Patent Publication Number: US-6334381-B1

Title: Adjustable punch assembly

Description:
This application is a divisional of U.S. application Ser. No. 08/820,577, filed Mar. 19, 1997, now U.S. Pat. No. 5,934,165. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to punch assemblies such as those usable with indexable multiple station turret punch machines. 
     BACKGROUND OF THE INVENTION 
     It is known to provide rotatable and indexable punching tools in a turret punch press where the upper and lower punching tools are rotated synchronously for different orientations of the punch tools. Further, it is known to provide multiple station turret punch machines which provide a large number of different punch stations for use in conjunction with a like number of opposing die surfaces. Each station may include an upper punch assembly and a lower die assembly. The typical configuration of the punch assembly includes a punch tip that is mounted onto the lower end of a punch driver which, in turn, is threadably connected to a punch head. 
     As illustrated in U.S. Pat. No. 4,375,774, which is incorporated herein by reference, the punch tip can become dull or worn during use. As a result, the tips are routinely sharpened using a grinding operation which shortens the overall length of the punch tip, and accordingly, the overall length of the punch assembly. Because the distance between the cutting edge of the punch tip and the workpiece is a critical dimension, control of the vertical position, and hence the overall length of the punch assembly, is important. U.S. Pat. No. 4,375,774 discloses an adjustable punch assembly whereby the punch driver is threadably attached to the punch head. By rotating the punch driver with respect to the punch head, the overall length of the punch assembly can be shortened or lengthened. 
     Further, punch presses having indexable tool stations enable the punch assembly, and hence the punch tip, to be rotated so that the punch tip can be applied to the workpiece in different orientations. Punch presses employing indexable punch stations are disclosed in U.S. Pat. Nos. 5,048,385 and 4,658,688, both of which are incorporated herein by reference and both of which are owned by the assignee of the present application. 
     Specifically, U.S. Pat. No. 4,658,688 discloses a turret punch press having an upper and lower turret tool holder which carries a number of punch and die sets in individual tool holding stations in the turrets. At least one of the corresponding tool holding stations in the upper and lower turrets is indexable to different angular orientations. Rotation of the indexable punch tools is accomplished by a slidably mounted motor for engagement with a timing pulley, which, through a timing belt and harmonic gear drive, acts to rotate the tool holder which carries the punch and die set. In this device, each of the turrets may be equipped with tool stations which receive tool support devices that are rotatable to selectively position the tools at chosen angular positions by rotating the tool sets about their longitudinal axes. 
     U.S. Pat. No. 5,048,385 discloses a punch assembly for an indexable punching station which includes a striker body having a solid portion and a punch carrier which carries a plurality of individual punches. A selectively actuable stop holds the striker body stationary, allowing the punch holder to be rotated so that one of the plurality of punches will underlie the solid portion of the striker body. The stop may then be deactivated so that the entire punch assembly may be rotated to a variety of angular orientations. Rotation of the assembly thus permits a single punch to be used to punch holes of the same shape but with differing angular orientations. 
     Thus, U.S. Pat. No. 4,375,774 discloses an adjustable punch assembly whereby the overall length of the punch assembly may be adjusted to accommodate for wear on the punch tip or the shortening of the punch tip due to sharpening or grinding operations. U.S. Pat. Nos. 4,658,688 discloses an indexable tool station which permits the angular rotation of the punching tool. U.S. Pat. No. 5,048,385 expands on this concept by enabling the angular rotation of the entire punch assembly and further angular rotation of a tool holder to thereby selectively dispose a selected punch tool under the solid portion of the striker body. 
     However, the punch tip disclosed in U.S. Pat. No. 4,658,688 and punch tips generally known in the art are attached to the punch driver by a threaded shaft that passes through axial passageways in both the punch head and the punch driver. The shaft needs to be tightened to a specific torque rating in order to properly retain the punch tip. Thus, changing the punch tip in favor of an alternative punch tip is time consuming and therefore costly. Accordingly, there is a need in the punch press art for punch tips that may be changed more quickly and therefore more economically than currently available punch tips. 
     Further, while U.S. Pat. No. 4,658,688 discloses a punch assembly having an overall length that may be adjusted by rotating the punch head with respect to the punch driver, the design disclosed in U.S. Pat. No. 4,658,688 requires that any length adjustment be made during the initial installation of the punch tip. There is no way to adjust the overall length of the punch assembly during operation of the punch press. Accordingly, there is a need for an improved punch assembly that may be length adjusted during operation to compensate for tip wear, changes in the workpiece material or other operational variables. 
     SUMMARY OF THE INVENTION 
     The present invention satisfies the aforenoted needs by providing an improved punch assembly and an improved punch press. 
     The punch assembly of the present invention includes a punch driver with an axial passageway extending therethrough. The axial passageway of the punch driver accommodates a locking shaft that is releasably coupled to the punch tip. More specifically, the locking shaft includes a downwardly directed tapered socket for receiving an upper end of a punch tip shaft that extends upward from the punch tip. The upper end of the punch tip shaft includes one or more detents that form one half of a ball/detent connection between the punch tip and the punch driver. 
     The axial passageway extending through the punch driver includes a lower end that accommodates a cylinder which receives the punch tip shaft. The cylinder includes a plurality of spaced holes, each hole being in alignment with a ball that is trapped between an inside surface of the socket and a cylinder. 
     To connect the punch tip to the locking shaft that extends through the punch driver, the locking shaft, and specifically the socket, is pushed downward onto the upper end of the punch tip shaft. As a result, an inside surface of the socket pushes the balls through the spaced holes of the cylinder so that the balls engage the detent disposed at the end of the punch tip shaft to provide a ball/detent connection between the punch tip shaft and the locking shaft. 
     In an embodiment, the locking shaft further comprises an upper end that is spring biased upwards and a middle section disposed between the upper end of the locking shaft and the socket, which is disposed at the lower end of the locking shaft. This middle section comprises a slot having a lower portion and an upper portion. The punch driver further comprises a cooperating key that is accommodated in the slot. As the locking shaft is pushed downward, and the key is disposed in the upper portion of the slot, the balls are pushed inward through the base openings of the cylinder by the inside surface of the socket so that the balls engage the detent of the punch tip shaft to make the ball/detent connection. 
     In an embodiment, an upper portion of the slot disposed in the middle section of the locking shaft extends horizontally and the lower portion of the slot extends vertically so that in order to lock the socket of the locking shaft onto the upper end of the punch tip shaft, the locking shaft is pushed downward so that the key of the punch driver extends through the vertical portion of the slot and then the locking shaft is twisted thereby causing the key to travel along the horizontal portion of the slot to lock the socket over the upper end of the punch tip shaft. 
     In an embodiment, the punch assembly further comprises a punch head that is threadably connected to an upper end of the punch driver. The punch head also includes an axial passageway that is in alignment with the axial passageway disposed in the punch driver. As a result, the upper end of the locking shaft is accessible through the axial passageway of the punch head. 
     In an embodiment, the punch driver is further equipped with a downwardly biased ejector pin that engages an upper surface of the punch tip and that assists in the removal of the punch tip from the punch driver. 
     In an embodiment, to remove the punch tip from the punch assembly, the locking shaft is rotated until the key of the punch driver is in alignment with the vertical portion of the slot disposed in the middle section of the locking shaft. When the key is in alignment with the vertical portion of the slot, the spring biasing of the locking shaft upward in combination with the spring biasing of the ejector pins downward, causes the upper end of the punch tip shaft to be pushed downward to release the ball/detent connection between the punch tip shaft and the socket of the locking shaft. 
     In an embodiment, a lower end of the axial passageway passing through the punch driver accommodates a ring structure. The ring structure, in turn, accommodates and supports the cylinder and prevents upward movement of the cylinder relative to the lower end of the axial passageway when the punch tip shaft is inserted upward through the cylinder to make the ball/detent connection. 
     In an embodiment, the punch assembly further comprises a punch head that is threadably connected to an upper end of the punch driver. The punch head is substantially disposed within a collar; the punch driver is substantially disposed within a punch guide. The collar includes an outwardly extending upper flange and is further axially disposed within a spring. The spring is trapped between the upper flange of the collar and the punch guide. The collar also includes a plurality of spaced openings disposed below the upper flange. The upper end of the punch head further comprises a plurality of outwardly and radially extending fingers that extend through the openings of the collar to engage an upper end of the spring. Upon depression of the punch head in a downward direction, the fingers engage the spring to compress the spring downward. 
     In an embodiment, the fingers are an integral part of a ring structure disposed on top of the punch head. 
     In an embodiment, the ring structure is disposed between an upper end of the punch head and an upper punch cap. 
     In an embodiment, the punch cap includes a notch for engaging a striker or brake mechanism that prevents rotational movement of the punch cap and punch head upon rotation of the punch driver. In this way, the lower portion of the punch assembly, i.e. the punch driver and punch tip, may be rotated with respect to the punch head to axially lengthen or axially shorten the punch head assembly. 
     In an embodiment, the axial length of the punch head assembly is adjusted by rotating the punch guide, which results in a rotation of the punch driver and punch tip, while, at the same time, the punch head is held in place. 
     The present invention also provides an improved punch press apparatus comprising a punch assembly which includes a punch driver accommodated within a punch guide for axial movement within the punch guide. The punch guide prevents rotational movement of the punch driver with respect to the punch guide. The punch assembly further comprises a punch head threadably attached to an upper portion of the punch driver and a punch tip connected to a lower end of the punch driver. Rotation of the punch driver with respect to the punch head results in an axial lengthening or an axial shortening of the punch assembly. The punch head further includes a notch for engaging a lock means which prevents rotational movement of the punch head upon rotation of the punch guide and punch driver. The punch press apparatus further includes a linkage for transmitting rotational movement from a motor to the punch guide and punch driver to thereby lengthen or shorten the punch assembly. 
     In an embodiment, the punch press apparatus of the present invention further includes a means for sensing the overall length of the punch assembly. 
     In an embodiment, the means for sensing the overall length of the punch assembly comprises a sensor for detecting a relative vertical position of a target disposed on the punch assembly. The sensor is linked to a controller for activating or deactivating the motor. 
     In an embodiment, the target sensed by the means for sensing the overall length of the punch assembly is disposed on the punch head. 
     In an embodiment, the target which is sensed by the means for sensing the overall length of the punch assembly is disposed on the punch tip. 
     In an embodiment, the means for sensing the overall length of the punch tip assembly comprises a proximity switch and a target. 
     In an embodiment, the means for sensing the overall length of the punch tip assembly comprises an acoustical transmitter and a receiver, the receiver detecting the presence of the punch assembly between the transmitter and the receiver. 
     In an embodiment, the means for sensing the overall length of the punch assembly comprises a light transmitter and a receiver, the receiver detecting the presence of the punch assembly between the transmitter and the receiver. 
     In an embodiment, the punch press apparatus of the present invention further comprises a punch cap mounted onto an upper end of the punch head. The notch for engaging the lock means is disposed on the punch cap. 
     It is therefore an advantage of the present invention to provide an improved punch assembly with an improved connection between the punch tip and the punch driver to facilitate the removal and installation of the punch tip onto the punch driver. 
     Another advantage of the present invention is an improved method of measuring the overall length of the punch assembly and adjusting the overall length of the punch assembly. 
     Another advantage of the present invention is to provide an improved means of engaging the spring with the punch head during the compression of the punch assembly. 
     Another advantage of the present invention is to provide an improved means of ejecting a punch tip during the removal of the punch tip from the punch driver. 
     Another advantage of the present invention is to provide an improved means of controlling and adjusting the overall length of a punch head assembly. 
     Other advantages and objects of the present invention will become apparent upon reading the following detailed description and appended claims, and upon reference to the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     For a more complete understanding of the present invention, reference should now be made to the embodiments illustrated in greater detail in the accompanying drawings and described below by way of examples of the present invention. 
     In the drawings: 
     FIG. 1 is a perspective view of an upper turret portion of a punch press made in accordance with the present invention; 
     FIG. 2 is a plan view of the punch press shown in FIG. 1, taken generally along lines  2 — 2 ; 
     FIG. 3 is an enlarged side elevational view of the punch press shown in FIG. 1, partially cut away; 
     FIG. 4 is an elevational sectional view of a punch assembly made in accordance with the present invention; 
     FIG. 4A is a partial enlarged sectional view of the punch assembly shown in FIG. 4; 
     FIG. 5 is a top plan view of the punch assembly shown in FIG. 4; 
     FIG. 6 is a sectional elevational view of an alternative embodiment of a punch assembly made in accordance with the present invention after the punch tip and stripper plate have been detached from the assembly; 
     FIG. 7 is an exploded view of the punch head assembly shown in FIG. 6; 
     FIG. 8 is an elevational sectional view of a prior art punch head assembly; and 
     FIG. 9 is a schematic diagram illustrating the linkage between the target, sensor, computer and motor of the punch press assembly of the present invention. 
    
    
     It should be understood that the drawings are not necessarily to scale and that the embodiments are sometimes illustrated by graphic symbols, phantom lines, diagrammatic representations and fragmentary views. In certain instances, details which are not necessary for an understanding of the present invention or which render other details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein. 
     DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS 
     Referring to FIG. 1, the punch press of the present invention is generally shown at  10  and includes a punch press housing  11 , an upper rotatable turret  12 , a lower rotatable turret  13  and at least one indexable tool station, two of which are shown at  14 ,  15 . The tool stations  14 ,  15  include indexable punch assemblies  16 ,  17 . The drive motor  18  is provided along with linkages  21 ,  22  to impart rotation to the punch assemblies  16 ,  17  as discussed below. 
     More specifically, turning to FIG. 2, the turret  12  rotates beneath the housing  11  which supports a slide  23 . The slide is mounted between V-shaped rails  24 ,  25 . The actuator  26  connects the bracket  27  to the slide lock  28 . The motor  18  is lowered by way of the slide  23  so that its drive shaft assembly  31  (see FIG. 1) engages the drive pulley  32 . Rotation of the drive pulley  32  rotates a second pulley  33  by way of the linkage or timing belt  34 . Rotation of the second pulley  33  in turn rotates the gear drive  35  which has a shaped opening  36  through which a gear bushing  37  extends to engage the cooperating gear bushing  38  disposed on the outside of the punch guide  41  of the punch assembly  17  which is illustrated in greater detail in FIG.  4 . The turret  12  is rotatable about the turret axis  42 . Further, as illustrated in FIGS. 1 and 2, the punch assembly  17  is also rotatable through the use of the motor  18 . Therefore, not only can the turret  12  be rotated to make use of all of the punching tools P available on the turret  12 , indexing stations such as the ones shown at  14  and  15  may also provide rotatable punch assemblies  16 ,  17  respectively in order to adjust the angular orientation of a punching tool disposed at the indexable station. 
     Referring now to FIG. 3, a ram  43  is disposed above the punch assembly  17 . The downward movement of the ram  43  will engage the punch cap  44  which will in turn compress the spring  45  ultimately causing the punch tip  46  to extend downward and engage the workpiece  47 . The workpiece  47 , as shown in FIG. 3, is resting on top of an indexable die  48  which is rotated using an apparatus similar to the apparatus used to rotate the punch assembly  17 . Specifically; a drive shaft  51  extending upward from a motor (not shown) engages a drive pulley  52  which rotates the second pulley  53  by way of the drive belt connection  54 . The second pulley  53  is linked to a gear bushing  155  which, in turn, is meshed with the gear bushing  156  that is connected to the indexable die  48 . 
     Similarly, with respect to the punch assembly  17 , lowering of the motor  18  on slide  23  by the actuator  26  results in an engagement of the first pulley  32  by the drive shaft assembly  31 . Rotation of the drive pulley  32  results in rotation of the second pulley  33  by way of the drive belt  34  as discussed above with respect to FIG.  2 . 
     Turning to FIG. 4, a punch assembly  17  made in accordance with the present invention includes a punch driver  55  that is threadably connected to a punch head  56 . The threadable connection between the punch head  56  and the punch driver  55  results in an overall lengthening or shortening of the punch head assembly  17 . As shown in FIG. 3 and 5, the length of the punch assembly  17  may be lengthened or shortened by engaging the notch  57  disposed at an outer periphery of the punch cap  44  with a retractable lock bar  58  which holds the punch cap  44  and consequently the punch head  56  in place while the punch guide  41  and consequently the punch driver  55  and punch tip  46  are rotated by the motor  18 . 
     Returning to FIG. 4, the punch head  56  includes an axial passageway  61  and, similarly, the punch driver  55  includes an axial passageway  62 . The axial passageway  62  of the punch driver accommodates a locking shaft  63  which features a lower socket  64  and an upper end  65  designed to accommodate a tool used to twist and push the locking shaft  63  downward to couple the lower socket  64  of the locking shaft  63  with the punch tip shaft  66 . Specifically, the upper end  65  of the locking shaft  63  is biased upward by the spring  67 . When the socket  64  is disconnected or decoupled from the punch tip shaft  66 , the key  68  of the punch driver  55  is disposed at the lower end of the vertical slot  69 . In the position shown in FIG. 4, the locking shaft  63  has been pushed downward and twisted so that the key is engaging the horizontal portion  71  of the slot. When the locking shaft  63  has been pushed downward and rotated to assume the position shown in FIG. 4, the socket  64  has been pushed downward over the punch tip shaft  66  and, more specifically, over the upper end  72  of a cylinder  73  (not shown in FIG. 4, see FIG. 6) which causes projecting members preferably in the form of balls  74 ,  75  to pass through openings in the cylinder  73  like those shown at  76 ,  77  in FIG. 6 thereby causing the balls to engage the detent  78  disposed at the upper end  79  of the punch tip shaft  66 . 
     Referring to FIG. 6, the cylindrical structure  73  is supported and held in place by the ring structure shown at  81 . The ring structure  81  is mounted at the lower end of the passageway  62 . The ring structure  81  supports and holds the cylindrical structure  73  in place under any upward pressure imparted by the punch tip shaft  66  and downward pressure imparted by the socket  64 . 
     Still referring to FIGS. 4 and 6 collectively, the punch driver  55  is slidably disposed primarily in the punch guide  41 . Rotation of the punch driver  55  within the punch guide  41  is prevented by way of the engagement between the key  82  and the slot  83 . The lower end of the punch guide  41  includes a bracket  84  which is detachably connected to a stripper plate  85 . The upper end of the punch guide  41  accommodates a shoulder  86  which supports the lower end of the spring  45 . 
     The punch head  56  is accommodated primarily within the collar  87 . An upper end of the collar  87  features an outwardly extending flange  88 . A washer  92  is disposed between the spring  45  and the flange  88 . 
     As illustrated in FIG. 7, the collar  87  includes a plurality of openings shown generally at  93 . Further, the upper end of the punch head  56  is attached to a ring  94  that includes a plurality of outwardly extending fingers  95 . The fingers  95  pass through the openings  93  in the collar  87  to engage the spring  45  when the punch head  56  and punch cap  44  are pressed downward by the ram  43  (see FIG.  3 ). Returning to FIGS. 4 and 6, a threaded opening  96  is provided through the fingers to accommodate set screws for securing the radial position of the ring  94  on the upper end of the punch head  56 . Similarly, a threaded opening  97  is provided in the punch cap  44  for securing the punch cap  44  to the punch head  56 . 
     In the embodiments shown in FIGS. 4 and 6, the punch driver  55  is connected to a punch driver end ring  98  by the bolt  102  which threadably connects the driver  55  to the end ring  98 . Referring now to FIG. 6, the punch assembly  17  is further equipped with an ejector pin  103  which is spring biased in the downward position by a spring  104 . The ejector pin  103  pushes downward on the punch tip  46  to assist in removal of the punch tip  46  from the punch assembly  17 . 
     Thus, in order to remove the punch tip  46  from the punch assembly  17 , the bracket  84  and stripper plate  85  are disconnected from the lower tab  105  disposed at a lower end of the punch guide  41 . Then, a tool is inserted downward through the axial passageway  61  and  62  to engage the upper end  65  of the locking shaft  63 . The shaft is twisted causing the horizontal portion  71  of the slot to pass over the key  68  so that the key  68  is in alignment with the vertical portion  69  of the slot. The bias exerted on the upper end  65  of the locking shaft  63  by the spring  67  forces the locking shaft  63  upward resulting in upward movement of the socket  64 . Without the socket  64  forcing the balls  74 ,  75  into the detent  78  disposed at the end of the punch tip shaft  66 , downward pressure exerted on the punch tip  46  by the ejector pin  103  causes disengagement between the balls  74 ,  75  and the detent  78  thereby releasing the punch tip shaft  66  and punch tip  46 . 
     Further, in order to adjust the overall height of the punch assembly  17 , referring to FIG. 3, the motor  18  and drive shaft assembly  31  are lowered so as to engage the drive pulley  32 . Rotation of the drive shaft assembly  31  results in rotation of the drive pulley  32  which, in turn, results in rotation of the second pulley  33 . As shown in FIG. 2, the second pulley  33  is coupled to the gear bushing  37  which, in turn, is in mesh with the gear bushing  38  that is attached to the exterior of the punch guide  41  (see FIG.  4 ). Upon activation of the motor  18 , the retractable locking bar  58  (see FIG. 3) is extended downward to engage the notch  57  (see FIGS. 4 and 5) so that the punch cap  44  and punch head  56  are not rotated while the punch guide  41  and punch driver  55  are being rotated to adjust the overall axial length of the punch assembly  17 . 
     Further, referring again to FIG. 3, a sensor is shown at  111  which may be used to detect the proximity of the punch cap  44  during the length adjustment of the punch assembly  17 . Generally, a number of different sensors can work in determining the overall axial length of the punch assembly  17 . A sensor  111  may be positioned at or above the punch cap  44  to send a signal to a computer (not shown in FIG. 3, see FIG. 9) to indicate that the punch assembly  17  has reached the pre-selected height or length. A sensor may also be positioned below the turret  12  for purposes of detecting the presence of the lower end  112  of the punch tip  46 . Generally speaking, a sensor such as the one shown at  111  may be combined with a target attached or disposed anywhere on the punch assembly  17  to determine the axial length of the punch assembly  17 . The sensor  111  may be a proximity sensor or switch, or the sensor  111  may be in the form of a transmitter, such as a sound transmitter or light transmitter, in combination with a receiver (not shown). During the axial lengthening of the punch assembly  17 , the transmission of a signal, either sound or light or other signal, between the transmitter and receiver would be interrupted or interfered with as a portion of the punch assembly  17 , such as the punch cap  44  or the punch tip  46  is extended axially in the path between the transmitter and receiver. In addition to a sound or light transmitter/receiver combination, it is anticipated that an electromagnetic transmitter/receiver combination would work as well. The linkage between the motor  18 , computer or controller  113 , sensor  111  and target  114  is illustrated in FIG.  9 . 
     FIG. 8 is an illustration of a prior art connection between a punch tip  46   a  and a punch driver  55   a . Specifically, a connecting bolt  63   a  threadably connects the punch driver  55   a  to the punch tip  46   a . The connecting bolt  63   a  must be tightened to a specific torque rating in order to retain the punch tip  46   a  on the punch driver  55   a . As shown in FIGS. 4-6, the connection between the punch tip  46  and the punch driver  55  is greatly facilitated by the present invention. 
     From the above description, it is apparent that the objects of the present invention have been achieved. While only certain embodiments have been set forth, alternative embodiments and various modifications will be apparent from the above description to those skilled in the art. These and other alternatives are considered equivalents and within the spirit and scope of the present invention.