Automated Free-End Hose Forming With Heated Contour Tools
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Solution Overview
Problem
Existing methods for shaping the free end of a tube section, such as plastic cannulas and catheters, are not fully automated and lack precision, requiring multiple manual handling steps and separate forming processes.
Innovation Solution
A device and method that includes a feed unit, transport unit, and processing station with a tool core and forming tool, allowing for precise deformation of the tube end using interchangeable tool components and controlled heating and cooling, enabling fully automated production with high precision and adaptability to different diameters and shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual handling steps are used for feeding and aligning hose sections, then flexibility in processing is maintained, but automation level and productivity are reduced
Solution Approach 1:
The patent combines multiple separate operations (feeding, aligning, and processing of hose sections) into a single integrated processing station. The hose section is fed in already aligned and processed continuously without release or repositioning, merging what were previously separate manual handling steps into one automated workflow.
Solution Approach 2:
The processing station is designed as a universal device that can handle multiple operations on the hose section simultaneously - feeding, aligning, and various processing tasks (cutting, forming, etc.) - all within one station, eliminating the need for multiple specialized stations and manual interventions.
2Adaptability or versatility
If separate forming processes are used for different hose end configurations, then adaptability is improved, but device complexity and processing time increase
Solution Approach 1:
The patent employs dynamically adjustable forming tools with interchangeable tool cores and adjustable forming elements that can be reconfigured for different hose end configurations. This dynamic adaptability allows a single forming station to handle multiple product variants without requiring separate dedicated forming processes for each configuration.
Solution Approach 2:
The forming process utilizes adjustable parameters including tool core dimensions, forming tool geometry, temperature settings, and pressure parameters that can be modified to produce different hose end configurations. By changing these parameters rather than using entirely different processes, the system achieves versatility while maintaining a unified processing approach.
3Manufacturing precision
If precision forming tools are used to achieve high surface quality, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces complex high-precision mechanical forming tools with a combination of heated forming tools and controlled cooling systems. The precision is achieved through thermal control and phased cooling rather than relying solely on mechanical tool precision, reducing the complexity of mechanical tolerances while maintaining high surface quality.
Solution Approach 2:
The forming process utilizes the phase transition of the hose material from solid to softened state (via heating) and back to solid (via cooling) to achieve precise forming. The material becomes pliable during heating, allowing easy deformation to the desired shape, then solidifies during controlled cooling to lock in the precise geometry, achieving high surface quality through material property changes rather than purely mechanical precision.
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 fully automated, precise, and reproducible shaping of tube ends with minimal contamination, allowing for quick processing times and easy adaptation to various materials and dimensions, suitable for clean room environments.
Implementation Method 1
the processing station has a heating system by means of which the free end of the hose section and/or the forming tool can be heated
Implementation Method 2
the outer contour of the free end of the hose section can be deformed by the forming tool
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention relates to a device and a method for forming the free end (12) of a hose section. The device has a feed unit and a transport unit for the hose section, as well as at least one processing station (50) for the free end (12) of the hose section. According to the invention, the processing station (50) has a tool core (58) over which the free end (12) of the hose section can be pushed. Furthermore, the processing station (50) has a forming tool (52) that can be positioned from the outside around the free end (12) of the hose section, such that the outer contour of the free end (12) of the hose section can be deformed by the forming tool (52). The free end (12) of the hose section and/or the forming tool (52) can be heated by means of a heating system (60).In the method according to the invention, the free end (12) of the hose section is first introduced into a processing station (50) via a linear movement. The free end (12) of the hose section is guided over a tool core (58). Subsequently, the free end (12) of the hose section and/or the forming tool (52) of the processing station (50) are heated and moved further into the forming tool (52) via a linear movement, thereby reshaping the outer contour of the free end (12) of the hose section.