Elastic Nesting Block for Roller Hemming Interference
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Solution Overview
Problem
In roller hemming processing, interference between the positioning means and the hemming processing tool can adversely affect the quality of the hemming process, leading to complex control of the tool's movement locus and reduced productivity.
Innovation Solution
A nesting block is provided around the hemming die, elastically supported to be retractable and swingable, allowing it to move out of the way of the hemming processing tool without compromising the hemming quality, simplifying the control of the tool's movement and maintaining productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fixed nesting block is used for positioning the workpiece, then positioning accuracy is improved, but interference with the hemming processing tool occurs and device complexity increases
Solution Approach 1:
The nesting block is designed to be movable rather than fixed, allowing it to dynamically adjust its position during the hemming process. The block can swing out of the way when the hemming tool approaches and return to its positioning function when the tool moves away, eliminating the need for complex control systems while maintaining positioning accuracy.
Solution Approach 2:
The nesting block is positioned within the hemming die structure, nesting its positioning function within the overall hemming apparatus. The block can be retracted into the die structure when not in use, allowing the hemming tool to pass freely over the workpiece area without interference.
2Reliability
If the hemming processing tool moves along a controlled locus to avoid the nesting block, then interference is avoided, but productivity decreases due to reduced moving speed
Solution Approach 1:
The nesting block dynamically swings out of the interference zone when the hemming tool approaches, allowing the tool to maintain a straight, simple trajectory at full speed. The block returns to its positioning position after the tool passes, ensuring positioning accuracy is restored for the next operation or workpiece.
Solution Approach 2:
The nesting block swings out of the way in advance before the hemming tool reaches its potential interference zone, allowing the tool to pass through without any speed reduction or trajectory adjustment. This preliminary action eliminates the need for controlled movement loci and maintains maximum productivity.
3Productivity
If the nesting block is made retractable and swingable, then interference with the hemming tool is avoided and productivity is improved, but the positioning stability may be compromised
Solution Approach 1:
The nesting block uses a swing mechanism that provides stable positioning when engaged with the workpiece flange root, while allowing controlled movement when the tool approaches. The dynamic design maintains stability during positioning by using the workpiece geometry itself as a reference, ensuring consistent positioning accuracy despite the block's ability to move.
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 prevents interference-related quality issues and simplifies the control of the hemming tool's movement, enhancing the productivity of the roller hemming process by allowing the tool to move freely along the longitudinal direction of the hemming flange without attention to the nesting block's presence.
Implementation Method 1
The nesting block is elastically supported to be retractable in the pressing direction
Implementation Method 2
The nesting block is elastically supported to be retractable in the pressing direction and to be swingably displaceable in the longitudinal direction of the hemming flange portion
Data Source
AI summary
A roller hemming processing apparatus adapted to perform a hemming processing has a hemming die, on which a panel-like workpiece having a hemming flange portion on a periphery portion thereof, is positioned and supported, a roller hemming processing tool that is moved along a longitudinal direction of the hemming flange portion to bend the hemming flange portion at a root portion thereof while pressing the hemming flange portion toward the hemming die, and a nesting block disposed at a part of the periphery of the hemming die. The nesting block performs positioning of the workpiece by being brought into contact with the root portion of the hemming flange portion with which the workpiece is formed. The nesting block is elastically supported to be retractable in the pressing direction and to be swingably displaceable in the longitudinal direction of the hemming flange portion.