Adjustable Roll Forming Stations for Ductwork Flange Height
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Solution Overview
Problem
Existing roll-forming machines are limited in their ability to produce multiple flange configurations and dimensions, requiring manual re-tooling and lack precise adjustment mechanisms for accurate and repetitive operations.
Innovation Solution
A flange-forming device with adjustable roll forming stations that can be concurrently adjusted using a motor or hand crank-driven adjustment mechanism, allowing for infinite adjustment within set limits, enabling the production of various flange heights and configurations without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual re-tooling is used to change flange configurations, then the machine can produce different flange types, but the loss of time and productivity decreases
Solution Approach 1:
The roll forming stations are made dynamically adjustable through a motorized drive mechanism that allows the rolling elements to be repositioned along the length of the metal sheet. This enables the machine to adapt to different flange configurations without manual re-tooling, resolving the contradiction between versatility and productivity by making the adjustment process automated and rapid.
Solution Approach 2:
The invention changes the positional parameters of the roll forming stations through motorized adjustment mechanisms. By varying the position of rolling elements along the metal sheet, different flange heights and configurations can be produced. This parameter-based adjustment system eliminates the need for manual re-tooling while maintaining production efficiency.
2Adaptability or versatility
If hydraulic cylinders are used for adjustment, then limited adjustment is possible, but the measurement precision and reliability decrease
Solution Approach 1:
The invention replaces hydraulic adjustment mechanisms with a motorized drive system that provides precise positional control through mechanical means. The motorized mechanism incorporates positive location features that ensure accurate and repeatable positioning of roll forming stations, eliminating the precision problems associated with hydraulic systems while maintaining a wide adjustment range.
Solution Approach 2:
The adjustment mechanism incorporates self-aligning and self-l locating features that automatically ensure precise positioning without requiring external calibration or complex control systems. The positive location mechanism inherently maintains measurement precision through its mechanical design, allowing the system to serve itself in maintaining accuracy.
3Device complexity
If roll forming stations are fixed, then the device complexity is reduced, but the adaptability and versatility worsen
Solution Approach 1:
The roll forming machine is segmented into multiple independently adjustable stations, each capable of being positioned separately along the metal sheet. This segmentation allows the machine to handle various flange configurations while maintaining a relatively simple overall structure. Each segment can be adjusted without affecting the others, providing versatility without excessive complexity.
Solution Approach 2:
The motorized adjustment mechanism serves multiple functions: it positions rolling elements for different flange heights, adjusts station spacing for various flange configurations, and enables rapid changeover between product types. This multi-functionality provides high adaptability while adding minimal complexity to the machine structure.
Data Source
AI summary
A flange-forming apparatus allows a user to automatically adjust the device's roll forming stations, concurrently together, for changing the height of a flange formed into a metal web by the roll forming stations, e.g., for ductwork. The height is adjustable within an infinite range between set maximum and minimum limits. Each roll forming station includes upper and lower roll forming pairs, which cooperate for forming the flange or portion thereof. Each roll forming pair includes a first roll forming portion, and a second, coaxial roll forming portion that is axially moveable towards and away from the first roll forming portion. (The portions are in effect a laterally split roll forming die.) The second roll forming portions are rotatably supported on a plate-like adjustment linkage assembly, which can be shifted, using an array of motor driven screw members, towards or away from the first roll forming portions.