Hemming Moving Die Floating Mechanism for Complex Flange Bending
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Solution Overview
Problem
Current hemming working methods face challenges in accurately and efficiently bending flanges with complex shapes, such as those with large radii of curvature, and struggle with maintaining contact between the workpiece and die, leading to distortion, wrinkles, and increased production time.
Innovation Solution
A hemming working method and apparatus that utilize a moving die with adjustable force and a floating mechanism to ensure precise contact with the workpiece, allowing for high-speed and accurate bending by dividing the carrying and mounting means to control the approach and contact steps, and employing a hemming roller with a ring-like recessed portion to avoid crushing projections and ensure proper welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the work is constituted by a box structure or welded plate members, then the work has high rigidity and maintains structural integrity, but the work is liable to bring about distortion by heat of welding and clearance at interval from die
Solution Approach 1:
The die is designed to be movable rather than fixed, allowing it to dynamically adjust its position and orientation during the hemming process. This enables the die to adapt to clearance and alignment variations in welded box structures, maintaining contact with the workpiece surface while accommodating welding-induced distortions.
Solution Approach 2:
The system changes the positional parameters of the die during operation, transitioning from a fixed position to a movable position that can be adjusted to match the actual workpiece surface. This parameter adjustment allows the die to compensate for clearance and alignment errors without requiring excessive press force.
2Reliability
If the press force of roller is excessively increased to eliminate clearance, then the work is firmly contacted with die, but the work is distorted
Solution Approach 1:
Instead of applying excessive static press force, the system uses a dynamic approach where the die moves to achieve contact. The press force is applied only after proper alignment is achieved through movement, eliminating the need for excessive force that would cause distortion while ensuring firm contact.
Solution Approach 2:
The die performs preliminary movement and positioning actions before applying press force. This preliminary alignment ensures that when press force is applied, the die is already correctly positioned, eliminating the need for excessive force and preventing workpiece distortion.
3Productivity
If the rolling speed of roller for hemming working is made high, then productivity is promoted and cycle time is shortened, but it is difficult to regulate attitude and press force of press roller
Solution Approach 1:
The system replaces manual or simple mechanical control of the roller with an automated control mechanism that can precisely regulate attitude and press force even at high rolling speeds. This substitution enables maintaining control precision while achieving high productivity.
4Device complexity
If guide groove is constituted only by one streak, then the structure is simple, but different hemming rollers need to be used in preparatory bending and finish bending requiring interchanging time
Solution Approach 1:
The guide groove is designed to serve multiple functions and accommodate different types of hemming rollers (both spherical and cylindrical) throughout the entire hemming process including both preparatory bending and finish bending. This universal design eliminates the need for roller interchange while maintaining structural simplicity.
5Ease of operation
If guide portion and guide groove are used for guiding roller, then rolling direction is controlled, but at high rolling speed the moving locus and teaching locus are shifted causing friction increase and guide portion riding over guide groove
Solution Approach 1:
The guide portion is designed to dynamically adapt to high-speed rolling conditions, with features that accommodate locus shifts between moving and teaching paths. The guide structure includes dynamic elements that maintain proper engagement even when friction increases at high speeds, preventing the guide portion from riding over the guide groove.
Data Source
AI summary
A moving die is held by a robot and made to approach a vehicle, and a positioning pin is inserted into a positioning hole of the vehicle. The moving die is brought into a floating state of being displaceable relative to the vehicle by reducing a force of the robot for maintaining an attitude thereof. In a state of holding the moving die by the robot, a surface of the moving die is brought into contact with the vehicle by an adsorbing mechanism including an adsorbing portion of an elastic member provided to the moving die. The moving die and the robot are cut to be separated.