Headrest Frame Tube Notching Without Material Removal
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Solution Overview
Problem
Existing methods for forming notches in tubular members, such as those used in vehicle seats, often result in weakened tubes due to material removal and can lead to bulges or burrs, which affect the structural integrity and engagement efficiency of the notches.
Innovation Solution
A machine and method utilizing a roller with a specific path of motion, guided by an eccentric assembly and cam mechanisms, deform the material inwardly to form notches without removing material, thereby maintaining the tube's strength and reducing bulges or burrs, allowing for precise notch shapes like V-shaped, U-shaped, and one-way locking notches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If material removal methods are used to form notches, then notch formation is achieved, but tube strength is weakened and bulges or burrs are created
Solution Approach 1:
The invention changes the fundamental parameter of notch formation from material removal to material deformation. By using a roller to deform material inwardly rather than removing it, the process maintains tube strength while creating the required notch geometry for engagement.
Solution Approach 2:
The invention converts the potential harm of material deformation (which could create defects) into a benefit by carefully controlling the deformation process to create precise notch shapes without bulges or burrs, thereby improving both strength and manufacturability.
2Ease of manufacture
If material removal methods are used to form notches, then notches can be created, but bulges or burrs are produced affecting engagement efficiency
Solution Approach 1:
The invention transitions from subtractive manufacturing to deformative manufacturing, changing the fundamental parameter of how notches are created. This allows for precise control of notch geometry through controlled material deformation rather than removal, eliminating bulges and burrs.
Solution Approach 2:
The invention replaces traditional mechanical cutting or drilling systems with a roller-based deformation system. This substitution enables continuous, controlled material deformation that produces precise notch geometries without the defects associated with material removal methods.
3Strength
If a roller deforms material inwardly to form notches, then tube strength is maintained and bulges are reduced, but complex path control is required
Solution Approach 1:
The invention segments the roller path control into distinct phases (approach, deformation, withdrawal) controlled by cam mechanisms. This segmentation simplifies the overall control system by breaking down the complex motion into manageable, repeatable segments that can be controlled by standard cam mechanisms.
Solution Approach 2:
The invention introduces cam mechanisms as intermediary elements between the roller and the tube. These cams serve as mediators that convert simple rotational motion into the complex roller paths required for precise material deformation, thereby reducing the overall system complexity.
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 effectively forms notches with uniform wall thickness, eliminating material removal-induced weaknesses and bulges, ensuring strong and precise engagement of the notches for height adjustment and locking functions in vehicle seats and other applications.
Implementation Method 1
deform the material inwardly to form notches without removing material
Implementation Method 2
A machine and method utilizing a roller with a specific path of motion, guided by an eccentric assembly and cam mechanisms
Implementation Method 3
guided by an eccentric assembly and cam mechanisms
Data Source
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AI summary
A device and method for forming notches in tubes or other parts includes a roller that travels along a non-linear path. The roller may include a component of motion away from the part to reduce bulging or other deformations in an outer surface of the part that could otherwise result from a straight roller path.