Cradle Anvil Hemming for Class-A Panel Deformation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing on-line hemming systems face challenges in managing complex panel shapes and preventing panel deformation due to angular pressure issues, limited flexibility in handling various vehicle body models, and inability to use conventional roller hemming tools, resulting in low-quality flanges and surface damage.
Innovation Solution
A system utilizing a single roller disconnected from a counter-pressure device with a cradle anvil for panel support, allowing variable tool angles and programmable positioning, combined with a robotic arm and slide-assists for secure matching and precise pressure application, enabling flexible hemming of various panel orientations and shapes without distorting the class-a surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional roller hemming tools are used with a common jaw supporting both rollers, then panel joining is achieved, but angular manipulation is restrained and complex panel shapes cannot be made
Solution Approach 1:
The patent separates the two rollers from a common jaw structure, allowing each roller to be independently positioned and manipulated. This segmentation enables complex panel shapes and bow-tie-flanges by eliminating the angular manipulation restraints of a unified jaw system.
Solution Approach 2:
The patent implements dynamic positioning capabilities where the hemming head can be repositioned along the panel edge with unlimited attack angles. This dynamic flexibility allows adaptation to various panel shapes and orientations without being constrained by a fixed common jaw structure.
2Stability of the object's composition
If pinch rollers apply pressure to prevent panel deformation, then panel stability is improved, but scratches and skid marks are evident on the class-a surface
Solution Approach 1:
The patent introduces a cradle anvil as an intermediary support structure between the panel and the hemming rollers. This cradle provides the necessary counter-pressure and stability to prevent panel deformation during hemming, while the panel surface itself does not contact the rollers directly, thereby avoiding scratches and skid marks on the class-a surface.
Solution Approach 2:
The cradle anvil creates a negative impression or mold of the panel's backside geometry. This copied shape provides precise support matching the panel contour, ensuring stability during hemming without the need for direct roller contact with the panel surface.
3Manufacturing precision
If off-line hemming systems use a stable rigid lower anvil mounted horizontally, then hemming quality is high, but the system cannot be used for on-line hemming where parts are oriented vertically
Solution Approach 1:
The patent creates a dynamically adaptable hemming system where the cradle anvil and rollers can be repositioned to accommodate various orientations. The system transitions from the fixed horizontal mounting of off-line systems to a flexible configuration suitable for vertical on-line hemming operations, maintaining high hemming quality through programmable positioning.
Solution Approach 2:
The patent develops a universal hemming system that can function in both off-line and on-line environments. The cradle-based support structure and independently positioned rollers provide the stability needed for high-quality hemming while adapting to different panel orientations and assembly line requirements.
4Adaptability or versatility
If multiple pinch rollers are used to accommodate different panel shapes, then versatility is improved, but the system requires substantial re-tooling to change angles
Solution Approach 1:
The patent implements programmable positioning systems that allow the hemming head and rollers to be repositioned to different angles and locations through software control rather than physical re-tooling. This dynamic reconfiguration capability provides versatility for different panel shapes while eliminating the need for substantial mechanical re-tooling.
Solution Approach 2:
The patent uses programmable parameters to control roller position, attack angle, and hemming force. By changing these parameters through software rather than physical reconfiguration, the system can accommodate various panel shapes and sizes without requiring substantial re-tooling or manufacturing changes.
Data Source
AI summary
An apparatus and method to cradle and hem panels at an assembly-line station. A cradle assembly is configured to conform to the shape of a first sheet material and prevents deformation of the class-a surfaces. A first robotic arm operatively associated with said cradle assembly and a slide-assist assembly cooperate to stabilize the cradle and secure a cradle anvil against the first sheet material. A roller head for hemming said first sheet material supported on a second robotic arm. The second robotic arm moves the roller head around the periphery of the first sheet material and against the cradle anvil to form a hem.