Dual Drawing Channel for Precise Bending of Oblong Metal Products
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Solution Overview
Problem
Existing machines for working metal products often result in uncontrolled deformation, leading to unsuitable finished products, and are complex, expensive, and prone to surface damage, especially when processing multiple metal products simultaneously.
Innovation Solution
A machine with a dual drawing apparatus system and adjustable guiding and holding means that uses a bending device with a contrast element and anchoring inserts to control metal product positioning and bending, allowing for precise shaping and simultaneous processing of two metal products while minimizing waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high retaining pressure is applied by drawing apparatus to prevent deformation, then control of metal product deformation is improved, but surface damage occurs on the metal product
Solution Approach 1:
A support device with support rollers is introduced as an intermediary element between the drawing apparatus and the metal product. The support rollers provide additional support to the metal product during the drawing process, distributing the retaining pressure and preventing direct high-pressure contact that causes surface damage, while still maintaining control over deformation.
Solution Approach 2:
The system changes the pressure distribution parameters by using multiple support rollers instead of a single high-pressure point. This distributes the retaining force across multiple contact points, reducing the pressure intensity at each point and preventing surface damage while maintaining overall control of the metal product.
2Manufacturing precision
If two or more drawing apparatuses are used in series to control deformation, then deformation control is improved, but device complexity and cost increase
Solution Approach 1:
The support device with support rollers is merged with the existing drawing apparatus to create a combined system. This integration provides enhanced deformation control through additional support points without requiring separate, independent drawing apparatuses, thereby reducing overall system complexity while maintaining precision.
Solution Approach 2:
The drawing process is segmented into multiple support zones along the metal product's path, with support rollers positioned at different locations. This segmentation allows control of deformation at multiple points along the product length using a single drawing apparatus, eliminating the need for multiple series-connected apparatuses.
3Reliability
If high retaining pressure is applied to ensure correct drawing, then drawing control is improved, but the pressure is not always sufficient for non-circular sections and causes surface damage
Solution Approach 1:
The system changes from applying single-point high pressure to distributed multi-point pressure through support rollers. This parameter change in pressure distribution maintains reliable drawing control for various cross-sections including non-circular shapes, while reducing the intensity of pressure at any single point to prevent surface damage.
4Reliability
If caterpillar systems are used in drawing apparatus, then drawing capability is improved, but pressure between tracks is not sufficient to prevent deformation
Solution Approach 1:
The caterpillar drawing system is merged with additional support rollers that provide supplementary retaining pressure. This combination maintains the drawing capability of the caterpillar system while adding the necessary pressure to prevent deformation that the tracks alone cannot provide.
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 machine produces high-quality metal products with reduced waste and simplified management, capable of handling a wide range of construction products without damaging them, and achieves precise bends with minimal tail ends, enhancing productivity and product compliance.
Implementation Method 1
a bending device (42) provided with a contrast element (43), advantageously having at least one cylindrical vertical wall, and with a bending element (44)
Implementation Method 2
The drawing apparatus generally consists of at least a pair of opposite rollers, at least one of which is motorized to feed the metal product toward the work apparatus
Implementation Method 3
The drawing channel has a lying plane, defined by a plurality of anchoring inserts, for the at least one metal product
Implementation Method 4
followed by a main cutting unit (45)
Data Source
Figure 1
Figure 2
Figure 3~6
AI summary
Machine to work oblong metal products, comprising a drawing apparatus (11) to feed at least one of said metal products (P) in a direction of feed (Z) and a work apparatus (41) aligned in said direction of feed (Z). The drawing apparatus (11) comprises a first drawing unit (12) and a second drawing unit (13) opposite each other with respect to said direction of feed (Z). The first drawing unit (12) and the second drawing unit (13) define between them, in said direction of feed (Z), a drawing channel (19) for the at least one metal product (P). The drawing channel (19) has a lying plane, defined by a plurality of anchoring inserts (21), for the at least one metal product (P), a supply apparatus (48) being possibly present upstream of said drawing apparatus (11). A method to work a metal product using such a machine is also disclosed.