Claims:1. A press machine for simultaneously manufacturing at least two components in a single stroke of a press cycle associated with the press machine, the press machine comprising:
a feeding system having at least two de-coilers (502-1, 502-2) having raw materials loaded thereon and at least one feeder (506) to progressively transfer the raw materials loaded on each of said at least two de-coilers simultaneously to a progressive press tool (508) at least two separate strip guides (504-1 and 504-2),
wherein each of said at least two separate strip guides (504-1 and 504-2) comprises at least one set of cutting and punching guides incorporated in at least a single die plate and at least one punch plate, and said at least two separate strip guides are adapted to receive at least one loaded raw materials from the at least two de-coilers for simultaneously manufacturing at least two components in the single stroke of the press cycle.

2. The press machine as claimed in claim 1, wherein each of said at least two separate strip guides (504-1 and 504-2) comprises at least one cutting and punching guide being incorporated in a single die plate.

3. The press machine as claimed in claim 1, wherein said at least two separate strip guides (504-1 and 504-2) respectively comprises at least two set of cutting and punching guides being incorporated in a single die plate.

4. The press machine as claimed in claim 3, wherein each of said different set of cutting and punching guides having at least one punch plate.

5. The press machine as claimed in claim 3, wherein each of said different set of cutting and punching guides having a plurality of punch plates.

6. The press machine as claimed in claim 1, wherein the at least two components are similar components.

7. The press machine as claimed in claim 1, wherein the at least two components are dissimilar components.

8. The press machine as claimed in claim 1, wherein the raw materials are loaded independently on each of the at least two de-coilers (502-1, 502-2).

9. The press machine as claimed in claim 1, wherein the single stroke of the press cycle associated with the press machine is pre-defined and pre-determined.

10. The press machine as claimed in claim 1, wherein the press machine is adapted to produce a scrap-less strip layout.
, Description:TECHNICAL FIELD
[0001] The present disclosure relates to press machines, and more specifically relates to, a press machine having a progressive tool and a feeding system consisting of a de-coiler and a feeder, and used in metal forming industry.

BACKGROUND
[0002] Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
[0003] Metal forming can be done in various methods, i.e., by rolling, forging, press working, extrusion and drawing. The manufacturing process for sheet metal component or stamping is by processing a sheet metal coil or strip in a press tool. The sheet metal strip or coil may be of ferrous or non-ferrous materials. Press working is one of the major processing techniques for converting sheet metal into 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.
[0004] Components or articles can be formed with various methods of press working, which includes the use of mechanical presses, pneumatic presses, hydraulic presses, hydro-pneumatic presses, servo presses or multi-slide machines.
[0005] Any machine mentioned above requires a tool or a set of tools to manufacture the intended shape of the component. One of the most commonly used is the progressive tool for a press machine. A typical manufacturing process using a progressive tool includes a de-coiler, feeder and a tool. The process involved in this is given below:
a) Loading the raw material coil on the de-coiler
b) Feed the raw material to the tool through a de-coiler
c) Metal forming using the tool

[0006] Efforts have been made in related art to address above stated problem by using a progressive tool. An example of such progressive tool is recited in United States patent 2591483A, entitled “Progressive tool and improved method of progressively forming articles from strip stock or the like”. The patent discloses a progressive tool, and to an improved method of progressively forming articles from strip stock or the like. The method and apparatus which comprise this invention are particularly adapted for forming links of the type which are used to constitute cartridge belts, and in which method and apparatus, Successive operations are simultaneously performed on different blanks, or on different portions of the stock, as they progress through the tool. This patent talks about progressively forming metal components like cartridge belts having three rings. This is formed using a single strip coil.
[0007] However, in the present construction of the tool generally has a single cavity (with scrap / scrap-less strip layout) or a two cavity (with scrap strip layout). A single strip of sheet is fed into one side of the tool and then formed using series of punches present in the tool. The strip progresses in the tool with a given pitch and feed using a feeder system which is connected in the series to the press machine. The process is pictorial represented in FIG.1. Since a single strip of sheet is fed to the tool, this results in forming of a single component per stroke. In case it is a two-cavity system, two components are formed, with a lot of scrap as the by-product. This also means that the strip being used is not consumed to its maximum potential. Further, conventional tool gives an output of one component per stroke or two components with an inefficient coil stock ratio which thereafter generates a huge amount of scrap. Furthermore, one of the most challenging and critical operation in a press working process is the tool loading/unloading, tool setting and feeder setting. Combine this is a mass manufacturing component, the activity becomes daunting. Hence, to overcome these problems during production, there was a need to upgrade the existing process/technology.
[0008] Whereas there is certainly nothing wrong with existing techniques or system, nonetheless, there still exists a need to provide an efficient, effective, reliable and improved press machine having a progressive tool and a feeding system consisting of a de-coiler and a feeder, and used in metal forming industry. Further, there exists a need of a system which reduces the cost of the component with increased productivity and lowered process cost. Increasing productivity with existing process was a challenge, since the machine would form only a given number of components in a fixed amount of time, which directly co-relates to the speed of the machine in strokes per minute (SPM). Furthermore, there exists a need of a system which provides a single tool which would functionally act as two different set of tools having a scrap-less layout. So, two different set of cutting and punching guides is incorporated in the same die plate. Additionally, there exists a need of a system which is able to form two components with one stroke of the machine. The strip layout used is that of a scrap-less layout. The added advantage of proposed invention is that even if one of the cavities is under breakdown, the other cavity would function independently, i.e., one tool is able to act as two different set of tools working simultaneously on the same machine. Moreover, there exists a need of a system which increases the productivity of the process by 100% and also reduces the operational costs. Down time and tool loading time is also reduced by half.
[0009] All publications herein are incorporated by reference to the same extent as if each individual publication or patent application were specifically and individually indicated to be incorporated by reference. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply.
[00010] In some embodiments, the numbers expressing quantities of ingredients, properties such as concentration, reaction conditions, and so forth, used to describe and claim certain embodiments of the invention are to be understood as being modified in some instances by the term “about”. Accordingly, in some embodiments, the numerical parameters set forth in the written description and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by a particular embodiment. In some embodiments, the numerical parameters should be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of some embodiments of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as practicable. The numerical values presented in some embodiments of the invention may contain certain errors necessarily resulting from the standard deviation found in their respective testing measurements.
[00011] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
[00012] The recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise indicated herein, each individual value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g. “such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.
[00013] Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description of all groups used in the appended claims.

SUMMARY
[00014] The present disclosure relates to press machines, and more specifically relates to, a press machine having a progressive tool and a feeding system consisting of a de-coiler and a feeder, and used in metal forming industry.
[00015] Accordingly, an aspect of the present disclosure relates to a press machine for simultaneously manufacturing at least two components in a single stroke of a press cycle associated with the press machine. The press machine can include a feeding system having at least two de-coilers. The feeding system having at least two de-coilers having raw materials loaded thereon and at least one feeder to progressively transfer the raw materials loaded on each of said at least two de-coilers simultaneously to a progressive press tool at least two separate strip guides. Each of said at least two separate strip guides can include at least one set of cutting and punching guides incorporated in at least a single die plate and at least one punch plate, and said at least two separate strip guides are adapted to receive at least one loaded raw materials from the at least two de-coilers for simultaneously manufacturing at least two components in the single stroke of the press cycle.
[00016] In an aspect, each of said at least two separate strip guides includes at least one cutting and punching guide being incorporated in a single die plate.
[00017] In an aspect, at least two separate strip guides respectively includes at least two set of cutting and punching guides being incorporated in a single die plate.
[00018] In an aspect, each of said different set of cutting and punching guides having at least one punch plate.
[00019] In an aspect, each of said different set of cutting and punching guides having a plurality of punch plates.
[00020] In an aspect, at least two components are similar components.
[00021] In an aspect, at least two components are dissimilar components.
[00022] In an aspect, the raw materials are loaded independently on each of the at least two de-coilers.
[00023] In an aspect, the single stroke of the press cycle associated with the press machine is pre-defined and pre-determined.
[00024] In an aspect, the press machine is adapted to produce a scrap-less strip layout.
[00025] Various objects, features, aspects and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.

BRIEF DESCRIPTION OF THE DRAWINGS
[00026] The accompanying drawings are included to provide a further understanding of the present disclosure, and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure. The diagrams are for illustration only, which thus is not a limitation of the present disclosure, and wherein:
[00027] FIG. 1 illustrates a conventional layout of a press working process.
[00028] FIG. 2 illustrates a conventional single strip guide die plate.
[00029] FIG. 3 illustrates a conventional or typical strip layout of a single cavity tool.
[00030] FIG. 4 illustrates an exemplary strip layout of a single cavity tool with scrap-less layout, in accordance with an exemplary embodiment of the present disclosure.
[00031] FIG. 5 illustrates layout of proposed press working process, in accordance with an exemplary embodiment of the present disclosure.
[00032] FIG. 6 illustrates a proposed progressive tool, in accordance with an exemplary embodiment of the present disclosure.
[00033] FIG. 7 illustrates a top view of a proposed progressive tool, in accordance with an exemplary embodiment of the present disclosure.
[00034] FIG. 8 illustrates a schematic representation of a tool die plate, in accordance with an exemplary embodiment of the present disclosure.

DETAILED DESCRIPTION
[00035] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the scope of the present disclosure as defined by the appended claims.
[00036] If the specification states a component or feature “may”, “can”, “could”, or “might” be included or have a characteristic, that particular component or feature is not required to be included or have the characteristic.
[00037] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
[00038] Exemplary embodiments will now be described more fully hereinafter with reference to the accompanying drawings, in which exemplary embodiments are shown. These exemplary embodiments are provided only for illustrative purposes and so that this disclosure will be thorough and complete and will fully convey the scope of the invention to those of ordinary skill in the art. The invention disclosed may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Various modifications will be readily apparent to persons skilled in the art. The general principles defined herein may be applied to other embodiments and applications without departing from the scope of the invention. Moreover, all statements herein reciting embodiments of the invention, as well as specific examples thereof, are intended to encompass both structural and functional equivalents thereof. Additionally, it is intended that such equivalents include both currently known equivalents as well as equivalents developed in the future (i.e., any elements developed that perform the same function, regardless of structure). Also, the terminology and phraseology used is for the purpose of describing exemplary embodiments and should not be considered limiting. Thus, the present invention is to be accorded the widest scope encompassing numerous alternatives, modifications and equivalents consistent with the principles and features disclosed. For purpose of clarity, details relating to technical material that is known in the technical fields related to the invention have not been described in detail so as not to unnecessarily obscure the present invention.
[00039] Each of the appended claims defines a separate invention, which for infringement purposes is recognized as including equivalents to the various elements or limitations specified in the claims. Depending on the context, all references below to the "invention" may in some cases refer to certain specific embodiments only. In other cases it will be recognized that references to the "invention" will refer to subject matter recited in one or more, but not necessarily all, of the claims.
[00040] All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.
[00041] Various terms as used herein are shown below. To the extent a term used in a claim is not defined below, it should be given the broadest definition persons in the pertinent art have given that term as reflected in printed publications and issued patents at the time of filing.
[00042] The present disclosure relates to press machines, and more specifically relates to, a press machine having a progressive tool and a feeding system consisting of a de-coiler and a feeder, and used in metal forming industry.
[00043] In the prior art, conventional tool generally has a single cavity (with scrap / scrap-less strip layout) or a two cavity (with scrap strip layout). A single strip of sheet is fed into one side of the tool and then formed using series of punches present in the tool. The strip progresses in the tool with a given pitch and feed using a feeder system which is connected in the series to the press machine. The process is pictorial represented in FIG.1. Since a single strip of sheet is fed to the tool, this results in forming of a single component per stroke. In case it is a two-cavity system, two components are formed, with a lot of scrap as the by-product. This also means that the strip being used is not consumed to its maximum potential. Further, conventional tool gives an output of one component per stroke or two components with an inefficient coil stock ratio which thereafter generates a huge amount of scrap. Furthermore, one of the most challenging and critical operation in a press working process is the tool loading/unloading, tool setting and feeder setting. Combine this is a mass manufacturing component, the activity becomes daunting. Hence, to overcome these problems during production, there was a need to upgrade the existing process/technology.
[00044] The present invention provides a press machine having a progressive tool and a feeding system consisting of a de-coiler and a feeder, and used in metal forming industry. The proposed system which reduces the cost of the component with increased productivity and lowered process cost. Increasing productivity with existing process was a challenge, since the machine would form only a given number of components in a fixed amount of time, which directly co-relates to the speed of the machine in strokes per minute (SPM). The proposed system provides a single tool which would functionally act as two different set of tools having a scrap-less layout. So, two different set of cutting and punching guides is incorporated in the same die plate. The proposed system able to form two components with one stroke of the machine. The strip layout used is that of a scrap-less layout. The added advantage of proposed invention is that even if one of the cavities is under breakdown, the other cavity would function independently, i.e., one tool is able to act as two different set of tools working simultaneously on the same machine. The proposed system increases the productivity of the process by 100% and also reduces the operational costs. Down time and tool loading time is also reduced by half.
[00045] FIG. 1 illustrates a conventional layout of a press working process.
[00046] FIG. 2 illustrates a conventional single strip guide die plate.
[00047] FIG. 3 illustrates a conventional or typical strip layout of a single cavity tool.
[00048] Since a single strip of sheet is fed to the tool, this results in forming of a single component per stroke. In case it is a two-cavity system, two components are formed, with a lot of scrap as the by-product. This also means that the strip being used is not consumed to its maximum potential. Hence, often only a single cavity scrap-less layout is used, thereby producing one component per stroke of the press machine. A typical strip layout of a single cavity tool is shown in FIG. 3. Strip layout of a single cavity tool with scrap less layout is shown in FIG. 4.
[00049] As part of life cycle management and technology up gradation in the field of press working, the proposed invention overcomes the drawbacks mentioned with the existing process of manufacturing. With added technology, it was important to reduce the cost of the component with increased productivity and lowered process cost. Increasing productivity with existing process was a challenge, since the machine would form only a given number of components in a fixed amount of time, which directly co-relates to the speed of the machine in SPM (strokes per minute). Hence, the proposed invention produce two components with a single stroke of the press machine and by also keeping the strip layout as a scrap-less layout, which was never done before. The proposed invention provides a new tool design which is different from the conventional tool design. The proposed single tool which would functionally act as two different set of tools having a scrap-less layout. So, two different set of cutting and punching guides incorporated in the same die plate. The mating surfaces of the top/punch plate were modified accordingly to accommodate the said changes. With these changes made the proposed tool able to form two components with one stroke of the machine. The strip layout used is that of a scrap-less layout. The added advantage of proposed invention is that even if one of the cavities is under breakdown, the other cavity would function independently, i.e., one tool is able to act as two different set of tools working simultaneously on the same machine. Also new system increases the productivity of the process by 100% and also reduces the operational costs. Down time and tool loading time is also reduced by half.
[00050] FIG. 4 illustrates an exemplary strip layout of a single cavity tool with scrap-less layout, in accordance with an exemplary embodiment of the present disclosure.
[00051] FIG. 5 illustrates layout of proposed press working process, in accordance with an exemplary embodiment of the present disclosure.
[00052] In an embodiment, the proposed system can include two de-coilers (interchangeably referred as “coil” or “coiler”) 502-1, 502-2 on to which the raw material coils are loaded. Strips 504-1 and 504-2 are then fed to the progressive tool 508 using a single feeder mechanism or single feeder or feeder (hereinafter interchangeably referred as “single feeder” “feeder”) 506.
[00053] In an exemplary embodiment, two separate coil 502-1, 502-2 feeding in a single tool using the single feeder 506 to produce two components with single stroke of the press machine. In another exemplary embodiment, two strips 504-1 and 504-2 can guide in the single die plate.
[00054] In an exemplary embodiment, the press tool is progressive in nature, i.e., it has a series of stations within the tool itself, is now able to produce two components at a single stroke of the press cycle as compared to one component per stroke with previous method.
[00055] In an embodiment, a coil stock of the raw material can be loaded independently on the two de-coilers 502-1, 502-2. These coils 502-1, 502-2 can be passed through the single feeder 506, whose pitch and feed rate are set according to the required component profile and also according to the strip layout designed initially. The feeder 506 helps in progressively transferring the coil into the tool at a definite rate.
[00056] In another embodiment, the proposed tool that has been loaded on to the press machine is set to operate at a certain speed, which is generally measured as strokes per minute. The set speed of the machine is in turn the number of cyclic movements that the tool will be subjected to in a minute; this directly corresponds to the output of the tool.
[00057] In an exemplary embodiment, the proposed tool can have two strip guide mechanism 504-1 and 504-2, the output results in two components per stroke of the machine, with maximum strip utilization. Whereas, the conventional tool would give an output of one component per stroke or two components with an inefficient coil stock ratio which thereafter generates a huge amount of scrap.
[00058] In an exemplary embodiment, one of the most challenging and critical operation in a press working process is the tool loading/unloading, tool setting and feeder setting. Combine this is a mass manufacturing component, the activity becomes daunting. Hence, to overcome these problems during production, there was a need to upgrade the existing process/technology. This resulted in coming up with a solution which could not only increase the production in the existing time frame, but also benefit the operator by reducing the tool down time and operation time.
[00059] FIG. 6 illustrates a proposed progressive tool, in accordance with an exemplary embodiment of the present disclosure.
[00060] Fig. 6 shows the construction of the proposed progressive tool with two separate strip guides. It can be seen from the picture that there are two different sets of piercing and cutting punches for the two strip guides. This enables the tool to function as two different set of tools running on the same machine at the same time, also with a scrap-less strip layout. Thereby, having the maximum strip utilization for any component formed through press working.
[00061] FIG. 7 illustrates a top view of a proposed progressive tool, in accordance with an exemplary embodiment of the present disclosure. FIG. 7 shows the top view of the new progressive tool. The two separate strip guides can be seen here. Two sets of cutting & piercing tools also have been highlighted.
[00062] Even though the new invention is a modification of the existing process, the benefit achieved with this is enormous. As shown in FIG. 7, the use of two strip guides has been incorporated in one single die plate. This not only doubles the productivity, but it also eliminates the need of an extra tool which is required to manufacture the components whose volumes are massive. Hence, the proposed invention results in lower operational costs.
[00063] FIG. 8 illustrates a schematic representation of a tool die plate, in accordance with an exemplary embodiment of the present disclosure.
[00064] The foregoing description of the specific embodiments will so fully reveal the general nature of the invention that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation.
[00065] It should be apparent to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. Moreover, in interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification claims refers to at least one of something selected from the group consisting of A, B, C ….and N, the text should be interpreted as requiring only one element from the group, not A plus N, or B plus N, etc. The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the scope of the appended claims.
[00066] While embodiments of the present disclosure have been illustrated and described, it will be clear that the disclosure is not limited to these embodiments only. Numerous modifications, changes, variations, substitutions, and equivalents will be apparent to those skilled in the art, without departing from the scope of the disclosure, as described in the claims.
[00067] In the description of the present specification, reference to the term "one embodiment," "an embodiments", "an example", "an instance", or "some examples" and the description is meant in connection with the embodiment or example described The particular feature, structure, material, or characteristic included in the present invention, at least one embodiment or example. In the present specification, the term of the above schematic representation is not necessarily for the same embodiment or example. Furthermore, the particular features structures, materials, or characteristics described in any one or more embodiments or examples in proper manner. Moreover, those skilled in the art can be described in the specification of different embodiments or examples are joined and combinations thereof.
[00068] All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.
[00069] Each feature disclosed in this specification (including any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.
[00070] The invention is not restricted to the details of the foregoing embodiment(s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.
[00071] While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.