Flanging Device Counter Pressure Roller Protective Structure
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Solution Overview
Problem
Existing methods for connecting an outer body part to an inner part, such as in vehicle wheel arches, often deform the outer shell due to the use of counter pressure rollers, and are not adaptable to different vehicle body types, resulting in unsatisfactory hem quality and limited applicability in production facilities.
Innovation Solution
A flanging device with a flanging head featuring at least one counter pressure roller and two pressing rollers, supported by a protective structure that allows the counter pressure roller to roll on a separate surface rather than directly on the component, enabling deformation minimization and adaptability to various component shapes, and can be integrated with a robot arm for precise movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If counter pressure rollers are used for hemming the outer shell, then the hemming connection is achieved, but the outer shell is deformed with dents and scratches
Solution Approach 1:
A protective structure is introduced as an intermediary between the counter pressure roller and the outer shell. This protective structure absorbs the counter pressure force, preventing direct contact with the outer shell surface and thus avoiding dents and scratches while still enabling the hemming connection to be formed.
Solution Approach 2:
The system is segmented into distinct functional components: the outer shell, the protective structure, and the counter pressure roller. This segmentation allows the protective structure to specifically address the surface protection requirement while the roller system maintains the hemming connection strength.
2Object-affected harmful factors
If sliders are moved radially outwards to avoid deforming the outer shell, then the outer shell is protected from deformation, but the hem quality becomes unsatisfactory due to omitted counter pressure
Solution Approach 1:
The protective structure serves as a mediator that enables the counter pressure roller to maintain contact and apply necessary counter pressure force without directly deforming the outer shell. This resolves the contradiction by allowing both hem quality and outer shell protection to be achieved simultaneously.
3Manufacturing precision
If specialized hemming equipment is designed for specific body types, then the hemming quality is optimized for that body type, but the device complexity increases and adaptability to different vehicle types is reduced
Solution Approach 1:
The protective structure is designed as a universal component that can be applied to different vehicle body types. By using the same basic hemming equipment with interchangeable protective structures, the system achieves both optimized hemming quality and adaptability across multiple vehicle models, reducing the need for specialized equipment for each body type.
Data Source
AI summary
A flanging device for roll-flanging a rim of a component includes a flanging head, a first flanging roller which is mounted by the flanging head and can be rolled off on the rim during roll-flanging, and a second flanging roller which is mounted by the flanging head and forms a counter pressure roller for the first flanging roller, the flanging device including a stable protective structure which is or can be fastened to the component and forms a rolling surface for one of the flanging rollers or supports a rolling surface.