Cold-Rolled Connecting Element for Weld-Free Ball Sections
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Solution Overview
Problem
Existing methods for producing connecting elements with ball-like sections require welding and multiple steps, leading to inefficiencies and material waste, while also limiting the ability to create secure connections and rotationally symmetrical shapes.
Innovation Solution
A method involving the cold forming of a cylindrical blank between rolling tools to create ball-like sections and connecting elements in a single process, eliminating the need for welding and allowing for the production of secure connections and varied shapes through the use of roller-type or flat rolling tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If welding is used to connect ball-like sections, then the connecting element can be produced from mass-produced individual balls, but the production process becomes complex and time-consuming with multiple steps
Solution Approach 1:
The patent combines multiple production steps (forming ball-like sections, creating connecting sections, and joining them) into a single cold forming rolling process. The rolling tool simultaneously shapes the blank into ball-like sections and creates connecting sections between them, eliminating the need for separate welding operations and mass-producing individual balls first.
Solution Approach 2:
The patent performs all necessary forming and connecting operations in advance during a single rolling process. The blank is pre-shaped into the final connecting element configuration with all ball-like sections and connecting sections formed simultaneously, so no subsequent welding or assembly steps are needed.
2Loss of substance
If welding is used to connect ball-like sections, then individual balls can be connected, but material waste increases and production costs rise
Solution Approach 1:
The patent changes the material state and forming parameters by using cold forming rolling instead of welding. The blank is progressively deformed through controlled rolling passes, changing its shape from a cylindrical blank to a connecting element with ball-like sections, all while maintaining material integrity and minimizing waste.
Solution Approach 2:
The rolling process itself performs multiple functions simultaneously: it forms the ball-like sections, creates the connecting sections between them, and produces the final connecting element in one self-contained operation, eliminating the need for separate welding operations and reducing overall manufacturing complexity.
3Shape
If traditional rolling is used to shape ball-like sections, then high deformation is achieved, but the ball shape is limited and refinishing work is required
Solution Approach 1:
The patent uses dynamic rolling tool designs with adjustable parameters that can vary during the rolling process. The rolling tools can modify their geometry, pressure, and motion characteristics to create different ball-like shapes (spherical, bulbous, etc.) from the same blank, eliminating the need for refinishing work while achieving high manufacturing precision.
4Productivity
If multiple production steps are used including welding, then connecting elements can be produced, but production time increases and efficiency decreases
Solution Approach 1:
The patent implements a continuous rolling process where the blank is continuously deformed and shaped through successive rolling passes without interruption. The forming of ball-like sections and connecting sections occurs in an unbroken sequence, maximizing production efficiency and minimizing the production cycle time compared to discrete welding operations.
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 the rapid and cost-effective production of connecting elements with high deformation capabilities, allowing for secure latching with clip elements and reduced material waste, while facilitating the creation of complex shapes and secure connections without the need for refinishing.
Implementation Method 1
the rolling of a single-piece blank, which is cylindrical at least in sections, between at least two rolling tools and the shaping of the at least two ball-like sections and optionally of the connecting section during the rolling
Implementation Method 2
The rolling of a cylindrical blank has surprisingly managed to achieve a very high degree of deformation, thus enabling the two ball-like sections to be shaped
Data Source
AI summary
The invention relates to a method for producing a connecting element comprising at least two ball-like sections, wherein two ball-like sections are directly adjacent to each other, or wherein two ball-like sections are connected to each other by means of a connecting section, wherein the rolling of a single-piece blank, which is cylindrical at least in sections, between at least two rolling tools and the shaping of the at least two ball-like sections and optionally of the connecting section during the rolling are provided.