Compact Sheet Edge Crimping Unit for Fast Single-Pass Forming
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Solution Overview
Problem
Current crimping technologies in the automotive industry face challenges such as slow production cycle times, limited space due to robot size, lack of flexibility, and bulkiness, which are incompatible with modern manufacturing demands for faster and more versatile assembly of vehicle bodywork components.
Innovation Solution
A crimping device and unit that utilize a support, a blade holder, and an actuation cylinder with a sliding rod and spring-loaded cylinders to enable translational and pivoting movements, allowing for compact and efficient crimping of metal sheet edges without the need for bulky connecting rod-crank systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a robot with a crimping roller is used, then the crimping operation can be automated, but the production cycle time increases due to the need for multiple passes
Solution Approach 1:
The patent replaces the robotic arm with a fixed mechanical crimping unit that uses a connecting rod-crank mechanism driven by an electric motor or cylinder. This substitution eliminates the need for programmable robot control and multiple passes, achieving both automation and high-speed single-pass crimping.
2Productivity
If the number of robots is increased to reduce production cycle time, then productivity improves, but the available space in the assembly area is limited by robot dimensions
Solution Approach 1:
The crimping unit is divided into modular components: a fixed support structure, a movable blade holder, and a connecting rod-crank mechanism. This segmentation allows the system to achieve high productivity through a compact single-pass design without requiring multiple large robotic systems.
3Ease of operation
If open-table crimping is used to access difficult areas, then accessibility improves, but the machine requires bulky dies and blades designed for specific body panel types
Solution Approach 1:
The blade holder is designed to be movable relative to the support, allowing dynamic adjustment of the crimping position and angle. This dynamic capability enables the same compact unit to access difficult areas and adapt to different body panel types without requiring bulky, specialized dies.
4Adaptability or versatility
If crimping tools are mounted on mobile platforms to improve versatility, then adaptability improves, but the mass and bulk of the crimping unit become incompatible with mobile platform movements
Solution Approach 1:
The heavy and bulky components (large dies, complex blade assemblies) are extracted from the movable part and placed in a fixed support structure. The movable blade holder retains only the essential crimping blade and actuation mechanism, significantly reducing mass while maintaining versatility through positional adjustment.
5Force
If a connecting rod-crank system is used to apply crimping forces, then the crimping action can be achieved, but the unit becomes heavy and bulky with significant dimensional requirements
Solution Approach 1:
The connecting rod-crank mechanism serves as an intermediary that converts the linear motion from a compact electric motor or cylinder into the rotational crimping motion needed at the blade. This allows high crimping forces to be generated by a small, lightweight actuator rather than requiring a large direct-drive motor.
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 reduces the size and cost of the crimping unit while enhancing flexibility and speed, enabling efficient crimping of various bodywork components, including vehicle windows and sunroofs, by minimizing deformation and stress on surrounding parts.
Implementation Method 1
an actuation cylinder (30) comprising a cylinder (25) linked to the blade holder (24) and a sliding rod (31) having a spherical distal end (32)
Implementation Method 2
at least one spring-loaded cylinder (38) fixed to the intermediate support (28) and exerting an elastic force on the blade holder (24) in the direction of translation
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The present invention relates to a device (20) for crimping edges of metal sheets by folding one of said edges onto another one of said edges. The crimping device comprises a support member (22), and a blade holder (24) movable relative to the support member and carrying at least one crimping blade (26). The crimping device is characterised in that it further comprises an intermediate support member (28) pivotably mounted on the support member, in that the blade holder is mounted so as to be translatable on the intermediate support member and in that said device comprises an actuator (30) comprising a cylinder (25) connected to the blade holder and a sliding rod provided with a spherical distal end facing the crimping blade and configured to engage with a bearing part on a die (12) for receiving the edges of metal sheets.