Blank Pile Deburring Rollers for Burr-Free Sheet Metal Edges
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Solution Overview
Problem
The manufacturing of vehicles faces issues with burrs on sheet metal blanks causing defects during the stamping process, leading to increased costs due to scrapped or reworked parts.
Innovation Solution
A deburring device comprising a pair of rotating cylindrical brushes with steel bristles, supported by a movable main body and driven by motors, which contacts the edges of a pile of sheet metal blanks to remove burrs, accompanied by a vacuum system to collect debris.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If sheet metal is cut into blanks using conventional cutting methods, then the blanks are produced for stamping, but burrs are generated along the edges causing defects and increasing manufacturing costs
Solution Approach 1:
The deburring device removes burrs from blank edges before the stamping process occurs. By performing preliminary deburring on the stacked blanks, the harmful burrs are eliminated in advance, preventing them from causing defects during subsequent stamping operations and eliminating the need for rework or scrap.
2Manufacturing precision
If deburring is performed on individual blanks, then edge quality is improved, but the process time and productivity are reduced
Solution Approach 1:
The deburring device processes multiple stacked blanks simultaneously in a single operation. By merging several blank treatments into one collective deburring action, the device maintains high edge quality for each blank while significantly improving overall productivity compared to individual blank processing.
Solution Approach 2:
The rotating brush rollers continuously contact the edges of stacked blanks, providing continuous deburring action as the device moves through the pile. This continuous useful action ensures all blanks are processed efficiently without interruption, maintaining both quality and productivity.
3Manufacturing precision
If a fixed deburring device is used, then manufacturing precision can be maintained, but adaptability to different blank piles is reduced
Solution Approach 1:
The deburring device incorporates movable and adjustable components that allow it to adapt dynamically to different blank pile configurations. The device can adjust to varying numbers of stacked blanks and different pile arrangements while maintaining consistent deburring quality, combining precision with versatility.
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
Effectively removes burrs from the edges of sheet metal blanks, reducing defects and associated costs by ensuring smoother stamping processes and improving the quality of final parts.
Implementation Method 1
rotating a first brush about a first axis and a second brush about a second axis... the first and second brushes contact the perimeter to remove burrs from the perimeter
Implementation Method 2
cylindrical brush having bristles that extend radially outward... contact between the first and second rollers and the edges of the pile of metal blanks
Implementation Method 3
the device further includes a vacuum, the vacuum including a vacuum inlet supported by the support structure, the vacuum inlet being positioned proximate to the first and second rollers
Data Source
AI summary
A device for deburring edges of a pile of metal blanks includes a first roller, a second roller, at least one motor, and a main body. The first roller is supported for rotation about a first axis. The second roller is supported for rotation about a second axis. The at least one motor is drivingly coupled to the first and second rollers to rotate the first roller in a first rotational direction and the second roller in a second rotational direction that is opposite the first rotational direction. The main body supports the first roller, the second roller, and the at least one motor. The main body is movable about a periphery of the pile of metal blanks and is configured to permit contact between the first and second rollers and the edges of the pile of metal blanks.