Electric Rebar Bending Tool With Feedback Angle Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing hydraulic rebar bending tools often cause overbending, necessitating the discarding of bent rebar and requiring a new piece to be bent, which is inefficient and wasteful.
Innovation Solution
A portable electric power tool with a bias portion and abutment mechanism that allows controlled bending of rebar by linearly moving an abutment portion relative to a support portion, using a DC brushless motor and planetary gear arrangement for precise control, and includes safety mechanisms to prevent overbending.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If hydraulic rebar bending tools are used, then bending force is sufficient, but overbending occurs causing waste of material
Solution Approach 1:
The patent employs a controlled bending mechanism with a moveable bias portion that applies force progressively to the rebar. The system includes a controller that monitors the bending process and adjusts the application of force through the bias portion, preventing overbending by providing real-time feedback and adjustment during the bending operation, thus eliminating material waste while maintaining sufficient bending force.
Solution Approach 2:
The patent uses a dynamic bending system where the bias portion can be moved to different positions along the rebar during the bending process. This dynamic adjustment allows the operator to control the bending force application precisely, applying force only where needed and for the required duration, preventing overbending while ensuring adequate bending force is delivered to achieve the desired shape.
2Ease of operation
If hydraulic rebar bending tools are used, then bending capability is achieved, but precision control of bend angle is poor
Solution Approach 1:
The controller monitors the bending operation and adjusts the force application through the bias portion based on real-time conditions. This feedback mechanism allows precise control of the bend angle by continuously adjusting the bending force to achieve the exact desired angle, preventing both under-bending and over-bending while maintaining ease of operation.
Solution Approach 2:
The system is configured with the bias portion positioned to apply force at optimal locations before the bending operation begins. The controller pre-positions the bias portion and prepares the bending mechanism in advance, ensuring that when the bending operation starts, the force is applied precisely at the correct location and angle, achieving high precision bend angle control from the outset.
3Device complexity
If simple bending mechanisms are used, then device complexity is reduced, but control precision over bending process is insufficient
Solution Approach 1:
The bending mechanism is segmented into distinct functional components: a support portion, a moveable bias portion, and a controller. This segmentation allows each component to perform its specific function with high precision - the support portion provides stable positioning, the bias portion applies controlled force, and the controller coordinates their interaction - achieving high bending control precision while keeping each individual component relatively simple in design.
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
Enables precise and controlled bending of rebar, reducing waste by allowing users to set and maintain desired bend angles, with improved weight distribution and safety features to prevent overbending.
Implementation Method 1
a DC brushless motor and planetary gear arrangement for precise control
Implementation Method 2
planetary gear arrangement for precise control
Data Source
Figure 1~2
Figure 3~5
Figure 6
AI summary
A portable electric power tool for bending elongate objects comprising an electric motor having a motor output shaft, a bend mechanism having a support portion and a bias portion and which is operatively coupled to the motor output shaft via a transmission of the tool which in use causes linear relative movement between the bias portion and the support portion, wherein such linear relative movement in a first direction between the bias portion and the support portion causes force to be applied by the bend mechanism to an elongate object in use at different locations along the length of the elongate object for bending the elongate object in a first direction, the bend mechanism configured such that linear relative movement in a second, opposite, direction between the bias portion and the support portion causes force to be applied by the bend mechanism to the elongate object at different locations along the length of the elongate object for bending the elongate object in a second direction.