Bent Sheet Metal Cover Plates for Flexible Oven Front Forming
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Solution Overview
Problem
The high costs and low flexibility associated with manufacturing metal cover plates for household appliances through deep-drawing, which requires expensive tooling and lengthy setup changes, limit the efficiency and adaptability of the process.
Innovation Solution
The use of two-dimensional bending methods to form sheet metal parts into cover plates, allowing for the use of simpler and less expensive machinery, rapid re-tooling, and flexible production, with bending lines extending over the entire width of the plate and employing techniques like roll-forming and air bending to achieve stable and thermally resistant designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If deep-drawing is used to manufacture cover plates, then the cover plates can be formed into desired three-dimensional shapes, but the tooling costs are high and the process lacks flexibility
Solution Approach 1:
The patent divides the cover plate into multiple sections separated by bending lines, allowing each section to be formed independently through sequential bending operations. This segmentation enables the use of simple, inexpensive bending tools rather than complex deep-drawing tooling, while still achieving the desired three-dimensional shape through cumulative deformation of multiple sections.
Solution Approach 2:
The patent transitions from three-dimensional deep-drawing to two-dimensional bending by introducing bending lines that extend across the cover plate. Instead of forming the entire three-dimensional shape in a single deep-drawing operation, the method uses multiple two-dimensional bending operations along linear bending lines to achieve the same result with simpler tools.
2Adaptability or versatility
If new tools are used to change the form of deep-drawn cover plates, then different designs can be produced, but the process is time-consuming and lacks flexibility
Solution Approach 1:
The patent employs adjustable and reconfigurable bending tools, particularly rollers and cylinders, that can be quickly repositioned and reconfigured for different bending line patterns. This dynamic tooling system allows rapid adaptation to new designs without requiring complete tool replacement, enabling fast changeovers between different cover plate configurations.
Solution Approach 2:
The patent uses adjustable bending parameters such as roller position, bending force, and bending line location that can be modified to produce different cover plate designs. By changing these parameters rather than replacing tools, the system achieves high design flexibility with minimal re-tooling time.
3Manufacturing precision
If complex deep-drawing tools are used, then precise three-dimensional forming can be achieved, but the machinery is large and expensive
Solution Approach 1:
The patent segments the complex three-dimensional forming process into multiple simple two-dimensional bending operations along linear bending lines. Each bending operation uses simple, precise tools that are much less complex than equivalent deep-drawing tooling, yet the cumulative effect of multiple precise bending operations achieves the same overall forming precision.
Solution Approach 2:
The patent reduces the dimensional complexity of the forming process by using two-dimensional bending operations instead of three-dimensional deep-drawing. This dimensionality reduction allows the use of simpler, more compact machinery while maintaining manufacturing precision through controlled sequential deformation.
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
This approach reduces manufacturing time and costs, enhances flexibility, and produces cover plates with minimal deformation under temperature changes and excess material, while maintaining a smooth surface and allowing for complex designs, thus improving the manufacturing efficiency and quality of household appliance cover plates.
Implementation Method 1
a cover plate (8, 11), which cover plate is a formed sheet metal part. The cover plate is a bent sheet metal part or piece having linear bending lines
Data Source
Figure 1
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AI summary
A cover plate (8) of a household appliance (1), which cover plate (8) is a formed sheet metal part, wherein the cover plate (8) is a bent plate sheet metal part having linear bending lines (16-18) that each extend over a respective width (W). A household appliance (1) comprises at least one cover plate (8). A method is used for manufacturing a cover plate (8) of a household appliance (1) wherein the cover plate (8) is formed by exclusively bending a sheet metal part over its entire width (W). The invention is particularly useful for front-sided cover plates of ovens or ranges.