Backward Flow Forming Control for Thickness-Driven Length Deviation
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Solution Overview
Problem
Existing backward flow forming processes face complications in process parameters, leading to production delays and forming defects due to variations in thickness, especially when producing products with varying thicknesses.
Innovation Solution
An automatic control system is introduced, comprising a mandrel, forming rollers with motion devices, detection members, and a controller, which detects and adjusts thickness variations using proximal, distal, and depth detectors, and a CNC program to manage biaxial motions of the rollers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If backward flow forming process is used to produce products with varying thicknesses, then product design flexibility is improved, but length deviation and forming defects occur due to thickness variations
Solution Approach 1:
The patent employs detection members (proximal detector, distal detector, depth detector) that continuously monitor the forming process and provide feedback signals to the controller. The controller adjusts the forming roller's depth and position in real-time based on this feedback, compensating for thickness variations and preventing length deviation in the final product.
Solution Approach 2:
The forming roller is equipped with motion devices that enable dynamic adjustment of its position and depth during the forming process. The controller dynamically modifies the forming parameters based on detection signals, allowing the system to adapt to varying material thicknesses and maintain manufacturing precision throughout the process.
2Device complexity
If manual control methods are used for flow forming, then process simplicity is maintained, but production delays and forming defects occur
Solution Approach 1:
The system performs self-adjustment through automatic detection and control. The detection members continuously monitor the forming process and the controller automatically modifies forming parameters without requiring manual intervention, enabling the system to self-correct thickness variations and maintain optimal forming conditions throughout production.
Solution Approach 2:
The patent replaces manual mechanical control with an automated control system that uses detection members, controllers, and motion devices. This substitution of manual operation with automated sensing and actuation systems eliminates human error, accelerates the forming process, and improves productivity while maintaining process simplicity through programmatic control.
3Manufacturing precision
If forming rollers are pressed against rotating material, then material thickness is reduced and length is increased, but thickness variations cause length deviation
Solution Approach 1:
The depth detector and other sensing devices continuously monitor the forming roller's position and the material's thickness during deformation. This feedback information is transmitted to the controller, which adjusts the forming roller's depth and pressure in real-time to compensate for thickness variations, ensuring uniform material reduction and preventing length deviation.
Solution Approach 2:
The controller dynamically changes forming parameters (roller depth, position, pressure) based on detection signals during the forming process. By continuously adjusting these parameters in response to real-time material state information, the system maintains precise thickness control despite the complexity of deforming rotating material.
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 system effectively prevents length deviations caused by thickness variations, reducing defects and enhancing productivity, particularly in small-batch productions.
Implementation Method 1
a detection member for detecting a signal associated with a motion of the forming member corresponding to the material
Data Source
AI summary
The present invention relates to an automatic control system for a backward flow forming process, the automatic control system including: a mandrel (10) for concentrically supporting a material (12); a forming member (20) including a plurality of forming rollers (22) disposed at a periphery of the mandrel (10), in which each of the forming rollers (22) includes a motion device; a detection member (30) for detecting a signal associated with a motion of the forming member (20) corresponding to the material (12); and a controller (40) for controlling the forming roller (22) to induce a variation in a depth at at least two set points while transferring the forming roller (22) backward. Accordingly, a length deviation caused by a variation in a thickness is prevented in a backward flow forming process of a workpiece to produce a product in which a thickness of a portion of the product varies.