Continuous Corrugation Bending for Metal Sheets Without Thickness Loss
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Solution Overview
Problem
Existing corrugation forming installations for metal sheets in the construction of waterproof membranes for tanks are inefficient due to non-continuous transverse corrugations and the degradation of metal sheet thickness through stamping processes, which affects the mechanical properties of the sheets.
Innovation Solution
A folding installation that continuously forms transverse corrugations in metal sheets using a drive device, a folding device with a movable chassis and punch, and a control unit to manage the sheet's advancement and punching process, ensuring minimal thickness modification and continuous corrugation production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If stamping process is used to form transverse corrugations, then corrugations can be produced, but the thickness of the metal sheet is altered and mechanical properties are degraded
Solution Approach 1:
The patent changes the fundamental parameter of the forming process from stamping (which alters thickness) to bending (which preserves thickness). The bending device uses a punch and die arrangement that deforms the metal sheet by bending rather than compressing, thereby maintaining the original sheet thickness and preserving mechanical properties while still achieving corrugation formation.
Solution Approach 2:
The patent replaces the stamping mechanical system with a bending mechanical system. Instead of using a stamping press that applies compressive force to create corrugations, the invention employs a bending device with a movable punch that applies controlled bending force, substituting one mechanical approach with another that is less harmful to the material properties.
2Ease of manufacture
If transverse corrugations are produced by stamping process, then corrugations can be formed, but the production efficiency is reduced due to non-continuous operation
Solution Approach 1:
The patent implements continuous production by synchronizing the bending device's movement with the continuous feed of the metal sheet. The control unit coordinates the punch movement, die positioning, and sheet advancement to ensure that corrugations are formed continuously as the sheet passes through, eliminating the stop-start nature of traditional stamping operations.
Solution Approach 2:
The patent introduces dynamic elements to the forming system, including a movable punch that travels with the sheet, a movable die that positions itself continuously, and a synchronized control system that adjusts all components in real-time based on sheet position and speed, transforming a static batch process into a dynamic continuous process.
3Ease of manufacture
If traditional bending device is used, then corrugations can be formed, but the device complexity increases and continuous production is not achieved
Solution Approach 1:
The patent designs the bending device with multi-functional components that perform multiple operations. The movable punch serves both as the forming tool and the positioning reference, the die structure provides both support and forming surface, and the control unit manages coordination of all movements, reducing the need for separate dedicated components for each function.
Solution Approach 2:
The patent merges several functions into integrated components. The bending device combines the punch mechanism, die positioning system, and sheet feed synchronization into a coordinated unit controlled by a single control unit, reducing overall system complexity compared to having separate independent systems for each function.
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 enables the production of corrugated metal sheets with improved mechanical properties and increased efficiency by forming continuous transverse corrugations without significant thickness modification, enhancing the sheets' durability and usability in tank membranes.
Implementation Method 1
a first actuator capable of moving said frame between the rear position and the front position
Implementation Method 2
a second actuator capable of moving said punch between the rest position and the bending position
Implementation Method 3
a drive device ensuring the advance of the metal sheet, horizontally, from rear to front in a direction of advance
Data Source
Figure 1~3
Figure 4~6
Figure 7
AI summary
The invention relates to a bending system for forming transverse corrugations in a metal sheet; the bending system (9) comprising: - a drive device (11) advancing the metal sheet (1); and - a bending device (12) comprising: - a frame (13) able to move parallel to the direction of advance, between a rear position and a front position, by means of a first actuator; and - a punch (16) able to move vertically on the frame (13) between a rest position and a bending position by means of a second actuator (17); and - a control unit (29) which is configured to control the first actuator (14) and the second actuator (17) and is configured to simultaneously move the frame (13) of the bending device (12) from the rear position to the front position and the punch (16) from the rest position to the bending position.