Acute Angle Metal Stock Bender with Sliding Hydraulic Actuator
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Solution Overview
Problem
Bending metal stock to an acute angle of 180 degrees requires a large force, which is difficult to achieve with existing hydraulic cylinder and ram systems due to the long distance over which the force must be exerted, leading to buckling issues and the need for complex and space-consuming apparatus.
Innovation Solution
A shop tool that translates a slide along a linear arm with a pivotable lever and die, using a hydraulic cylinder and ram to make multiple bending steps, allowing for a 180-degree bend by positioning the slide and die to lock in place at specific locations, enabling the use of either hydraulic or manual power and eliminating the need for electricity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a hydraulic cylinder with an extending ram is used to bend stock to an acute 180 degree angle, then the required large force can be transmitted, but the long distance over which the force must be exerted causes the cylinder and ram to buckle
Solution Approach 1:
The bending process is divided into multiple smaller bends performed at different locations along the stock. Instead of making one large bend over a long distance, the apparatus makes several smaller bends sequentially, each over a shorter distance, thereby avoiding buckling of the cylinder and ram while still achieving the total 180 degree bend angle.
Solution Approach 2:
The apparatus uses a swinging frame that changes the angle and distance of the frame with respect to a forming die during operation. This dynamic adjustment allows the same apparatus to perform multiple smaller bends at different positions, effectively reducing the required stroke length of the hydraulic cylinder while maintaining the capability to achieve large total bend angles.
2Force
If a swinging frame apparatus is used to make multiple smaller bends, then the required force for each bend is reduced, but the apparatus becomes complex and requires substantial shop space
Solution Approach 1:
The patent combines multiple functions into a single compact apparatus. The linear arm integrates the slide bar, slide, and lever mechanisms, while the form roller serves both as a bending tool and a positioning element. This merging reduces the overall complexity and space requirements compared to separate components for each bending operation.
Solution Approach 2:
The apparatus is designed with universal components that can perform multiple functions. The slide mechanism can be positioned at different locations along the linear arm to perform bends at various points, and the form roller can be used for different bend radii by adjusting its position. This multi-functionality reduces the need for multiple specialized tools, thereby reducing overall device complexity and space requirements.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient bending of metal stock to 180 degrees with reduced force requirements, avoiding buckling issues and simplifying the apparatus design, while ensuring operator safety by eliminating electrical components.
Implementation Method 1
A hydraulic cylinder has a ram which extends under hydraulic pressure and retracts when the pressure is removed
Implementation Method 2
The slide has a pivotably mounted spring loaded clapper arranged to urge a gudgeon through an aligned hole in the slide against the slide bar
Data Source
AI summary
Apparatus for bending stock to an acute angle. A hydraulic cylinder with a ram extendable under hydraulic pressure provides the bending power. The ram automatically retracts from an extended position when hydraulic pressure is removed. One end of an apparatus supporting arm consists of a slide bar. The slide bar end of the arm is secured to a support with the opposite end pivotably mounting a forming die and a lever. The lever pivotably mounts a forming roller. The lever carries the forming roller around the die and bend stock secured to the die around the die. A slide is slideably attached to the slide bar. The cylinder and ram are pivotably attached extending between the slide and the lever. With this arrangement providing hydraulic pressure to extend the ram will rotate the lever and forming roller around the die and bend secured stock around the die, then removing pressure will retract the ram and move the slide with the attached cylinder and ram towards the die where the slide is automatically locked in place. This permits making an acute angle bend by successive bends with the cylinder and ram at two different locations with respect to the die.