Motorized Blank Holder Positioning for Incremental Forming
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Solution Overview
Problem
Incremental forming technologies face challenges in manufacturing vehicle components due to limitations such as simple shapes, low-strength materials, forming quality defects, and the need for manual adjustment of blank holders, which results in non-uniform quality and excessive development costs.
Innovation Solution
An apparatus that automatically adjusts the position of a blank holder in conjunction with a forming robot, using a motor and interlocking means with guide screws and gear units to move the holder perpendicular to the forming surface, allowing for precise positioning and size-dependent fixation of blanks, thereby enhancing forming quality and reducing process complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a stationary holder is used for incremental forming, then the structure is simple and easy to manufacture, but the blank position cannot be automatically adjusted and forming quality is non-uniform
Solution Approach 1:
The holder is transformed from a stationary structure to a dynamic one capable of automatic position adjustment. The holder body can move vertically along guide rails, and the blank clamping position can be adjusted automatically through a motor-driven screw mechanism, enabling real-time adaptation to different blank sizes and forming positions
Solution Approach 2:
The holder is designed with universal adaptability to process blanks of different sizes and shapes. Through adjustable clamping mechanisms and variable positioning capabilities, a single holder structure can accommodate multiple blank configurations, eliminating the need for multiple specialized holders
2Productivity
If manual adjustment of blank holder is used, then the device structure is simple, but excessive working processes are required and quality is non-uniform
Solution Approach 1:
The holder system performs self-adjustment through automated mechanisms. The motor-driven screw mechanism automatically positions the blank holder without requiring manual intervention, and the system can autonomously adapt to different blank configurations, reducing the number of manual working processes
Solution Approach 2:
The system incorporates feedback control where the position of the blank holder is automatically adjusted based on detected blank dimensions and forming requirements. This closed-loop control ensures uniform quality by maintaining optimal holder position throughout the forming process
3Adaptability or versatility
If single-size holder is used, then the device complexity is low, but the holder cannot adapt to different blank sizes and excessive development costs are incurred
Solution Approach 1:
The holder incorporates dynamic adjustment capabilities allowing it to adapt its configuration to different blank sizes. The clamping positions and holder dimensions can be modified through motorized mechanisms, enabling a single holder to replace multiple fixed-size holders
Solution Approach 2:
The holder is designed as a universal fixture that can accommodate various blank sizes and geometries. Through adjustable clamping mechanisms and reconfigurable structure, one holder performs the function of multiple specialized holders, reducing development costs
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 solution enables the production of components with complex shapes and various materials, improves forming quality, reduces the number of working processes, and minimizes additional facility investments by allowing a single facility to manufacture blanks of different sizes.
Implementation Method 1
guide screws fastened to the jack nuts by screw structures, provided to be rotatable about axes of the guide screws, and configured to move the blank holder in an axial direction by rotating
Implementation Method 2
a worm wheel fixed to an end portion of a corresponding guide screw and configured to rotate about an axis thereof; and a worm configured to receive the driving power from the motor and engage with the worm wheel to rotate the worm wheel
Implementation Method 3
the driveshafts and the worms at the two opposite sides may be connected to one another by a bevel gear set so that the driving power of the motor may be equally transmitted to the worms at the two opposite sides
Data Source
AI summary
An apparatus of holding a blank for incremental forming, includes a blank holder to which a blank is configured to be coupled; a motor configured to provide driving power; an interlocking mechanism engaged to the motor and configured to rectilinearly move the blank holder in a direction perpendicular to a forming surface of the blank in conjunction with an operation of the motor; and a controller configured to control the operation of the motor so that the blank rectilinearly moves in accordance with a position of a forming robot configured for forming the blank.