Facade Mounting Bracket with 90-Degree Roll-Formed Profile
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Solution Overview
Problem
The production of mounting brackets for attaching facade elements to a wall is complex and costly due to the need for separate tools for different leg lengths and the requirement of multiple stamping and pressing molds for profiling and opening production.
Innovation Solution
A method utilizing a roll-formed profile with pre-existing profiling for rigidity, allowing for the production of mounting brackets with different leg lengths using a single tool by machining only the end of the leg, which includes simultaneous creation of necessary openings, enabling efficient and cost-effective manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate stamping and pressing molds are used for each leg length, then manufacturing precision and product quality are maintained, but device complexity and tooling costs increase significantly
Solution Approach 1:
A single stamping and pressing mold is designed to process multiple leg lengths by positioning the profile at different locations on the molding plate, eliminating the need for separate molds for each leg length while maintaining profiling precision
Solution Approach 2:
The mold system is made adaptable through dynamic positioning capabilities, allowing the same mold to accommodate different leg lengths by adjusting the profile position on the molding plate during the stamping and pressing process
2Manufacturing precision
If separate machining tools are used for each leg length, then manufacturing precision is maintained, but productivity decreases and tooling costs increase
Solution Approach 1:
A single machining tool is designed to process openings for different leg lengths by positioning the profile at different locations on the machining plate, enabling one tool to perform multiple functions across various product configurations
Solution Approach 2:
The machining system incorporates dynamic positioning capabilities that allow the same tool to accurately locate and process openings for different leg lengths by adjusting the profile position on the machining plate
3Manufacturing precision
If multiple specialized tools are used for different leg lengths, then product quality is ensured, but loss of time in tool changes and setup increases
Solution Approach 1:
Universal stamping and pressing molds and machining tools are employed that can process multiple leg lengths without requiring tool changes, as the same tools can accommodate different profile positions through adjustable positioning mechanisms
Solution Approach 2:
The production system uses dynamic positioning and adjustable fixtures that allow rapid reconfiguration between different leg lengths within the same tool, eliminating tool change time while maintaining quality standards
Data Source
Figure 1~2
Figure 3
AI summary
The method involves bending a roll-shaped profile so that a blade (1) is fastened to an external wall and another blade (2) is fastened to assembly strip of facade elements. The former blade and latter blade are arranged to each other in ninety angle degree. The free end (5) of the latter blade is flat pressed. An independent claim is included for an assembly bracket for fastening facade elements at wall.