Dual Flanging Die Tool Head for Single-Run Beading
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Solution Overview
Problem
Existing roll-hemming devices require multiple processing runs to completely bead a hemming web around a hemming edge, increasing time and cost for the flanging process, particularly in the construction of motor vehicles.
Innovation Solution
A flanging device with a tool head bearing two flanging dies that can assume processing positions simultaneously, allowing for two flanging steps in a single run, with one die acting as a primary and the other as a secondary die, and featuring transverse mobility to adapt to curved edges and corner regions, reducing the need for multiple actuator movements and processing runs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple processing runs are used to bead the hemming web around the hemming edge, then the flanging can be completed thoroughly, but the processing time and cost increase
Solution Approach 1:
The patent combines multiple flanging operations into a single processing run by using a tool head that carries multiple flanging dies (at least two dies: first and second flanging dies). These dies simultaneously assume their respective processing positions and act on the flanging web in one coordinated operation, eliminating the need for multiple separate processing runs while maintaining complete beading quality
Solution Approach 2:
The flanging dies are designed with transverse mobility relative to each other, allowing them to adjust their positions dynamically during the processing run. This dynamic capability enables the dies to adapt to curved edges and corner regions while maintaining simultaneous operation, thus completing thorough flanging in a single run without sacrificing precision
2Productivity
If multiple flanging rollers are moved into processing positions consecutively, then each roller can perform its flanging step, but the device complexity and control effort increase
Solution Approach 1:
Multiple flanging operations are merged into a single processing run using a tool head that carries multiple flanging dies. The dies are mechanically fixed relative to each other in terms of their location and orientation, allowing them to be moved as a unit by a single actuator platform, thereby reducing control complexity while maintaining high productivity
Solution Approach 2:
The tool head serves as a universal bearer for multiple flanging dies, allowing a single actuator platform to control the movement of all dies simultaneously. This multi-functional design enables one actuator system to perform what would otherwise require multiple separate actuators, reducing overall device complexity
3Device complexity
If the flanging dies are mechanically fixed relative to each other, then they can be moved as a unit by a single actuator, but they cannot adapt to curved edges and corner regions
Solution Approach 1:
The flanging dies are designed with transverse mobility relative to each other, allowing them to adjust their positions dynamically during the processing run. This dynamic capability enables the dies to adapt to curved edges and corner regions while maintaining simultaneous operation, thus resolving the contradiction between mechanical fixing for simplicity and adaptability for complex geometries
Data Source
AI summary
A flanging device for beading a flanging web of a component part around a flanging edge. The flanging device includes a tool head; a first flanging die and a second flanging die which the tool head simultaneously bears, situated in a processing position, and one of which is arranged following the other in a processing direction.