Magnetic press brake and machine tooling engagement systems

A machine tool apparatus for a press brake, folding press or punch press system includes a tool holder body having a receiving portion configured for selective engagement with a coupling end of a machine tool. The apparatus also includes a magnetic coupling assembly comprising one or more magnetic elements configured to generate a magnetic coupling adapted for the selective engagement of the tool holder body with the coupling end of the machine tool. In some embodiments, the apparatus may further include an actuator configured to manipulate at least one of the magnetic elements to modulate the strength of the magnetic coupling for selective engagement and disengagement of the tool holder body with the coupling end of the machine tool.

TECHNICAL FIELD

This application is directed to engagement systems for press brake tooling and other machine tool components. Applications include, but are not limited to, magnetic engagement mechanisms for press brake tooling and press brake tool holders. The technology can be adapted to punch press and press brake tooling for sheet metal fabrication, and other machine tool punch and die systems.

BACKGROUND

A typical machine press system includes a press apparatus with an upper table or ram arranged to move vertically with respect to a lower table or other (e.g., stationary) fixture. Different press brake and punch tooling components can be mounted to the upper and lower tables, and configured to bend or impress a sheet metal element or other workpiece by operation of the press. Generally, the upper table can be configured for coupling with (e.g., male) punch or press brake tooling components adapted for the desired sheet metal fabrication or other manufacturing applications, in cooperation with complementary (e.g., female) forming tools such as dies coupled with the lower table. Alternatively, the upper and lower table arrangement may be reversed, and the punch apparatus can be either horizontally or vertically oriented. A variety of different press brake and punch tooling components can also be employed, in order to perform selected forming operations on a range of different workpieces.

In operation, it can often be necessary to exchange tooling on either the upper or lower table (or both), in order to perform the desired press operations. On the upper table or ram, the forming tools may be held in place by a clamping mechanism configured to engage each machine tool component simultaneously within a tool holder. Upon unlocking or releasing the clamping mechanism, the tooling is disengaged and can be removed, for example by sliding the tooling components horizontally to an open end of the table, or by manipulating in a vertical or transverse direction to disengage the tooling from the holder.

The exchange of press brake and punch tooling can be time consuming and cumbersome due to proximity to the press apparatus and other tooling component in the upper or lower tables. This may necessitate the removal of some or all of the adjacent tooling components when only selected tools are being exchanged, and the clamping mechanism itself can also interfere with tooling selection. Similar shortcomings may exist with respect to both male and female tooling, e.g., whether supported from a tool holder in the upper table or ram, or from a lower table, die holder or similar fixture.

Tooling removal and insertion operations may introduce safety risks associated with handling the (often heavy) machine tool components. In particular, loosening the clamping mechanism without taking proper precautions may result in one or more tool components coming loose or falling, which can in turn result in process delays or tooling damage, or introduce a risk of operator injury. To prevent this, mechanisms such as safety tangs have been developed, e.g., with a tang member that protrudes laterally from an engagement surface of the tooling component, and is adapted to engage a complementary groove defined by the tool holder to secure the tool until is it clamped. Such mechanisms may require additional manipulations by the operator to actuate the safety mechanism, which may be concealed by the holder or otherwise not directly accessible. For these and other reasons, there is a need for improved techniques to engage and secure punch and press brake tooling to a table or ram while the clamping mechanism is disengaged. These techniques are also applicable to engage and secure machine tool, punch and die and components for which no clamping mechanism is provided.

SUMMARY

In accordance with the various examples and embodiments of the disclosure, a machine tool apparatus may include a tool holder or holder body defining a receiving portion configured for selective engagement with a coupling end of a machine tool, for example a press brake or punch tooling component. A magnetic coupling assembly or mechanism can be provided for engaging the machine tool with the holder, including one or more magnetic elements configured to generate a magnetic coupling adapted for selective engagement and disengagement of the holder with the coupling end of the machine tool.

The magnetic elements may include both field sources (e.g., permanent magnets or other sources of magnetic flux) and flux guides (e.g., ferromagnetic elements or similar materials with suitable magnetic properties). An actuator can be configured to manipulate at least one of the magnetic elements to modulate a strength of the magnetic coupling, in order to achieve selective engagement and disengagement of the holder with the coupling end of the machine tool. In some examples, the components of the magnetic assembly may be fixed or movable in position or rotation and switchable, selective, non-switchable or non-selective with respect to magnetic orientation, such that the magnetic coupling assembly is configured to generate a selective magnetic coupling adapted for engagement and disengagement of the tool holder with the coupling end of the machine tool insert.

In some embodiments, the actuator may be configured to manipulate at least one of the magnetic elements of the magnetic coupling assembly between a locked or engaged position, in which the coupling end of the machine tool is selectively engaged within the receiving portion of the holder body, and an alternate unlocked or disengaged position, in which the coupling end of the machine tool is selectively disengaged from the receiving portion of the holder body. For example, one or more of the magnetic elements may be responsive to actuation of the actuator, such that the locked and unlocked positions are bi-stable. In the locked position, the magnetic coupling may support a weight of the machine tool disposed within the receiving portion of the holder body, e.g., within a vertically oriented upper table or ram.

Some embodiments may include an adjustment mechanism configured to adjust a strength of the magnetic coupling, e.g., in order to support the weight of a selected machine tool component. Press brake and punch press apparatus embodiments are also encompassed, along with their associated punch press and press brake tooling components and corresponding methods of manufacture and fabrication of sheet metal elements and other workpieces.

Some embodiments may include a machine die apparatus. The machine die apparatus may include a tool holder body having a receiving portion configured for selective engagement with a coupling end of a machine die. The machine die apparatus may further include a magnetic coupling assembly comprising one or more magnetic elements configured to generate a magnetic coupling adapted for the selective engagement of the tool holder body with the coupling end of the machine die. In some examples, the magnetic components of the machine die apparatus may be fixed or movable in position or rotation and switchable, selective, non-switchable or non-selective with respect to magnetic orientation, such that the magnetic coupling assembly is configured to generate a selective magnetic coupling adapted for engagement and disengagement of the tool holder body with the coupling end of the machine die.

DETAILED DESCRIPTION

FIG. 1Ais an isometric view of a press brake, punch or similar machine tool apparatus100having a tool holder102coupled with a machine tool or tool insert104. While generally described as a press brake tool herein, tool104may alternatively be configured as a press brake punch, folding press, punch tool, or similar machine tool component for use with a press brake or punch press apparatus.

As illustrated inFIG. 1A, holder102may define a receiving portion or cavity106exposed at holder side surface108. Tool104may be coupled with holder102by inserting an upper portion or tang110of the tool into receiving cavity106, where at least one relief, groove, recess, shelf or ledge112may provide a surface for mounting tool102. Opposite holder102, tool104includes a tool end or working end114.

To lock or otherwise secure tool104to holder102, a movable clamp116secured to holder102may be tightened against a surface of tang110, thereby laterally sandwiching tang110between clamp116and an opposing stationary surface of receiving cavity106. To tighten and loosen clamp116, a front surface118of holder102may be configured to receive one or more fasteners through at least one fastener aperture120. In operation, such a press brake assembly may punch, impress, crimp, fold, crease or otherwise shape various workpieces inserted beneath working end114and optionally one or more forming dies. In embodiments, a workpiece may include a sheet material component or other material to be tooled.

FIG. 1Bis a front view of machine tool apparatus100with holder102coupled to tool104, showing three fasteners121inserted within apertures120of front surface118. Fasteners121may include various set screws, studs, T-handles, pins, cams, levers, or bolts. As such, the fasteners may be driven into and out of apertures120with a drill, screw driver, or hex key.

FIG. 1Cis a section view of machine tool apparatus100with holder102coupled to tool104, taken along line B-B ofFIG. 1B. This section view illustrates the inner portion of holder102and tool104. As shown, each fastener121may extend through a portion of holder102, contacting clamp116at one end. By adjusting the distance by which clamping bar116protrudes into receiving cavity106, via the fasteners, differently-sized tangs may be coupled tightly with holder102.

FIG. 1Dis a side view of machine tool apparatus100with holder102coupled to tool104, taken at detail B ofFIG. 1C. As more closely shown inFIG. 1D, fastener121may define a tapered edge122, which may directly contact clamp116when fastener121is inserted through aperture120. In the engaged configuration shown, the lateral gaps present between tapered edge122, clamp116and tang110may be reduced or eliminated.

Magnetic Tooling Engagement

FIG. 2Ais an isometric view of a magnetic engagement system200for a tool holder202coupled with a machine tool or tool insert204, e.g., a press brake or punch tooling component. As shown, magnetic tool holder202may define two opposing tool shoulders205a,205b. A receiving portion or cavity206comprising a cavity ceiling207is defined at side surface208of holder202. Tool204may be coupled with holder202by inserting an upper portion or tang210of the tool into receiving cavity206such that two shoulders211a,211bof the tool abut shoulders205a,205bof the holder.

In some embodiments, the tool204may define only one shoulder, e.g., shoulder211aor211b, such that only one of the opposing tool shoulders205aor205babuts the shoulder of the tool when inserted within receiving cavity206. In some examples, receiving cavity206may define at least one relief, groove, recess, shelf or ledge212. Like tool104, tool204may define a working end214opposite the holder. Side surface208may define one or more apertures216a,216b, each exposing a portion of a slidable rack218aand218b, respectively.

An upper stator magnet219a,219bmay be positioned above each rack218a,218b, and a lower stator magnet220a,220bmay be positioned below each rack. In the embodiment shown, a portion of each stator magnet219a,219b,220a,220bis exposed through each aperture216a,216b.FIG. 2Aalso shows vertical center magnets222protruding from holder202into receiving cavity206, where an end of each center magnet222may directly contact an upper surface of tang210after its insertion.

A handle, lever or other actuator224is attached to front surface225of holder202. In this particular example, actuator224includes an elongated knob226, but in various embodiments actuator224may comprise any protrusion or feature manipulable or graspable by an operator for manually securing holder202to tool204. As described in greater detail below, actuator224may be operatively coupled with slidable racks218a,218bsuch that moving, rotating, or otherwise adjusting or manipulating actuator224may cause the racks to slide longitudinally within holder202. A plurality of fastener apertures228are defined by front surface225, the apertures configured to receive fasteners that may be tightened to urge a clamping bar or similar clamping mechanism235against a surface of tang210.

Together, actuator224, racks218a,218b, and various magnetic elements included within holder202may comprise at least a portion of a coupling mechanism configured to reversibly couple tool204with holder202. More particularly, the magnetic elements may form a magnetic assembly configured to generate a magnetic flux coupling between holder202and tool204. By selectively manipulating at least one of the magnetic elements, for example by physically moving the element(s), the coupling mechanism modulates the strength of the magnetic flux coupling by guiding the flux between the tool holder202and machine tool204, thereby regulating the strength of the magnetic coupling to switch holder202between engaged (locked), disengaged (unlocked) and/or intermediate configurations with respect to tool204. Tool204may include or be made of ferromagnetic materials selected to increase the strength of the magnetic coupling, and to guide the flux from the tool holder202to the tool204, and back from the tool204to the tool holder202.

The coupling mechanism may be used to couple tool204with holder202while arranging or staging additional tools within holder202and/or other holders. In some embodiments, the coupling mechanism may provide a safety mechanism for temporarily coupling tool204with holder202, for example before an additional clamping mechanism is activated and the press brake apparatus begins operating to form a workpiece. In some examples, the magnetic coupling mechanism may suffice to secure tool204with holder202without additional support, for example as provided by clamping bar235. Alternative examples may include fixed or stationary magnets, e.g., fixed, non-switchable magnets. Such embodiments may be sufficient for coupling smaller tools, in particular, and may exert a magnetic flux coupling readily overcome by manual engagement.

FIG. 2Bis an alternate isometric view of magnetic engagement system200for tool holder202coupled with machine tool204. As shown, actuator224may be positioned approximately near the center of front surface225. Three fasteners229, e.g., set screws, are also shown inserted into each of the fastener apertures228. Fasteners229may be implemented in embodiments in which tool204is particularly heavy and/or an amount of side loading or torque may be applied against tool204during operation, thereby necessitating the supplemental clamping force provided by the fasteners applying a lateral force against clamping bar235.

In some embodiments, where a basal or nominal level of magnetic coupling strength is sufficient to retain tool204within a disengaged holder202, for example, fasteners229and tightening clamp235may be unnecessary. Such embodiments may thus lack fastener apertures228within front surface225or elsewhere on holder202, and may also lack clamping bar235. In some embodiments, however, the magnetic strength of the coupling mechanism provided by the magnetic elements may be relied upon to retain tool204on a temporary basis, e.g., while staging for tool installation. In such embodiments, the physical coupling mechanism provided by clamping bar235may provide the supplemental clamping strength necessary to secure tool204in place for use in metal forming operations.

In implementations that include clamping bar235, receiving cavity206may be partially defined by a stationary side, e.g., the interior surface of shoulder205a, and an opposing movable side comprised of clamping bar235. In some examples, clamping bar235may be configured for selective engagement with a surface of the coupling end of the machine tool in response to activation of the magnetic flux coupling. Additional embodiments may include alternative mechanisms for adjusting clamping bar235, e.g., other than fasteners229. For example, clamping bar235may be movable by a cam and lever and/or an electric or hydraulic actuator.

FIG. 2Cis an isometric view of engagement system200for tool holder202coupled with machine tool204, showing the internal configuration of a magnetic assembly embedded within the holder. Pinions232aand232bare coupled with an axle234, which begins at actuator224and extends laterally though the body of holder202. Each pinion232a,232bis configured to engage a complementary gear surface233defined by each rack218a,218b, such that rotation of each pinion causes each rack to slide longitudinally within the holder, transverse to axle234. Each of the racks218a,218bincludes a plurality of alternately-oriented rack magnets, which may be embedded within or otherwise fixed or coupled with the racks.

In the example shown, rack218aincludes four pairs of rack magnets, each pair comprising a first rack magnet236aand a second rack magnet237a. Likewise, rack218bincludes four pairs of rack magnets, each pair comprising a first rack magnet236band a second rack magnet237b. Four vertical center magnets222are included in this embodiment, each positioned proximate, e.g., beneath, a vertically oriented center spring238. Pairs of ferromagnetic brushes240a,240bextend laterally outward from each center magnet222, mating with a portion of each upper stator magnet219a,219b. In various embodiments, each brush may comprise a high-permeability, ferromagnetic material.

The magnetic assembly shown inFIG. 2Cis configured to induce parallel magnetic circuits of adjustable, magnetic strength (e.g., switchable with respect to magnetic orientation) for selectively engaging and disengaging holder202with tool204by exerting a reversible pulling force thereon or a reversible attractive force therebetween. In an unclamped, unlocked or otherwise disengaged state, when the magnetic strength is reduced, the holder202may allow installation and removal of tool204with respect to receiving cavity206. In a clamped, locked or otherwise engaged state, when the magnetic strength is increased, the holder202may hold the tool204in place for use in forming and/or folding operations. As shown, upper stator magnets219a,219band lower stator magnets220a,220bmay be included within both shoulders205a,205bof holder202, so as to exert a magnetic pulling or attractive force on both shoulders211a,211band tang210of tool204.

In operation, the magnetic assembly of holder202is configured to generate a magnetic flux coupling adapted for the selective engagement of the tool204, specifically at tang210, which may be ferromagnetic and comprised of carbon steel or medium alloy steel in some embodiments. The magnetic flux coupling may be engaged, and disengaged, by manually manipulating actuator224via knob226. In turn, actuator224manipulates at least one of the internal magnetic elements shown inFIG. 2Cto modulate the strength of the magnetic flux coupling.

The strength of the magnetic flux coupling may be adjusted by altering the alignment of rack magnets236a/b,237a/bwith the upper stator magnets219a,219band lower stator magnets220a,220b. Adjusting the alignment of the rack magnets relative to the stator magnets is driven by rotation of the pinions232a/b, which causes the racks, and thus the rack magnets embedded therein, to slide within the holder. In some examples, the slidable racks, along with the magnets embedded therein, are responsive only to the actuator, such that the locked and unlocked positions of the holder are bi-stable or non-momentary.

The number of parallel pairs of magnetic components, e.g., upper stator magnets219a/b, lower stator magnets220a/band ferromagnetic brushes240a/bmay vary. The example shown includes four parallel magnetic subassemblies, each subassembly including single center magnet222. The number of magnetic subassemblies may range from 1 to about 10, 1 to about 15, 1 to about 20, or any suitable range therebetween and may depend at least in part on the length of the holder and/or the weight of the tool to be coupled with the holder. In some examples, each subassembly may induce two magnetic circuits.

FIG. 2Dis a section view of engagement system200for tool holder202coupled with machine tool204, showing the internal arrangement and magnetic orientation of a magnetic subassembly in an engaged configuration of holder202. As illustrated inFIG. 2D, the magnetic elements within holder202are magnetically oriented to induce a magnetic circuit in the engaged configuration. In particular, each of the lower stator magnets220a,220bis oriented such that its north pole is positioned above its south pole, and each of the upper stator magnets219a,219b, positioned directly above the lower stator magnets, is also oriented such that its north pole is oriented above its south pole. The magnets may be arranged in the reverse orientation in additional examples. Similarly, rack magnets237aand237bare also oriented with the north pole facing up in this configuration.

The center magnet222is magnetically oriented with its south pole facing up, e.g., in the reverse orientation relative to the stator magnets and rack magnets. Ferromagnetic brushes240a,240bare positioned laterally between each upper stator magnet219a,219band center magnet222, and when inserted into receiving cavity206, tang210of tool204is positioned below center magnet222and laterally between each lower stator magnet220a,220b. As a result, a magnetic circuit that generates a magnetic flux may be established through the magnetic elements included in holder202.

The flux may pass vertically through upper stator magnet219a, laterally through ferromagnetic brush240a, vertically through center magnet222, diagonally through tang210, and vertically through lower stator magnet220a. A similar magnetic circuit may be simultaneously established through lower stator magnet220b, rack magnet237b, upper stator magnet219b, ferromagnetic brush240b, center magnet222and tang210. Thus, parallel magnetic circuits may be established in the configuration shown, collectively generating a total magnetic force sufficient to couple tool204with holder202.

In some embodiments, clamping bar235may contribute and/or be affected by the magnetic circuits, particularly the circuits generated by the magnetic components embedded in shoulder205b. As a result, clamping bar235may not drop, droop or otherwise hang down within receiving cavity206. Securing clamping bar235via the magnetic circuits to prevent dropping may be necessary to properly position the clamping bar for tightening against tang210without, for example, lowering tool204onto a deformable material to force the tool and the clamping bar into an acceptable position for clamping.

Suitable configurations may also include one or more magnetic components coupled with clamping bar235, for example embedded within clamping bar235or installed in a top portion of the clamping bar. Such magnetic components may urge clamping bar235against the inner surface of shoulder205b, and may also contribute to the magnetic pulling or attractive force exerted on tool204. In addition or alternatively, one or more magnetic components may be included within shoulder205bto pull clamping bar235tightly against an inner surface thereof, preventing the clamping bar from drooping or dropping in a vertical direction. In addition or alternatively, one or more magnetic components may be installed in a bottom portion of clamping bar235to urge the clamping bar against shoulder205b. Magnetic components included in both a top and bottom portion of clamping bar235may also be included.

To strengthen the magnetic circuits established by the magnetic components embedded within shoulders205a/b, the clamping bar magnets can each be similarly oriented, e.g., either north-to-south or south-to-north. Clamping bar235may comprise a ferromagnetic material or a non-ferromagnetic material. In some embodiments, clamping bar235may include one or more high-permeability inserts aligned with the magnetic components included in shoulder205bof the holder body such as to avoid interference with, and/or contribute to, the magnetic circuit passing therethrough.

As disclosed, each pair of rack magnets (e.g.,236aand237a) may comprise oppositely oriented magnets, alternating between north pole-up and south pole-up along the length of each slidable rack218a,218b. Because each rack magnet within a rack magnet pair is oppositely oriented, and because the slidable racks are positioned between each pair of upper and lower stator magnets, sliding the racks alternately strengthens or disrupts the magnetic circuit established in the configuration depicted inFIG. 2D, depending on which rack magnet, e.g.,236avs.237a, is aligned with a pair of lower and upper stator magnets. For instance, rack magnet237ais shown in magnetic alignment with lower stator magnet220aand upper stator magnet219a. However, upon manipulating actuator224via knob226, rack218amay slide longitudinally (into or out of the page), thereby moving rack magnet237aout of alignment with upper stator magnet219aand lower stator magnet220a.

Because each rack magnet may comprise a relatively strong magnetic material, e.g., an NdFeB or similar permanent magnet material, such misalignment may disrupt the magnetic circuit and allow tang210, and thus tool204, to be released from holder202. In this manner, actuator224may modulate the strength of the magnetic flux coupling between holder202and tool204, switching the holder between locked and unlocked configurations by adjusting the alignment of the rack magnets with the other magnetic components of the holder via movement of the slidable racks.

In various embodiments, center magnets222may be vertically slidable to adapt to variation in the amount of clearance between the top surface of tang210and cavity ceiling207. The amount of clearance may vary due to variation in punch tang heights, with greater clearance generally resulting from shorter tangs relative to taller tangs. Thus, to accommodate tangs of different heights, center magnets222may slide up and down within cylindrical holes in the body of holder202, between the arcuate side surfaces of each ferromagnetic brush240a,240b.

Because tang210may contact center magnet222, the vertical distance by which the center magnet protrudes into the holder body may depend on the height of the tang, such that taller tangs may force the center magnet further into the holder body. Center springs238positioned above each center magnet may accommodate such movement by compressing upon insertion of the tang. Upon release of the from the receiving cavity, the springs may urge center the magnet back downward, returning the magnet back to its resting state position ready to receive another tang.

To establish defined magnetic circuits between the magnetic components of holder202, e.g., permanent magnets, ferromagnetic elements and/or electromagnets, the holder body may comprise a non-ferromagnetic material, including various stainless steels, e.g., austenitic stainless steel. In some embodiments, the holder body may include one or more high-permeability inserts aligned with the stator magnets and center magnets to optimize the magnetic circuits generated therethrough. In some embodiments, at least a portion of the body of the holder may be ferromagnetic.

FIG. 2Eis an isometric view of magnetic engagement system200for tool holder202, highlighting the internal structure of upper stator magnet219a, lower stator magnet220a, and center magnet222. As shown, each of these magnetic elements may be vertically oriented within holder202, transverse to the ferromagnetic brushes. The relative dimensions of each magnet are merely examples, and other configurations may be acceptable. In this particular embodiment, lower stator magnet220aand upper stator magnet219aare approximately cylindrical and elongate. Center magnet222defines alternating wide and narrow portions, the narrow portions facilitating slidable retention within the holder body.

FIG. 2Fis a section view of magnetic engagement system200for tool holder202coupled with machine tool204, showing the internal configuration of pinions232a,232b, actuator224and axle234. As shown, the length of axle234may be approximately equal to the width of holder204. Pinion232ais positioned directly above rack218aand pinion232bis positioned directly above rack218b, such that rotation of pinion232acauses rack218ato slide, and rotation of pinion232bcauses rack218bto slide. As further illustrated inFIG. 2F, fastener229may extend within aperture228through a portion of holder204such that an end of the fastener contacts clamp235. Tightening of fastener229may thus apply a lateral force against clamp235, urging the clamp against the side surface of tang210. In this manner, fastener229may apply a mechanical coupling mechanism in addition to the adjustable magnetic coupling mechanism comprised of the magnetic elements discussed above.

FIG. 2Gis an isometric view of magnetic engagement system200for holder202coupled with machine tool204, showing the internal structure of the holder210in an engaged configuration with the tool. In the engaged configuration, slidable racks218aand218bare positioned such that rack magnets237aand237b, respectively, are aligned with each set of the upper stator magnets219a,219band lower stator magnets220a,220b. The polarity of the rack magnets strengthens a magnetic circuit with the upper and lower stator magnets, ferromagnetic brushes, center magnets, and tang sufficient to reversibly couple tool204with holder202. As further shown, knob226is biased to the right in this configuration.

FIG. 2His an isometric view of magnetic engagement system200for holder202coupled with machine tool204, showing the internal configuration of holder202in a disengaged configuration with the tool204. In the disengaged configuration, slidable racks218aand218bare positioned such that rack magnets236aand236b, respectively, are aligned with each set of upper stator magnets219a,219band lower stator magnets220a,220b. The reverse polarity of rack magnets236aand236bdisrupts the magnetic circuit between the upper and lower stator magnets, ferromagnetic brushes, center magnets222, and tang210. Such disruption may be sufficient to disengage, or release, tool204from holder202.

In some embodiments, an amount of residual magnetic strength or coupling force may remain even in the disengaged configuration. The magnetic strength of the holder remaining in the disengaged configuration may be sufficient to retain various tools, especially smaller or less heavy tools. This basal or residual magnetic strength may be particularly advantageous for coupling multiple tools within the same holder, as the first-inserted tools may remain coupled with the holder while additional tools are added. After all tools are coupled with such a holder, the actuator224may be manipulated to switch the holder into the engaged configuration, ready for operation. Relative to its orientation inFIG. 2G, knob226is biased to the left as a result of its engagement by a user. Slidable racks218a,218bare also positioned deeper within the body of holder202.

In various examples, one or more control mechanisms may also be implemented to adjust the strength of the magnetic flux coupling between holder202and tool204. For example, a control mechanism may be configured to reduce the strength of the magnetic circuit generated by the holder while various tools are being coupled with the holder. When all tools are correctly positioned, an operator can fully activate the control mechanism to secure all tools to the holder.

As further discussed below with reference toFIGS. 8A-8H, one or more magnetic elements of the holder may comprise an electromagnet. The electromagnet may be configured to modulate the strength of the magnetic flux coupling between the tool and the holder under the direction of an instruction received from a press control panel or directly at the press brake assembly. In some embodiments, the control mechanism may include an electronic controller. The electronic controller may include or be at least communicatively coupled with a sensor configured to detect the presence or absence of tool204within receiving cavity206. Based on this detection, the sensor provides feedback signaling to the electronic controller. Additional components of the controller may then adjust the position of the slidable racks218a,218bto increase, decrease, or maintain the magnetic strength of holder202. For example, the sensor may determine that tang210is positioned within, or in close proximity to, receiving cavity206, prompting the sensor to provide an indication to the controller that a magnetic coupling should be established or strengthened to couple holder202with tool204.

FIG. 2Iis an isometric view of a rotatable pinion and actuating handle assembly230, e.g., for a magnetic engagement system200as described herein. As shown, each pinion232a,232bmay define a central, circular aperture configured to receive axle234. The pinions may each be fixed to axle234to prevent the pinions from sliding along the axle and ensure that rotation of axle234causes concurrent rotation of each pinion. The pinions may thus rotate in synchronized fashion upon engagement of actuator224, which comprises a circular cap portion and protruding knob226in this embodiment. Actuator224may rotate relative to side surface225of holder202upon manual manipulation of knob226. In additional embodiments, the actuator may be configured to slide along the length of holder202to effect rotation of the pinions. In embodiments that include an electronic controller, a manually manipulable actuator, such as actuator224, may be absent.

FIG. 2Jis an isometric view of a ferromagnetic brush assembly240with a plurality of two or more ferromagnetic brushes240aand240b. Each ferromagnetic brush defines two arcuate, e.g., semicircular, end portions. One end portion of each brush is configured to mate with a complementary surface of center magnet222, and a second end portion, opposite the first, is configured to mate with a complementary surface of upper stator magnet219a(with respect to ferromagnetic brush240a) or upper stator magnet219b(with respect to ferromagnetic brush240b). The brushes may be press-fit or affixed within holder202. The ferromagnetic material comprising each brush may vary, provided the material is sufficient to propagate a magnetic flux between center magnet222and the upper stator magnets. In some examples, the brushes may be highly permeable and may comprise a magnetically soft material such as silicon steel or 47-50 Fe—Ni alloy.

FIG. 2Kis an isometric view of a rack assembly245with slidable rack218aand paired rack magnets236a,237aembedded therein. This particular rack comprises four pairs of rack magnets, but embodiments may comprise less or more rack magnets, ranging from 1 to about 5, 1 to about 10, 1 to about 15, or 1 to about 20 pairs of rack magnets. Gear surface233is positioned about the longitudinal center of rack218a, where it can engage with pinion232a. In examples, gear surface225may not be located at the center of the rack. The rack may be comprised of non-ferromagnetic material in various examples.

The magnetic strength of holder202in the disengaged configuration, and the movement of each rack218a,218brequired to switch the holder between engaged and disengaged configurations, may depend on the strength and/or positioning of rack magnets236a,237a,236b,236b. As mentioned above, alternately oriented rack magnets236a,237aand236b,237bmay comprise strong permanent magnets (for ease of explanation only the “a” magnet sets are referred to in this paragraph). Within each pair, rack magnet236ais shown positioned relatively close to rack magnet237a. In other implementations, the distance between the rack magnets in each pair may be adjusted.

Different distances between each rack magnet within a pair may modify the rate at which the magnetic strength of the magnetic circuit is adjusted. For example, oppositely-oriented rack magnets236a,237apositioned in close proximity may cause an abrupt switch between engaged and disengaged configurations of the holder202in response to even slight movement of rack218a. By contrast, oppositely-oriented rack magnets236a,237apositioned further apart may cause a more gradual adjustment in the strength of the magnetic circuit upon movement of rack218a, thereby causing a less abrupt switch between engaged and disengaged configurations of holder202. According to such embodiments, greater movement of rack218amay be required to toggle holder202between engaged and disengaged configurations.

Relatedly, rack218amay be positioned in an intermediate configuration, between locked and unlocked configurations, in which the magnetic strength may be variable, e.g., at a level of magnetic strength capable of retaining some tools but not others. The strength of each rack magnet236a,237a(especially relative to the other magnets in the holder) may also impact the switch rate and/or the movement of rack218arequired to effect the switch. For example, if the rack magnet oriented to disrupt the magnetic circuit, e.g., the “reverse magnet,” is stronger than its pairwise partner magnet, then the magnetic strength of the holder in the disengaged configuration may be nearly eliminated. Similarly, if upper stator magnets219aand lower stator magnets220ahave a lower strength, the reduction in magnetic strength imparted by the reverse magnets in the disengaged configuration may be greater.

FIG. 2Lis an isometric view of an alternate rack assembly245with slidable rack218aand magnets236a,237cembedded therein. As shown, each pair of rack magnets within slidable rack218amay include rack magnet236aand237c. Each rack magnet237cmay comprise a ferromagnetic slug. Consequently, the magnetic circuit generated by alignment of rack magnets237cwith the upper and lower stator magnets may be weaker than the magnetic circuit generated by each rack magnet237b, which may comprise a strong, permanent magnet. Additional embodiments may include different magnetic components. For example, in some embodiments the rack may include pairs of alternating magnets and air gaps. Additional embodiments may include pairs of alternating ferromagnetic slugs and air gaps. Various materials may be coupled with slidable rack218ato alter the strength of the magnetic circuit generated by the rack in combination with the remaining components of holder202.

Multiple Holder Assemblies

FIG. 3is an isometric view of a plurality of magnetically engaged tool holders202arranged in a machine tool holder assembly300. The battery or assembly300of holders may allow independent selective engagement of variously-sized tools within the same press brake assembly. For example, the arrangement shown inFIG. 3may facilitate coupling of one or more tools by selectively placing the holders coupled with such tools into the engaged configuration. Meanwhile, additional holders within the same press brake assembly may remain in the disengaged configuration while tools are installed or rearranged in such holders. This arrangement of multiple holders, each independently adjustable via independent actuators224, represents an improvement over traditional all-at-once (e.g., mechanical) clamping holders. The magnetic strength of each holder may vary, such that individual holders may generate magnetic circuits of equal or different magnetic strength. The number of individual holders included in an assembly may vary. Five holders202are illustrated inFIG. 3, but embodiments may include one to about ten, one to about fifteen, or one to about twenty holders202, or more.

As a result, the length of assembly300may also vary. For instance, a 1-meter long assembly300may include as many as ten or more individual holders202, each being approximately 100 mm in length, or more or less. In some embodiments, individual holders202may be differently sized, such that some holders include different numbers of magnetic subassemblies. According to such embodiments, shorter and/or lighter tools may be sufficiently coupled with holders having smaller numbers of magnetic subassemblies, e.g., one or two subassemblies, compared to longer and/or heavier tools, which may be paired with holders having a greater number of magnetic subassemblies, e.g., three, four, five, six, seven or more subassemblies. Generally, the greater the number of magnetic subassemblies exerting an upward pulling or attractive force on the tang of a tool, the greater the total force imposed on the tool, thus enabling holders having greater numbers of magnetic subassemblies to secure heavier tools.

FIG. 4Ais an isometric view of a plurality of multiple tool holders202arranged in a press brake or punch holder apparatus400. Each holder202is coupled at a top end with an upper table243. Several holders202are coupled with relatively larger tool component244, and one holder202is coupled with a relatively smaller tool component246. A machine die component248sits below the holders202and tool components244,246.

As shown inFIG. 4A, multiple holders202may accommodate a single machine tool component, especially where such a tool is heavy and/or elongate, such as tool244. Even though each holder202, individually, may be equal in maximum magnetic strength, the combination of multiple holders, collectively, may comprise greater maximum magnetic strength by inducing multiple magnetic circuits along the length of tool244. By contrast, a single holder may be sufficient to accommodate lighter and/or smaller tools, such as tool246. Because each holder202may be individually operable, tools244and246may be coupled to press apparatus400at different times without the need to rearrange either tool.

FIG. 4Bis a side view of press apparatus400, including tool holders202coupled with machine tooling components244,246. As shown, tools244and246, despite their difference in length, may be equal in height, such that both tools may impress a workpiece overlaying die248.

Press Brake, Punch and Die Tooling

FIG. 5Ais an isometric view of a machine tool holder apparatus500with multiple magnetic tool holders202coupled with machine tool components244,246, and multiple magnetic dies250coupled with adjustable die holders252. Each die holder252includes an actuator254, which, similar to actuator224of holder202, includes a knob or other mechanism256engageable by an operator, e.g., by manual operation or manipulation to selectively operate actuator254. Multiple aperture fasteners257are defined by each die holder252. To couple with dies250, die holders252may apply a coupling mechanism analogous to that applied by holder202. More specifically, each die holder252may be configured for selective engagement with one or more dies250by repositioning one or more internal magnetic elements configured to generate a magnetic flux coupling between the body of the die holder and the die.

FIG. 5Bis a side view of machine tool holder apparatus500with a plurality of tool holders202coupled with machine tool components244,246, and the magnetic die holders252coupled with the dies250. As shown, slidable racks260a,260bmay be partially exposed, each of which may include a plurality of alternately-oriented rack magnets (analogous to rack magnets236a/b,237a/bdiscussed above), which may be embedded within the racks. Actuator254may protrude laterally outward with respect to a front surface of die holder252, and die250may define a die tang251.

FIG. 5Cis a section view of machine tool holder apparatus500with die holder252coupled with die250in an engaged configuration. Die holder252includes upper stator magnets264a,264band lower stator magnets266a,266b. Between each lower and upper stator magnet, a portion of slidable rack260a,260bis visible. Ferromagnetic brushes268a,268bare positioned laterally between each lower stator magnet and a vertically-slidable center magnet270. A center spring272is positioned below center magnet270. The magnetic assembly shown inFIG. 5Cis configured to induce parallel magnetic circuits of adjustable, e.g., switchable, magnetic strength for selectively engaging and disengaging die holder252with die250by exerting a reversible pulling force thereon or a reversible attractive force therebetween. Adjustments in magnetic strength may be caused via manipulation of actuator254. In the locked, coupled or otherwise engaged state, when the magnetic strength is increased, the die holder252may hold die250in place for use in workpiece forming and/or folding operations. The downward force applied by die250may force center magnet270downward, thereby compressing spring272. Because spring272is configured to compress in this manner, differently sized tangs251may be accommodated by die holder252.

The magnetic components of die holder252may comprise a magnetic assembly configured to generate a magnetic flux coupling adapted for the selective engagement of the die holder body with die tang251. In particular, the magnetic elements within die holder252may be magnetically oriented to generate a magnetic circuit in the engaged configuration shown. Each of the lower stator magnets266a,266bmay be similarly oriented, for example such that its north pole is positioned above its south pole (and vice versa), and each of the upper stator magnets264a,264b, positioned directly above the lower stator magnets, may also be similarly oriented such that, for example, its north pole is oriented above its south pole. In various examples, the stator magnets may remain stationary or fixed within die holder252, having a fixed magnetic orientation.

Likewise, rack magnets embedded within the slidable racks may also be oriented with the north pole facing up in the engaged configuration. Center magnet270may be magnetically oriented with its south pole facing up, e.g., in the reverse orientation relative to the stator magnets. When inserted into a receiving portion or cavity258defined by die holder252, die tang251is positioned between each upper stator magnet264a,264band above center magnet270. As a result, a magnetic circuit may be established through the magnetic elements included in die holder252. Parallel circuits may generate parallel magnetic fluxes that exert a downward magnetic force on die250, thereby securely coupling die250with die holder252such that lateral movement, e.g., sliding, wobbling and/or shifting, of die250is prevented.

For instance, in the engaged configuration, a magnetic flux may pass vertically through upper stator magnet264a, rack magnet262aand lower stator magnet266a, pass laterally through ferromagnetic brush268a, and then proceed vertically through center magnet270, eventually looping through at least a portion of die tang251, which may be ferromagnetic, and back through upper stator magnet264a. A similar magnetic circuit may be simultaneously established through lower stator magnet266b, rack magnet262b, upper stator magnet264b, tang251, center magnet270and ferromagnetic brush268b. Thus, parallel magnetic circuits may be established in the configuration shown, collectively creating a magnetic force sufficient to couple die250with die holder252.

Additional or alternative magnetic components may be included in die holder252, for example including one or more electromagnets (for example as shown with respect to a tool holder inFIGS. 8A-8H), rotatable magnets (for example as shown with respect to a tool holder inFIGS. 9A-9M), and/or rotatable ferromagnetic components (for example as shown with respect to a tool holder inFIGS. 10A-10E), each configuration to modulate the magnetic flux coupling generated between the holder and the die. Alternative examples may include fixed, stationary magnets, e.g., non-switchable magnets within die holder252, such that the body of the die holder has a receiving portion configured for engagement with a coupling end of a machine die. The magnetic coupling assembly of the die holder in such examples may thus include one or more magnetic elements configured to generate a magnetic coupling adapted for the engagement of the die holder body with the coupling end of machine die250.

Such embodiments may be sufficient for coupling smaller dies, in particular, and may exert a magnetic flux coupling readily overcome by manual engagement. Non-switchable magnetic elements in such embodiments may include one or more permanent magnets and/or one or more ferromagnetic components. Example arrangements of such magnets are shown with respect to a tool holder inFIGS. 6A-6D and 12A-12Dof this disclosure. In some examples, non-switchable magnets of a die holder may exert a constant magnetic coupling force such that one or more decoupling members, e.g., levers or pry bars, may be used to mechanically urge the die away from the body of the die holder to facilitate die removal, for example as shown by pry bars1206inFIGS. 12A-12Dof this disclosure.

In some embodiments, one or more mechanical clamping mechanisms may be included in die holder252. Such mechanical mechanisms may be implemented to provide additional clamping strength as necessary to retain a die250. In some examples, a mechanical clamping mechanism may include one or more fasteners257acting in concert with a clamping bar configured to apply a lateral pressure against tang251, similar to clamping bar235.

FIG. 5Dis a section view of machine tool holder apparatus500with die holder252and die250in a disengaged configuration. In the unclamped, unlocked or otherwise disengaged state, the magnetic circuits described above can be disrupted or at least weakened by longitudinal movement of sliding racks260a,260bthrough the die holder body such that rack magnets263a,263b, which are in the reverse magnetic orientation relative to the rack magnets262a,262b, are positioned between the upper and lower stator magnets. Upon weakening the magnetic circuit, die250may be installed or removed from die holder252.

The slidable racks260a,260bmay be moved via manual engagement with actuator254, which thereby modulates the strength of the magnetic flux between the die holder and the die. As further shown, alleviation of the downward force applied by die250upon its removal may cause spring272to extend upward and center magnet270to move upward, protruding into receiving cavity258. In some examples, the slidable racks may be responsive to the actuator, such that the locked and unlocked configurations of the die holder are bi-stable or non-momentary.

In some embodiments, one or more mechanical removal mechanisms may be included in die holder252. Such mechanical removal mechanisms may be implemented for directly leveraging or pry die250away from die holder252. Mechanical removal mechanisms may be necessary for overcoming particularly strong magnetic circuits, which may continue to retain die tang251within receiving cavity258even after switching to the disengaged state. In some examples, mechanical removal mechanisms may include one or more decoupling members, such as pry bars, similar to the pry bars shown inFIG. 11A.

Magnetic Clamping Mechanisms

FIG. 6Ais an isometric view of a machine tool holder and clamping assembly600with a tool holder602having a movable (mechanical) clamping bar606with magnetic components, which is selectively couplable with a machine tool or tool insert604for a press brake, punch or similar machine tool apparatus. Holder602includes a clamping mechanism608, which may be electric or hydraulic, and comprises lateral caps610. A receiving portion or cavity612configured to receive an upper portion or tang614of tool604is also defined by holder602. Clamping bar606may provide a movable side of receiving cavity612, opposite a stationary shoulder portion615of the holder.

FIG. 6Bis an isometric view of a machine tool assembly600with tool holder602, showing the internal configuration of holder602and magnetic clamping bar606. Clamping bar606includes arrays of magnetic elements that may induce a magnetic circuit with the magnetic elements included within the body of holder602, thereby tightly securing clamping bar606against the body of holder602and preventing the clamping bar from drooping or dropping downward within receiving cavity612.

To couple holder602with tool604, mechanical clamping mechanism608may move clamping bar606in the lateral direction via extension or retraction of each axle616and thus each cap610. When pulled tightly against the surface of tang614, clamping bar606may secure tool604within receiving cavity612. The magnetic circuit established between holder602and the vertical arrays of magnetic elements within clamping bar606can minimize or eliminate air gaps between tool604, clamping bar606and holder602, which may enhance the coupling strength between holder602and tool604. In some embodiments, the magnetic circuit created between the magnetic elements of clamping bar606and holder602may be sufficient in magnetic strength to at least temporarily coupled tool604with holder602.

In the particular arrangement shown, the body of holder602includes three holder magnets618positioned proximate to three vertical arrays of magnetic elements positioned within clamping bar606. Each array includes an upper clamp magnet620, a lower clamp magnet622, and a high-permeability insert624. To propagate a magnetic flux between the holder magnets and the magnetic components of the clamping bar, adjacent components may be arranged in alternating fashion, e.g., north-up, then south-up, north-up, then south-up, etc. In some examples, this configuration of magnetic components may be non-switchable, such that clamping bar606is consistently prevented from hanging loosely or dropping by maintaining a magnetic circuit with holder602, thereby positioning clamping bar606to effectively couple tool604with holder602.

The arrangement of magnetic components in clamping bar606and holder602may vary in different embodiments. Example configurations may include magnetic components, e.g., permanent magnets or ferromagnetic inserts, installed only in a top portion of the clamping bar, e.g., upper clamp magnets620. Some embodiments may comprise one or more magnetic components, e.g., permanent magnets or ferromagnetic inserts, installed only in a bottom portion of clamping bar235, e.g., lower clamp magnets622. In some examples, holder magnet618may be supplemented or replaced by one or more ferromagnetic inserts. One or more electromagnets may also be included within clamping bar606and/or holder602.

The vertical arrays of magnetic components within clamping bar606may be configured as cylindrical island assemblies within non-ferromagnetic isolating tubes, as rectangular block assemblies having flat isolating shims, or as solid magnets installed directly into the clamping bar and/or the body of the holder. Direct installation of one or more magnets may be more cost-efficient to manufacture. The clamping bar may comprise a ferromagnetic material or a non-ferromagnetic material.

FIG. 6Cis a side view of a machine tool assembly600with holder602and clamping bar606coupled with tool604. Receiving cavity612is shown, with clamping bar606in an engaged configuration. Clamping mechanism608, along with the magnetic circuit established between holder602and clamping bar606, pulls the clamping bar into place, flush against the surfaces of tool604and tang614. A narrow air gap626may exist, even in the engaged configuration, between the inner surfaces of clamping bar606and the body of holder602.

FIG. 6Dis a section view of a machine tool assembly600with holder602and clamping bar606coupled with tool604in the engaged configuration. The magnetic circuit may be established through holder magnet618, upper clamp magnet620, insert624, and lower clamp magnet622. Tool604may be ferromagnetic, thus contributing to the circuit.

FIG. 7Ais an isometric view of a magnetic adapter assembly700including a press brake or punch tool body701coupled with an insert704for a machine tool apparatus. Insert704includes the working end of the press brake or punch tool component, and is coupled to tool body701, e.g., via a magnetic clamping bar or similar magnetic coupling member706, forming a magnetically engaged tool holder apparatus for insert704. The adapter assembly includes a magnetic clamping bar706and, in the example shown, a plurality of fasteners708. Adapter assembly700defines an upper portion or adapter tang709configured for installation and removal with respect to a tool holder, such as holder202. The adapter assembly may allow particularly small tools, such as punch insert704, to be coupled with standard-sized tool holders, e.g., holder202.

FIG. 7Bis a detail view of the adapter assembly700and punch tool or tool insert704, taken at detail E ofFIG. 7A. As shown, punch insert704may comprise an upper portion or tang710configured to couple with a receiving portion or cavity in a tool holder apparatus defined by the combination of tool body701and magnetic clamping bar706. Clamping bar706is configured to selectively engage with punch insert704upon manipulation of one or more internal magnetic components and in some embodiments, concurrent tightening of one or more fasteners708.

FIG. 7Cis a top view of the adapter assembly700, showing a top surface712of adapter tang709and two shoulder portions714a,714bof tool body701, which extend laterally outward with respect to tang709.

FIG. 7Dis a front view of adapter assembly700with tool body701coupled with punch tool insert704, showing fasteners708. The number of fasteners, if included in the adapter assembly, may vary. In embodiments, the number of fasteners may range from 0 to about 5, 0 to about 10, 0 to about 15, 0 to about 20, or any suitable range therebetween, depending on the size of clamping bar706and/or the weight of punch insert704.

FIG. 7Eis a section view of adapter assembly700, with clamping bar706and punch insert704, taken along line B-B ofFIG. 7D. Clamping bar706includes a clamp magnet716and tool body701includes adapter magnet718. The magnetic poles of clamp magnet716and adapter magnet718may be oriented reversely relative to each other, to induce a magnetic circuit through punch insert704, thereby coupling the tool with tool body701of adapter assembly700.

FIG. 7Fis a section view of adapter assembly700, clamping bar706and punch insert704, taken along line A-A ofFIG. 7D. An elongate portion720of fastener708protrudes through clamping bar706and tool body701in this example. By tightening fastener708in a lateral direction, clamping bar706may be moved laterally toward tool body701, thereby clamping punch insert704within the receiving cavity defined by the tool body701and clamping bar706. Thus, adapter assembly700forms a holder for tool insert704. In some examples, the strength of the magnetic circuit induced through punch insert704via one or both of clamp magnet716and adapter magnet718may be sufficient to at least temporarily couple punch insert704with tool body701, rendering the physical coupling provided by one or more fasteners unnecessary.

Electromagnetic Flux Generation

FIG. 8Ais an isometric view of a magnetically engaged machine tool holder system800with machine tool holder802for a press brake, punch or similar machine tool apparatus. Holder802includes two shoulder portions803a,803b, which define the lateral surfaces of a receiving portion or cavity806configured to receive a tool. Holder802includes a side surface808and a front surface810, the front surface defining two laterally disposed apertures812. A top surface813defines two vertically disposed apertures814. In embodiments, the shape of holder802may vary. Holder802is configured to selectively couple with a tool via electromagnetic modulation.

FIG. 8Bis a front view of holder802, showing front apertures812. In embodiments, the number of apertures defined by the front surface may vary, ranging from 0 to about 10, depending on the number and/or arrangement of internal magnetic components in the holder.

FIG. 8Cis a section view of machine tool system800and tool holder802, taken along line P-P ofFIG. 8B.FIG. 8Cdepicts numerous magnetic components that may contribute to the adjustable magnetic coupling mechanism of holder802. In particular, holder802includes a pair of ferromagnetic shoulder rods816, one rod positioned within each shoulder portion803a,803b. The shoulder rods816may each be cylindrical and may have an elongate body portion, extending vertically from a bottom surface of each shoulder803a,803bto a position approximately in line with at least one electromagnet818, which may include a solenoid820comprised of coils wrapped around a ferromagnetic core821. Laterally-disposed ferromagnetic inserts822may be positioned proximate to electromagnet818, and at least one solenoid lead824may extend laterally through a control aperture825defined by holder802.

In operation, the magnetic components of holder802may induce a magnetic circuit826(represented by the arrows). Selective activation of electromagnet818modulates the strength of the magnetic flux coupling between holder802and a tool828inserted into receiving cavity806. Electromagnet activation may switch the holder into an engaged state in which tool828is reversibly coupled with the holder. Electromagnetic deactivation may switch the holder into disengaged or unlocked state, which allows for the installation or removal of tool828. The ferromagnetic components of the circuit, e.g., shoulder rods816and inserts822, may concentrate the magnetic circuit such that the magnetic flux is in the direction of the arrows representing magnetic circuit826.

To selectively adjust the magnetic flux coupling between holder802and tool828, the solenoid lead824may be electrically coupled with an electronic controller830, which may thus provide an actuator854for the magnetic flux coupling. For example, electrical voltage supplied by controller830may enter solenoid820via solenoid lead824, thereby activating electromagnet818and inducing magnetic circuit826. In some embodiments, controller830may include or be at least communicatively coupled with one or more sensors831configured to detect the presence or absence of tool828within receiving cavity806. Based on this detection, sensor831can provide feedback signaling to controller830. The magnetic coupling assembly815of the die holder802may thus include one or more magnetic elements configured to generate a magnetic coupling adapted for engagement of the die holder body with the coupling end of a machine die.

For instance, in response to detecting at least a portion of tool828, e.g., a tang, within receiving cavity806, sensor831can transmit a signal to controller830prompting the controller to activate magnetic flux coupling via electromagnet818. Likewise, in response to detecting no or zero tool components within receiving cavity806(or the absence thereof), sensor831may transmit a signal to controller830prompting the controller to deactivate magnetic flux coupling via electromagnet818by reducing or cutting off a voltage supply.

In some embodiments, controller830may adjust the magnetic strength of holder802by increasing, decreasing, or maintaining the voltage transmitted to the electromagnet, thus providing an adjustment mechanism for altering the maximum strength of the holder as necessary to accommodate machine tools of varying weights. The position of sensor831may vary and is not limited to the example position shown. In some embodiments, the electromagnet may be responsive to the electronic controller, such that the locked and unlocked configurations of the holder are bi-stable or non-momentary.

In some examples, a high frequency signal is superimposed on a DC supply835to the electromagnet(s), reacting with the inductance of the solenoid coils of the electromagnet(s), the amplitude of which can be assessed or demodulated. Since the magnetic circuit through the electromagnet(s) is effectively part of the flux coupling core of said electromagnet(s), and the magnetic circuit passes through the tool, when present, the presence or absence, or even proximity of a tool within the holder, will change the inductance of said electromagnet(s) and thus attenuate the high frequency signal and so could be measurable by the electronic controller with A to D conversion and programming. The data measured by the controller may then be used to present an indication of the presence or proper seating of the tool within the holder, or even to increase the DC voltage, thereby increasing the magnetic strength of the holder to maintain secure seating of the tool within the holder, or for an intermediate holding force such as to facilitate hand movement of the tool(s) coupled with the holder, which may be useful for staging or alignment of tools together for a particular function.

FIG. 8Dis a top view of holder802. Through apertures814, solenoids820are visible, each solenoid disposed horizontally within holder802. A portion of each lead824is also shown protruding beyond the body of holder802. As shown, solenoids820may be approximately parallel.

FIG. 8Eis a section view of holder802, taken along line B-B ofFIG. 8D. Each electromagnet core821is shown encapsulated by a solenoid820. Each vertical aperture814may extend downward into holder802. In some examples, each electromagnet818may be affixed, e.g., glued, into place within holder802and/or cast into pockets of the holder by a thermally conductive potting compound834. The body, or frame, of holder802may comprise various materials. In some examples, the body of holder802may include austenitic stainless steel. The material comprising holder802may be slightly ferromagnetic or non-ferromagnetic in various embodiments.

FIG. 8Fis a top view of holder802, showing the internal configuration of several magnetic components embedded therein, including a pair of electromagnets818, each comprising a coiled solenoid820positioned between a pair of laterally-oriented ferromagnetic inserts822. The ends of vertically-oriented ferromagnetic rods816included in the shoulders of holder802appear circular due to their cylindrical shape in the embodiment shown.

FIG. 8Gis side view of holder802, showing the internal configuration of the magnetic components depicted inFIG. 8F. Rods816are shown, extending vertically downward away from electromagnet818and inserts822. Controller aperture825is also shown, with leads824extending therethrough. In some embodiments, rods816may be permanent magnets, such that the solenoid coils can be energized to oppose the permanent magnets, thereby engaging the magnetic coupling mechanism without supplying energy to the coils. Examples may include one or more permanent magnets in addition to or instead of rods816to generate a magnetic circuit.

FIG. 8His an isometric view of holder802, showing the internal configuration of the magnetic components depicted inFIG. 8F. Lateral apertures812extend through a portion of the body of the holder, forming cylindrical cavities along the longitudinal axis of electromagnet818. More generally, either permanent magnet or electromagnet flux generation can be applied to any of the magnetically engaged machine tool application described herein.

Rotary and Lateral Magnetic Engagement

FIG. 9Ais an isometric view of a machine tool apparatus900with magnetic tool holder902for a press brake, punch, or similar machine tool apparatus. Holder902defines two shoulder portions903a,903band receiving portion or cavity906, which may receive an upper portion or tang of a tool. Holder902further includes a slidable pin908, which at least in a first, engaged position, may protrude laterally outward from front surface910, which defines two apertures912that extend laterally within holder902.

At a side surface914, holder902defines a gear window916. Within gear window916, the holder includes a rotatable pinion918configured to engage with pin908such that together, the two components comprise a rack and pinion assembly, the slidable pin functioning as the rack. An idler920centrally disposed within pinion918couples the pinion to the holder. A gear member922is positioned proximate to pinion918, where it may rotatably engage the pinion upon lateral movement of pin908. Defined in a top surface923of holder902are vertical apertures924. Holder902is configured for selective engagement and disengagement of a tool, e.g., a punch, upon manipulation of one or more magnetic components included in the holder.

FIG. 9Bis a detail view of holder902, taken at detail K ofFIG. 9A.FIG. 9Bprovides a magnified view of gear window916, showing idler920mounted within a central portion of pinion918. Gear member922, positioned below pinion918in the example shown, rotates upon rotation of the pinion.

FIG. 9Cis a top view of holder902in an engaged or locked configuration, showing the openings to vertical apertures924within top surface923, and pin908protruding from a side of the holder. As shown, vertical apertures924may be approximately circular and equally sized, positioned near the center of top surface923.

FIG. 9Dis a section view of machine tool holder apparatus900and tool holder902, taken along line B-B ofFIG. 9C. The internal magnetic components of holder902are shown, including two rotatable magnets926, two fixed lower magnets928, two fixed upper magnets930, and ferromagnetic inserts931. A cylindrical rotatable insert932is shown between rotatable magnets926. As further shown, an axle933coupled with gear member922may extend laterally through an internal cavity934defined by holder902, mounting each rotatable magnet926and rotatable insert932. A cross-section of pin908is also shown, along with pinion918and idler920.

In operation, lateral sliding of pin908(e.g., into and out of the page) can cause pinion918, and thus gear member922, to rotate. Consequently, axle933, which may be coupled, fixed, or formed integrally with gear member922, also rotates. Rotation of axle933causes rotation of rotatable magnets926and rotatable insert932attached thereto. Rotation of rotatable magnets926modulates the magnetic alignment of the rotatable magnets with lower magnets928and upper magnets930.

As shown in the configuration ofFIG. 9D, rotatable magnets926may have identical magnetic orientations, which relative to each other, may remain the same. The rotatable magnets may each be quadrupolar, each comprising two opposing north poles and two opposing south poles. In the configuration shown, each rotatable magnet926is oriented such that its north poles are vertically aligned. By contrast, lower magnets928and upper magnets930, which may be dipolar, are each oriented such that a south pole is positioned above a north pole, thereby aligning the north poles of the rotatable magnets with the south poles of the fixed magnets.

This particular arrangement may induce a magnetic circuit that loops through holder902and receiving cavity906. The circuit may induce a magnetic flux coupling adapted for the selective engagement of holder902with the coupling end of a machine tool. Ferromagnetic inserts931, positioned between the rotatable magnets and each set of upper and lower magnets, may concentrate the magnetic circuit through the tool coupled with holder902.

FIG. 9Eis a front view of holder902, showing front face910. Lateral apertures912are shown, along with pin908.

FIG. 9Fis a section view of machine tool holder apparatus900in an engaged configuration, taken along line P-P ofFIG. 9E. Holder902includes laterally oriented magnets935positioned between each rotatable magnet926and shoulder inserts936. Like lower magnets928and upper magnets930, lateral magnets935may be dipolar and fixed within the body of holder902. In this engaged configuration of holder902, the magnetic orientation of the poles of rotatable magnet926adjacent to lateral magnets935may be reversed with respect to each lateral magnet935, such that the south pole of each lateral magnet faces one of the north poles of the rotatable magnet, or vice versa. With respect to each other, the magnetic orientations of lateral magnets935may be reversed.

Rotatable magnet926can modulate the strength of the magnetic circuit induced through holder902by rotating, via movement of pin908, such that its magnetic poles move in and out of alignment with each upper magnet930, lower magnet928, and lateral magnets935. Shoulder inserts936may comprise ferromagnetic material configured to concentrate the magnetic circuit induced by the magnets through a tool904inserted within receiving cavity906. As indicated by the arrows, the magnetic components of holder902may induce two magnetic circuits938a,938bgenerating oppositely-directed magnetic flux paths. The net magnetic flux generated by both circuits act cooperatively to retain tool904. The rotatable magnets may be configured for various degrees of rotation. In some embodiments, each rotatable magnet may rotate a maximum of about 90° to effect switching between engaged and disengaged configurations.

FIG. 9Gis a section view of holder902, taken along line N-N ofFIG. 9E. As shown, vertical aperture924may extend within the body of holder902, and pin908may extend laterally within holder902. Pin908may be configured to slide within a pin cavity939upon receiving a lateral force applied by an operator. In some examples, pin cavity939includes a spring940at one end. Upon insertion of pin908within cavity939, the spring940may be compressed. In some examples, alleviation of the lateral force applied by the operator causes spring940to extend, thus pushing pin908into the resting state shown inFIG. 9G, in which a portion of the pin protrudes laterally from the holder.

FIG. 9His a top view of holder902in a disengaged, unlocked or released configuration. In this configuration, pin908may be inserted entirely into the body of holder902. In additional embodiments, pin908may be partially inserted into the holder.

FIG. 9Iis a section view of machine tool holder apparatus900and tool holder902, taken along line R-R ofFIG. 9H. As shown in this disengaged configuration, the magnetic poles of each rotatable magnet926may be misaligned with the poles of each lateral magnet935, lower magnet928and upper magnet930, such that the south poles of the rotatable magnet face the south poles of each lateral magnet and each upper and lower magnet, or vice versa. In this configuration, the magnetic circuit between the magnetic components of the holder may be disrupted or at least diminished, such that a tool may be removed or installed.

FIG. 9Jis an isometric view of machine tool holder apparatus900, showing the internal structure of the tool holder902in an engaged configuration. In addition to the components illustrated inFIGS. 9A through 9I,FIG. 9Jshows the position of two upper magnets930within vertical apertures924. The number of magnetic components may vary in different embodiments. For example, embodiments may include more than one slidable pin to allow locking/unlocking of holder at various access points. In addition or alternatively, more than two rotatable magnets may be included in a single holder, especially if such a holder has a greater length than holder902.

FIG. 9Kis a side view of machine tool holder apparatus900, showing the internal structure of the tool holder92in an engaged configuration. As shown, pin908may define a gear surface942configured to engage with pinion918such that lateral movement of pin908drives rotation of pinion918, and thus gear member922. Rotation of gear member922rotates rotatable magnets926, thereby modulating the magnetic strength of the magnetic flux coupling between the holder and a tool.

FIG. 9Lis an isometric view of a rotatable magnet assembly950. Within holder902, rotatable magnet assembly950may be positioned within internal cavity934. Gear member922is coupled with axle933. Rotatable magnet assembly950further includes rotatable magnets926and rotatable insert932. Rotatable insert932, which may comprise a ferromagnetic material, may rotate in unison with the rotatable magnets926.

FIG. 9Mis an isometric view of a lateral magnet935. The lateral magnet may define arcuate portions at each end to mate with rotatable magnet assembly950at one end and a shoulder insert936at the other end. In some examples, lateral magnet935may comprise two or more sub-components, e.g., two or more magnets and/or ferromagnetic inserts.

FIG. 10Ais an isometric view of a machine tool assembly1000with tool holder1002, showing the internal configuration of the holder in an engaged configuration. Holder1002may comprise numerous magnetic components that are identical or at least analogous to the magnetic components of holder902. For instance, holder1002also comprises a slidable pin1005, which is configured to modulate the strength of a magnetic flux coupling generated by the components of the holder.

Instead of rotatable magnets, holder1002may include a rotatable ferromagnetic paddle1006, which may be positioned adjacent to rotatable insert1008. Together with gear member1009, these components may comprise a rotatable magnetic assembly that is manipulable via lateral movement of the pin. In the engaged configuration shown, holder1002may be selectively coupled with a tool via a magnetic flux coupling.

FIG. 10Bis an isometric view of machine tool holder assembly1000, showing the internal structure of the tool holder1002in a disengaged configuration. As shown, pin1005is inserted to a greater depth within holder1002relative to the position of pin1002in the engaged configuration ofFIG. 10A. Ferromagnetic paddle1006has been rotated approximately 90° due to the repositioning of pin1005. In this configuration, paddle1006may disrupt or at least weaken the strength of a magnetic circuit established via the configuration shown inFIG. 10Aby introducing large air gaps between the magnetic components of holder1002, such that a tool coupled with the holder may be installed or removed.

FIG. 10Cis a side view of machine tool holder assembly1000, showing the internal configuration of the tool holder1002in the disengaged configuration. As shown, holder1002may lack upper and lower magnets and/or ferromagnetic components, such as components928,930, and931included within holder902. Lateral magnets1012are also shown within holder1002.

Rotation of ferromagnetic paddle1006drives modulation of the strength of the magnetic circuits induced by holder1002. The shape of paddle1006may alternate the magnetic strength. In particular, paddle1006may not be cylindrical, like the rotatable magnets926shown inFIG. 9. Instead, paddle1006may comprise a greater width than height, such that in one orientation, the ends of the paddle may contact, or be in close proximity with, each of the lateral magnets1012. This proximity may allow paddle1006to contribute to a magnetic circuit passing through the lateral magnets1012and ferromagnetic shoulder inserts1014.

In the disengaged configuration shown inFIG. 10C, the ends of paddle1006may not contact, or be in close proximity with, each of the lateral magnets1012, thereby disrupting or diminishing the magnetic circuit passing through the lateral magnets. In this manner, rotation of paddle1006may modulate the magnetic coupling strength of holder1002. Like holder902, holder1002may include a pinion1016, idler1018and gear member1020which cooperate to translate lateral sliding of pin1005into rotation of ferromagnetic paddle1006.

FIG. 10Dis a top view of machine tool holder assembly1000, showing the inner configuration of the tool holder1002in an engaged configuration. The circular cross-sectional shape of shoulder inserts1014is shown, but in embodiments, the shape may vary. Four lateral magnets1012are also shown, each positioned laterally between a shoulder insert1014and a ferromagnetic paddle1006. The orientation of the ferromagnetic paddles, such that each paddle abuts two lateral magnets, strengthens the strength of a magnetic circuit passing through the lateral magnets, coupling the holder with a tool.

FIG. 10Eis a plan view of machine tool holder assembly1000, showing the internal structure of the tool holder1002in a disengaged configuration. As shown, rotation of each ferromagnetic paddle1006creates a lateral air gap1022between each paddle and each lateral magnet1012, thereby disrupting or at least diminishing the magnetic circuit passing therethrough. In his configuration, a tool may be released from the holder.

Decoupling Elements

FIG. 11Ais an isometric view of a machine tool holder system1100with tool holder1102including an assembly of pry bars or lever members1105. Pry bars or lever members1105may assist in the removal of a tool from holder1102by leveraging or prying the tool away from the holder, or at least far enough away so as to weaken a magnetic circuit induced within the holder, which may be induced according to the same or similar mechanism as holder202. To selectively engage and disengage holder1102from a tool, the holder also includes an actuator1108manipulable by an operator.

The particular embodiment shown includes three pry bars or levers1105, but the number of pry bars may vary. In various examples, the number of pry bars may range from one to about five, from one to about ten, from one to about fifteen, or from one to about twenty or more. Greater numbers of pry bars may be necessary to remove tools from a holder having a relatively high magnetic strength even in a disengaged configuration. The pry or lever members1105can provide enhanced safety to operators by serving as an additional component requiring manipulation before a tool may be released from the holder, in addition to the magnetic coupling components operably coupled with actuator1108. The pry bars shown inFIG. 11Acomprise straight, elongate bars, but in various embodiments, the length and shape of the pry bars may vary.

FIG. 11Bis an isometric view of machine tool holder system1100, showing the internal configuration of the tool holder1102in an engaged configuration. With the exception of the pry bars or levers1105, the components of holder1102are similar in form and function to holder202(as shown particularly inFIG. 2H). In the engaged configuration, each pry bar is angled downward. A portion of each pry bar extends within pry cavities1106, where the pry bars are rotatably engaged with cylindrical anchor rods1108positioned with a longitudinally extending anchor cavity1109. The pry bars can rotate about the rods when manipulated by a user, for example by moving the pry bars up and down. The embodiment shown includes pry bars one side of the holder. In additional embodiments, pry bars may be coupled with two or more sides of the holder.

FIG. 11Cis a section view of machine tool holder system1100with tool holder1102in an engaged configuration. Each pry bar or lever1105is similarly oriented in a downward position. An upper portion or tang1112of tool1114is positioned within a receiving portion or cavity1116defined by holder1102. A top surface of tang1112abuts a center magnet1118, thereby compressing spring1119. In this configuration, slidable racks1120position rack magnets in magnetic alignment with upper stator magnets1122and lower stator magnets1124, inducing a magnetic circuit through tool1114and holder1102.

FIG. 11Dis a section view of the tool holder1102with a portion of machine tool1114with at least one pry bar or lever1105in a disengaged configuration. As shown, manipulation of a pry bar1105can create separation between tool1114and holder1102, forming a gap1126abetween a side surface of tang1112and the body of holder1102, a gap1126bbetween a top surface of tang1112and center magnet1118, and a gap1126cbetween a surface of the receiving shoulder1127of the holder and the upper shoulder1128of the tool. The creation of gap1126cmay be useful in facilitating removal of tool1114from holder1102. In embodiments, movement of one or more pry bars may be utilized to initiate release of the tool from the holder. Movement of a single pry bar into a disengaged position may be sufficient to disrupt or diminish relatively weak magnetic circuits, while movement of two or more pry bars may be necessary to disrupt or diminish relatively strong magnetic circuits.

FIG. 12Ais an isometric view of a machine tool holder and pry bar assembly1200with tool holder1202engaging machine tool component1204, showing the internal configuration of the tool holder1202. In addition to pry bars1206, holder1202includes a plurality of permanent, rod-like magnets1208fixed, e.g., not adjustable or switchable, within the holder. Magnets1208may generate magnetic circuits that include portions of tool1204.

The strength of the circuits may be sufficient to at least temporarily couple tool1204with holder1202. Because the magnetic strength of magnets1208may not be modulated, pry bars1206may selectively switch holder1202between engaged and disengaged configurations. In particular, the pry bars mechanically leverage or pry the tool away from the holder, overcoming the retaining strength of the magnetic circuit induced by magnets1208and ferromagnetic components included in the holder and tool. In some embodiments, the pry bars may suffice to release tool1204from holder1202. In other embodiments, the pry bars, alone, may be insufficient to fully separate tool1204from holder1202. Such embodiments may require an operator to manually remove tool1204from holder1202. In various examples, this manual removal step may be performed with ease.

FIG. 12Bis a side view of the machine tool holder and pry bar or lever assembly1200with tool holder1202and machine tool component1204, showing the internal configuration of tool holder1202. As shown, movement of at least one pry bar1206may create a gap1210between a shoulder portion1212of tool1204and holder1202. In some examples, movement of only one pry bar to create separation between tool1204and holder1202may be sufficient to release tool1204from holder1202. In some embodiments, movement of two or more pry bars may be required.

FIG. 12Cis a side view of the machine tool holder and pry bar assembly1200with tool holder1202and tool1204, after movement of at least one pry bar1206into a disengaged configuration. Separation between the holder and the tool is evident at a vertical gap1210aand horizontal gap1210b. A leveraging portion1214of a pry bar is also shown. Each pry bar1206comprises a leveraging portion1214, which directly contacts the tool and may be irregular or oblong in shape. Leveraging portion1214rotates upon manipulation of the pry bar, pushing downward against the shoulder portion1212of tool1204. An upper portion or tang1215of the tool is shown protruding into a receiving portion or cavity1216defined by the holder.

FIG. 12Dis a side view of holder1202and tool1204in an engaged configuration. When engaged, vertical gap1210amay be partially or entirely closed, such that shoulder portion1212of tool1204is in direct contact with holder1202. Horizontal gap1210bmay be maintained, partially closed, or entirely closed in various embodiments. Due to the tightening of tool1204with holder1202, tang1215protrudes a greater distance within receiving cavity1216compared to the position of tang1215shown inFIG. 12C, when at least one pry bar is leveraging the tool away from the holder.

Sliding Actuator Elements

FIG. 13Ais an isometric view of a machine tool holder assembly1300with tool holder1302comprising a slidable actuator1305. Like holder202, holder1302may be configured for selective engagement and disengagement with a tool via an adjustable magnetic flux coupling. The slidable actuator1305is positioned within an actuator window1306. Holder1302also includes a plurality of fasteners1308, e.g., set screws, configured to adjust the position of clamping bar1310with respect to shoulder1312. Holder1302defines a receiving portion or cavity1314configured to receive a tool.

FIG. 13Bis an isometric view of machine tool holder assembly1300, showing the internal configuration of the holder1302. Like holder202, holder1302includes two slidable racks1316, each rack including a plurality of alternately-oriented rack magnets between upper stator magnets1318and lower stator magnets1320. To slide each rack1316within the body of the holder, slidable actuator1305may be slid back and forth within actuator window1306. The textured surface of actuator1305may facilitate manual engagement, e.g., gripping, by an operator.

In various embodiments, actuator1305may be physically or operatively coupled with rack1316. Movement of the actuator can cause equal, parallel movement of rack1316. By moving actuator1305laterally within window1306, holder1302may be switched between engaged and disengaged configurations, the holder configured to induce a magnetic circuit capable of retaining a tool in the engaged configuration. In some examples, the engaged and disengaged configurations of holder1302may be bi-stable or non-momentary.

FIG. 13Cis an isometric view of tool holder1302and actuator1305, showing the internal configuration of the actuator and a portion of the holder. As shown, the actuator may include a locking pin1322. The pin may be vertically oriented, transverse to rack1316.

FIG. 13Dis an isometric view of tool holder1302and actuator1305, showing a tip portion1324of locking pin1322seated in a first groove1326defined by the body of holder1302. A second groove1328, also configured to seat tip portion1324of locking pin1322, is vacant in the configuration shown. Locking pin1322can secure actuator1305, and thus holder1302, in an engaged or disengaged configuration when an operator is not biasing actuator toward either end of actuator window1306. In some examples, the locking pin may automatically snap into the grooves defined by the holder upon being positioned above one of the grooves. Embodiments may include a compression spring configured to urge the locking pin into each of the grooves.

FIG. 13Eis a section view of machine tool holder assembly1300with holder1302, showing an elongate rod portion1330formed or coupled with the manually engageable portion of actuator1305. The rod portion1330extends through the body of the holder, passing perpendicularly through each of the slidable racks1316such that movement of the elongate rode drives equal movement of the racks.

EXAMPLES

In accordance with examples and embodiments of the above disclosure, a machine tool apparatus includes a holder body having a receiving portion configured for selective engagement with a coupling end of a machine tool; a magnetic coupling assembly including one or more magnetic elements configured to generate a magnetic coupling adapted for the selective engagement of the holder body with the coupling end of the machine tool; and an actuator configured to manipulate at least one of the magnetic elements to modulate a strength of the magnetic coupling for selective engagement and disengagement of the holder body with the coupling end of the machine tool.

In some embodiments, the actuator may be configured to manipulate at least one of the magnetic elements of the magnetic coupling assembly between a locked position, in which the coupling end of the machine tool is selectively engaged within the receiving portion of the holder body, and an alternate unlocked position, in which the coupling end of the machine tool is selectively disengaged from the receiving portion of the holder body. In some embodiments, the one or more magnetic elements may be responsive to actuation of the actuator such that the locked and unlocked positions are bi-stable. In some examples, in the locked position, the magnetic coupling may support a weight of the machine tool disposed within the receiving portion of the holder body. Some embodiments may further include an adjustment mechanism configured to adjust a maximum strength of the magnetic coupling to support the weight of the machine tool.

In any of the above examples and embodiments, the magnetic elements may include one or more permanent magnets and one or more ferromagnetic components, and the actuator may be configured to selectively move at least one of the permanent magnets or ferromagnetic components to modulate the strength of the magnetic coupling by forming a flux path therebetween.

In some embodiments, at least one of the magnetic elements may be configured to slide to selectively form the flux path and/or to modulate a magnetic impedance thereof. In some implementations, at least one of the magnetic elements may be configured to rotate to selectively form the flux path and/or to modulate a magnetic impedance thereof. In some examples, the one or more magnetic elements may include at least one electromagnet configured to selectively generate a magnetic flux to modulate the strength of the magnetic coupling. According to such embodiments, the actuator may include an electronic controller electronically coupled with the magnetic coupling assembly. The electronic controller may be coupled with a feedback sensor configured to detect the machine tool within the receiving portion of the holder body.

In any of the above examples and embodiments, the receiving portion of the holder body may comprise a cavity defined by an inner surface of the holder body and a clamping member configured for selective engagement with the coupling end of the machine tool disposed within the cavity. In some embodiments, the magnetic coupling assembly further includes one or more magnetic elements embedded within the clamping member. In some examples, the magnetic coupling assembly further includes one or more magnetic elements embedded within the inner surface of the holder body.

In any of the above examples and embodiments, the magnetic coupling may define a magnetic flux circuit that passes through the coupling end of the machine tool and at least a portion of the holder body. Some examples may further include one or more mechanical coupling members comprising at least one clamp, screw, cam, or lever configured to secure the coupling end of the machine tool within the receiving portion of holder body. Embodiments may further include one or more decoupling members configured to mechanically urge the machine tool away from the holder body such that the machine tool may be removed from the receiving portion of the holder body. In some examples, the magnetic coupling assembly may include one or more magnetic coupling sub-assemblies arranged along a length of the holder body, each of the sub-assemblies including one or more magnetic elements configured to generate a magnetic coupling adapted for the selective engagement of the holder body with the coupling end of the machine tool.

A machine tool assembly in accordance with the present disclosure may include a holder body having a receiving portion configured for engagement with a coupling end of a machine tool; and a magnetic coupling assembly comprising one or more magnetic elements configured to generate a magnetic coupling adapted for the engagement of the holder body with the coupling end of the machine tool. In some embodiments, the receiving portion of the holder body comprises a cavity defined by an inner surface of the holder body and a clamping member, the clamping member configured for engagement with the coupling end of the machine tool in response to activation of the magnetic coupling.

In some examples, the magnetic coupling assembly may further include one or more magnetic elements embedded within the inner surface of the holder body. In some embodiments, the magnetic coupling assembly may further include one or more magnetic elements embedded within the clamping member. Some implementations may further include one or more decoupling members configured to mechanically urge the machine tool away from the holder body such that the machine tool may be removed from the receiving portion of the holder body.

A machine die apparatus in accordance with the present disclosure may include a holder body having a receiving portion configured for selective engagement with a coupling end of a machine die; and a magnetic coupling assembly comprising one or more magnetic elements configured to generate a magnetic coupling adapted for the selective engagement of the holder body with the coupling end of the machine die. Examples may further include an actuator configured to manipulate at least one of the magnetic elements to modulate a strength of the magnetic coupling for selective engagement and disengagement of the holder body with the coupling end of the machine die.

In some embodiments, the magnetic elements may include one or more permanent magnets and one or more ferromagnetic components, and the actuator may be configured to selectively move at least one of the permanent magnets or ferromagnetic components to modulate the strength of the magnetic coupling by forming a flux path therebetween. In some examples, the actuator may be configured to manipulate at least one of the magnetic elements of the magnetic coupling assembly between a locked position, in which the coupling end of the machine die is selectively engaged within the receiving portion of the holder body, and an alternate unlocked position, in which the coupling end of the machine die is selectively disengaged from the receiving portion of the holder body. In some embodiments, in the locked position, the magnetic coupling may support a weight of the machine die disposed within the receiving portion of the holder body.

In any of the above examples and embodiments, the one or more magnetic elements may include at least one electromagnet configured to selectively generate a magnetic flux to modulate the strength of the magnetic coupling. Some embodiments may further include one or more mechanical coupling members comprising at least one clamp, screw, cam, or lever configured to secure the coupling end of the machine die within the receiving portion of holder body. Examples may further include one or more decoupling members configured to mechanically urge the machine die away from the holder body such that the machine die may be removed from the holder body.

Methods of operating a machine tool apparatus can be performed according to any of the examples and embodiments above. Suitable applications of the mechanisms and techniques described in this disclosure also include, but are not limited to, the following enumerated examples and embodiments.

A punch holder, or an upper tool holder for a folding press or press brake, is disclosed. The punch holder has a downward opening cavity designed to receive a punch or punch insert with a top protrusion or tang that fits into said holder cavity. The punch holder includes a magnetic restraining means for holding said punch or punch insert in said press brake using magnets or a magnetic assembly that urge or retain the punch or punch insert upward into a holder receiving cavity for placement or staging until said holder is fully activated, whence said punch is solidly clamped in place for use.

In the above example, the punch holder may comprise a switchable or adjustable magnetic assembly for holding a punch or punch insert in said press brake, said magnetic assembly having two or more states: one state with a stronger magnetic attraction for retaining the punch or punch insert in the holder, and another state with less or nil magnetic attraction to allow release of said punch or punch insert from said tool holder. The tool holder thus has a locked position, wherein said punch or punch insert is securely held in said holder, an unlocked position, wherein said punch or punch insert can be manually installed in or removed from said punch holder, and/or any variety of intermediate states of magnetic attraction, such as could be useful for staging a set of punches or punch inserts for use.

In any of the above examples and embodiments, the punch holder may comprise an assembly of permanent magnets and ferromagnetic parts arranged to work cooperatively in a magnetic circuit, with some magnet or magnets configured to be selectively moveable such that said magnetic circuit can be debilitated or weakened, as for punch or punch insert installation or removal, or alternatively positioned so as to be optimized or enabled, to facilitate secure retention of punch or punch insert in the holder until said holder is activated to clamp said punch or punch insert solidly in the holder for folding operation.

In any of the above examples and embodiments, the punch holder may comprise an assembly of permanent magnets and ferromagnetic parts arranged to work cooperatively in a magnetic circuit, with some ferromagnetic part or parts configured to be selectively moveable such that said magnetic circuit can be debilitated or weakened (as for punch or punch insert installation or removal), or alternatively positioned so as to be optimized or enabled, to facilitate secure retention of punch or punch insert in the holder.

In any of the above examples and embodiments, the punch holder may comprise a magnetic assembly that includes one or more electromagnets which can be switchable or adjustable to selectively aid or conflict with the magnetic circuit, thereby effecting retention or release of said punch or punch insert.

In any of the above examples and embodiments, the punch holder may comprise a downward opening cavity in said tool holder formed by a solid or stationary protrusion extending downward on one side of said opening, and a moveable or articulated downward extending protrusion on the other side of a gap. Together, the solid or stationary protrusion and moveable or articulated protrusion form said opening, which is designed to receive a punch or punch insert with a top protrusion or tang that fits into said holder cavity or opening, with said magnetic assembly configured to urge both punch or punch insert and said moveable protrusion tightly into an acceptable position for use or for further clamping.

In any of the above examples and embodiments, the punch holder may comprise a magnetic assembly that completes a magnetic circuit through the punch or punch insert, which may be made of a highly ferromagnetic material.

In any of the above examples and embodiments, the punch holder may comprise a magnetic force sufficiently strong in the clamped or locked state such that no additional clamping means is needed for press operation.

In any of the above examples and embodiments, the punch holder may comprise a supplementary mechanical clamping means, such as a cam and lever, or set screws, to solidly clamp the punch or punch insert in place for folding press operation.

In any of the above examples and embodiments, the selectively moveable magnet or magnets may move slidably.

In any of the above examples and embodiments, the selectively moveable magnet or magnets may move rotatably.

In any of the above examples and embodiments, the selectively moveable ferromagnetic part or parts may move slidably.

In any of the above examples and embodiments, the selectively moveable ferromagnetic part or parts may move rotatably.

In any of the above examples and embodiments, optimization of the magnetic circuit, and thus the magnetic force on the punch or punch insert may be fully adjustable.

In any of the above examples and embodiments, the magnetic clamping means may be controlled electronically and may include feedback from a sensor detecting the presence of the punch or punch insert, such that the magnetic force can be increased as needed to keep the punch or punch insert seated in the holder.

In any of the above examples and embodiments, the magnetic assembly may employ electromagnets or permanent magnets built into the articulated or moveable part of the holder.

In any of the above examples and embodiments, the magnetic assembly may employ electromagnets or permanent magnets built into the fixed or non-moveable part of the holder.

In any of the above examples and embodiments, a mechanical means may be included for leveraging or prying the punch or punch insert away from the holder, or at least far enough away so as to weaken the magnetic circuit sufficiently to allow removal of said punch or punch insert from said holder.

In any of the above examples and embodiments, the magnetic assembly or assemblies may employ a bi-stable or non-momentary clamped and released state.

In any of the above examples and embodiments, one or more magnetic assemblies or multiple banks of magnetic holder subassemblies may be arranged along the length of the punch holder.

A punch holder for holding a punch in a folding press or press brake with a downward opening cavity in said tool holder is disclosed. The punch holder is designed to receive a punch or punch insert with a top protrusion or tang that fits into said holder cavity, said holder using a non-switchable permanent magnet assembly or a permanent magnet or an array of magnets to urge or retain the punch or punch insert upward into said receiving cavity.

In any of the above examples and embodiments, said downward opening cavity in said tool holder may be formed by a solid or stationary protrusion extending downward on one side of said opening, and a moveable or articulated downward extending protrusion on the other side of a gap, forming said opening, which is designed to receive a punch or punch insert with a top protrusion or tang that fits into said holder cavity or opening, with said magnetic assembly configured to urge both punch or punch insert and said moveable protrusion tightly into an acceptable position for use or for further clamping.

In any of the above examples and embodiments, the magnetic assembly may employ a magnet or magnets built into the fixed or non-moveable part of the holder.

In any of the above examples and embodiments, the magnetic assembly may employ a magnet or magnets built into the articulated or moveable part of the holder.

In any of the above examples and embodiments, a mechanical means for directly leveraging or prying the punch or punch insert away from the holder may be included.

A die holder, or lower tool holder for a folding press or press brake, is disclosed. The die holder may include an upward opening cavity designed to receive a die or die insert with a bottom protrusion or tang that fits into said holder cavity, with a magnetic restraining means for securing said die or die insert in said press brake, thereby sufficiently holding said die or die insert securely in place for use or until additional clamping is engaged.

In any of the above examples and embodiments, the die holder may comprise a switchable or adjustable magnetic assembly to urge or retain the die securely in said holder receiving cavity, thus clamping said die or die insert solidly in place for use, the die holder thus having a clamped position wherein said die or die insert is securely restrained in said die holder, or a released position, wherein said die or die insert can be manually installed in or removed from said die holder.

In any of the above examples and embodiments, an assembly of permanent magnets and ferromagnetic parts may be arranged to work cooperatively in a magnetic circuit, with some magnet or magnets, or ferromagnetic parts, configured to be selectively moveable such that said magnetic circuit can be debilitated or weakened, as for die or die insert installation or removal, or alternatively positioned so as to be optimized or enabled, to facilitate secure retention of the die or die insert in the holder.

In any of the above examples and embodiments, the magnetic assembly may include one or more electromagnets which can be switchable or adjustable to selectively aid or conflict with the magnetic circuit, thereby effecting retention or release of said die or die insert.

In any of the above examples and embodiments, the magnetic force may be sufficiently strong in the clamped state so that no additional clamping means is needed for press operation.

In any of the above examples and embodiments, the die holder may comprise a supplementary mechanical clamping means, such as a cam and lever, or set screws, to solidly clamp the die or die insert in place for folding press operation.

In any of the above examples and embodiments, the die holder may comprise a mechanical means for directly leveraging or prying the die or die insert away from the holder.

A machine tool apparatus is disclosed. The machine tool apparatus includes a tool holder defining a receiving portion configured for selective engagement with a coupling end of a machine tool insert; a magnetic coupling assembly comprising one or more magnetic elements configured to generate a magnetic coupling adapted for the selective engagement of the tool holder with the coupling end of the machine tool insert; and an actuator configured to manipulate at least one of the magnetic elements to modulate a strength of the magnetic coupling for selective engagement and disengagement of the tool holder with the coupling end of the machine tool insert.

In the above example, the magnetic elements may comprise one or more permanent magnets or one or more ferromagnetic components, the actuator being configured to selectively move at least one of the permanent magnets or the ferromagnetic components with respect to another of the permanent magnets or the ferromagnetic components to modulate the strength of the magnetic coupling by modulating a magnetic reluctance of a flux path therebetween.

In any of the above examples and embodiments, the magnetic elements may comprise one or more flux guides configured to guide a magnetic flux between the tool holder and the machine tool insert, the strength of the magnetic coupling being further responsive to the magnetic flux guided therebetween.

In any of the above examples and embodiments, the actuator may be configured to manipulate at least one of the magnetic elements of the magnetic coupling assembly between an engaged position in which the coupling end of the machine tool insert is selectively engaged within the receiving portion and an alternate disengaged position in which the coupling end of the machine tool insert is selectively disengaged from the receiving portion.

In any of the above examples and embodiments, the actuator may be configured to manipulate the at least one magnetic element by rotation or displacement with respect to another of the magnetic elements.

In any of the above examples and embodiments, the one or more magnetic elements may be responsive to actuation of the actuator such that the engaged and disengaged positions are bi-stable.

In any of the above examples and embodiments, in the engaged position, the magnetic coupling may support a weight of the machine tool insert disposed within the receiving portion.

In any of the above examples and embodiments, the machine tool apparatus may further comprise an adjustment mechanism configured to adjust a maximum strength of the magnetic coupling to support the weight of the machine tool insert when disposed within the receiving portion.

In any of the above examples and embodiments, at least one of the magnetic elements may be configured to slide to selectively form the flux path, and to break or modulate the strength thereof.

In any of the above examples and embodiments, at least one of the magnetic elements may be configured to rotate to selectively form the flux path, and to break or modulate the strength thereof.

In any of the above examples and embodiments, the one or more magnetic elements may comprise at least one electromagnet configured to selectively generate a magnetic flux to modulate the strength of the magnetic coupling.

In any of the above examples and embodiments, the actuator may comprise an electronic controller electronically coupled with the magnetic coupling assembly, the electronic controller coupled with a feedback sensor configured to detect the machine tool insert within the receiving portion.

In any of the above examples and embodiments, the receiving portion may comprise a cavity defined by an inner surface of the tool holder and a clamping member configured for selective engagement with the coupling end of the machine tool insert disposed within the cavity.

In any of the above examples and embodiments, the magnetic coupling assembly may further comprise one or more magnetic elements embedded within the clamping member or the inner surface of the tool holder.

In any of the above examples and embodiments, the one or more magnetic elements may comprise one or more permanent magnets and one or more ferromagnetic components.

In any of the above examples and embodiments, the machine tool apparatus may further comprise one or more mechanical coupling members comprising at least one clamp, screw, cam, or lever configured to secure the coupling end of the machine tool insert within the receiving portion.

In any of the above examples and embodiments, the machine tool apparatus may further comprise one or more decoupling members configured to mechanically urge the machine tool insert away from the tool holder such that the machine tool insert may be removed from the receiving portion.

In any of the above examples and embodiments, the magnetic coupling assembly may comprise a plurality of magnetic tool holder sub-assemblies arranged along a length of the tool holder, each of the sub-assemblies comprising one or more magnetic elements configured to generate magnetic flux to provide the magnetic coupling adapted for the selective engagement of the tool holder with the coupling end of one or more such machine tool inserts.

In any of the above examples and embodiments, a plurality of machine tool inserts may be engaged within the plurality of magnetic tool holder subassemblies.

A machine tool assembly is disclosed. The machine tool assembly may comprise a tool holder body defining a receiving portion configured for engagement with a coupling end of a machine tool insert; and a magnetic coupling assembly comprising one or more magnetic elements configured to generate a magnetic coupling adapted for the engagement of the tool holder with the coupling end of the machine tool insert.

In the above example, the receiving portion of the tool holder body may comprise a cavity defined by an inner surface of the tool holder body and a clamping member, the clamping member configured for engagement with the coupling end of the machine tool insert in response to activation of the magnetic coupling.

In any of the above examples and embodiments, the magnetic coupling assembly may further comprise one or more magnetic elements embedded within the inner surface of the tool holder body.

In any of the above examples and embodiments, the magnetic coupling assembly may further comprise one or more magnetic elements embedded within the clamping member.

In any of the above examples and embodiments, the machine tool assembly may further comprise one or more decoupling members configured to mechanically urge the machine tool insert away from the tool holder body such that the machine tool insert may be removed from the receiving portion of the tool holder body.

A machine die apparatus is disclosed. The machine die apparatus may comprise a tool holder body having a receiving portion configured for selective engagement with a coupling end of a machine die; and a magnetic coupling assembly comprising one or more magnetic elements configured to generate a magnetic coupling adapted for the selective engagement of the tool holder body with the coupling end of the machine die.

In the above example, the machine die apparatus may further comprise an actuator configured to manipulate at least one of the magnetic elements to modulate a strength of the magnetic coupling for selective engagement and disengagement of the tool holder body with the coupling end of the machine die.

In any of the above examples and embodiments, the magnetic elements may comprise one or more permanent magnets and one or more ferromagnetic components, and the actuator may be configured to selectively move at least one of the permanent magnets or ferromagnetic components to modulate the strength of the magnetic coupling by inducing a flux path therebetween.

In any of the above examples and embodiments, the actuator may be configured to manipulate at least one of the magnetic elements of the magnetic coupling assembly between a locked position in which the coupling end of the machine die is selectively engaged within the receiving portion of the tool holder body and an alternate unlocked position in which the coupling end of the machine die is selectively disengaged from the receiving portion of the tool holder body.

In any of the above examples and embodiments, in the locked position, the magnetic coupling may prevent lateral movement of the machine die disposed within the receiving portion of the tool holder body.

In any of the above examples and embodiments, the one or more magnetic elements may comprise at least one electromagnet configured to selectively generate a magnetic flux to modulate the strength of the magnetic coupling.

In any of the above examples and embodiments, the machine die apparatus may further comprise one or more mechanical coupling members comprising at least one clamp, screw, cam, or lever configured to secure the coupling end of the machine die within the receiving portion of tool holder body.

In any of the above examples and embodiments, the machine die apparatus may further comprise one or more decoupling members configured to mechanically urge the machine die away from the tool holder body such that the machine die may be removed from the tool holder body.

A machine die apparatus is disclosed. The machine die apparatus may comprise a tool holder body having a receiving portion configured for engagement with a coupling end of a machine die; and a magnetic coupling assembly comprising one or more magnetic elements configured to generate a magnetic coupling adapted for the engagement of the tool holder body with the coupling end of the machine die.

In the above example, the magnetic elements may comprise one or more permanent magnets and one or more ferromagnetic components.

In any of the above examples and embodiments, the machine die apparatus may further comprise one or more decoupling members configured to mechanically urge the machine die away from the tool holder body such that the machine die may be removed from the tool holder body.

A method of operating a machine tool apparatus is disclosed, according to any of the examples and embodiments above.

While this invention has been described with respect to particular examples and embodiments, changes can be made and equivalents can be substituted in order to adapt these teaching to other configurations, materials and applications, without departing from the spirit and scope of the invention. The invention is not limited to the particular examples that are disclosed, but encompasses all embodiments that fall with the scope of the claims.