Integrated Twisting in Bending Machines for Complex Flat Parts
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Solution Overview
Problem
The production of complex bent parts from flat material is hindered by inefficiencies in existing methods, which struggle to achieve high productivity and dimensional accuracy, especially in narrow and geometrically complex installation environments.
Innovation Solution
A bending machine with an integrated twisting device that applies a torsional deformation to the flat material before separation, allowing for the creation of twisted sections in addition to two-dimensional or three-dimensional bends, enabling the production of extremely complex bent parts with improved productivity and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional bending machines without integrated twisting devices are used, then the device complexity is lower, but the manufacturing precision and adaptability for complex installation environments deteriorate
Solution Approach 1:
The patent combines the twisting device and bending device into a single integrated bending machine system. The twisting device with rotatable component and counter-support is merged with the bending device, allowing both twisting and bending operations to be performed in one machine. This integration resolves the contradiction by achieving high manufacturing precision for complex parts while managing device complexity through unified system architecture rather than separate machines.
Solution Approach 2:
The bending machine is designed with multi-functionality, capable of performing both twisting operations (via the rotatable component that rotates up to 360 degrees) and bending operations (via the bending device with forming elements). This universal machine can produce complex three-dimensional bent parts with twisted sections, eliminating the need for multiple specialized machines and improving manufacturing precision for intricate geometries while optimizing device complexity.
2Productivity
If multiple separate operations (twisting then bending) are performed on different machines, then the device complexity is lower, but the productivity deteriorates
Solution Approach 1:
The patent merges the twisting device and bending device into one integrated system, allowing twisting and bending operations to be performed sequentially in a single machine setup. The control unit coordinates both operations automatically, eliminating the need to transfer workpieces between separate machines. This integration significantly improves productivity by reducing setup time and handling operations while managing device complexity through unified control architecture.
Solution Approach 2:
The bending machine enables continuous useful action by performing twisting and bending operations in uninterrupted sequence within the same machine. The workpiece remains in the machine throughout the entire process, with the twisting device operating first, followed immediately by the bending device. This continuous operation eliminates idle transfer time between machines, maximizing productivity while the integrated control system manages the complexity of coordinating multiple operations.
3Adaptability or versatility
If complex bent parts with twisted sections are produced, then the adaptability to intricate installation environments improves, but the manufacturing precision deteriorates
Solution Approach 1:
The bending machine achieves universality by incorporating both twisting capability (rotatable component with 0-360 degree rotation) and bending capability (forming device with multiple forming elements). This multi-functional machine can produce highly adaptable complex bent parts with twisted sections that match intricate installation environments. The integrated control unit ensures that despite the complexity of the operations, dimensional accuracy is maintained through coordinated control of both twisting and bending processes.
Solution Approach 2:
The patent applies segmentation by dividing the complex forming process into distinct sequential operations: first the twisting operation creates the twisted section with precise angle control, then the bending operation creates the required bends. The control unit manages each operation separately with specific parameters, allowing precise control over the final complex geometry. This segmented approach to complex part formation maintains manufacturing precision while achieving high adaptability to intricate installation environments.
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
The solution significantly enhances productivity and dimensional accuracy in producing complex bent parts by integrating a twisting operation into the bending process, allowing for precise alignment and adaptation to intricate installation environments.
Implementation Method 1
a permanent deformation in the form of a twisted or torsioned section is produced in at least one section of the flat material by means of a twisting operation through torsion of the flat material
Implementation Method 2
a permanent deformation in the form of a twisted or torsioned section is produced in at least one section of the flat material
Data Source
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AI summary
In the case of a bending machine (100) and a method for producing a bent part from flat material (190), the flat material is fed to the bending machine from a material supply (100), is formed in the bending machine (100) into a bent part of flat material that is two-dimensionally or three-dimensionally bent and after that the bent part is detached from the fed flat material in a cutting operation. In at least a portion of the flat material (190), a permanent deformation is produced by torsion of the flat material by means of a twisting operation. The twisting operation is carried out before the detachment of the bent part from the fed flat material on the flat material guided in the bending machine by means of a twisting device (200) integrated in the bending machine.