluralities of the pusher element punches are used in the press tool assembly.
8. The assembly according to claim 1, wherein the taper angle of the taper surface provided at the pusher element punches is identical, when pluralities of the pusher element punches are used in the press tool assembly.
9. The assembly according to claim 1, wherein the point at which the taper surface starts in all the pusher element punches is identical, when pluralities of the pusher element punches are used in the press tool assembly.
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10. The assembly according to claim 1, wherein the spring has a height based on the stroke required for the punch, shut height of the press tool and the thickness of the coil/strip material.
11. The assembly according to claim 1, wherein the two washers are arranged to provide resting surface for both the Allen screw and the pusher elements with the respective plates in the press tool assembly.
12. The assembly according to claim 1, wherein the load of the spring is designed in such a manner to prevent the formation of dent marks on the edges of the coil/strip.
13. The assembly according to claim 1, wherein the pusher elements are arranged on the opposite side of the strip guiding surface of the stripper plate to push the strip to butt against the guiding surface of the stripper plate.
14. The assembly according to claim 1, wherein the fastener is an Allen screw.