Lamella Block With Laterally Offset Lamellae For Profile Calibration
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Solution Overview
Problem
Existing calibrating devices for extruded profiles, such as pipe profiles, face challenges in achieving high surface quality without rotating the calibrating basket, which requires complex and costly constructions and can generate tracks on the profile surface during calibration.
Innovation Solution
The development of lamella blocks with laterally offset lamellae that describe a diagonal or wavy progression, allowing for a rotation-free calibration by smoothing out tracks on the profile surface without the need for a rotating calibrating basket, and can be manufactured using 3D printing or other additive processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a rotating calibrating basket is used to achieve high surface quality, then surface finish is improved, but device complexity and manufacturing cost increase significantly
Solution Approach 1:
Instead of rotating the calibrating basket to smooth tracks, the patent inverts the approach by using laterally offset stationary lamellae that naturally smooth tracks through their offset arrangement, eliminating the need for rotation mechanisms
Solution Approach 2:
The patent extracts and eliminates the rotating basket mechanism entirely, replacing it with a stationary calibrating device that uses laterally offset lamellae to achieve the same surface quality improvement without complex moving parts
2Manufacturing precision
If a rotating calibrating basket is used to smooth tracks, then surface finish is improved, but manufacturing cost increases due to complex construction
Solution Approach 1:
The patent removes the expensive rotating basket mechanism and replaces it with a simple stationary structure using laterally offset lamellae, dramatically reducing manufacturing cost while maintaining surface quality improvement
Solution Approach 2:
The patent uses simple, inexpensive lamellae with lateral offsets instead of expensive rotating mechanisms, achieving the same functional result with much lower cost components
3Device complexity
If traditional lamella blocks with straight lamellae are used, then device complexity is reduced, but track smoothing capability is insufficient
Solution Approach 1:
The patent introduces lateral offsets in the lamella arrangement, creating an asymmetric pattern that effectively smooths tracks while maintaining relatively simple device construction
Solution Approach 2:
The lateral offsets create a wavy or diagonal progression pattern in the lamella arrangement, which smoothly guides the profile through calibration and eliminates tracks through the curved/wavy contact path
Data Source
AI summary
A lamella block is provided for a calibrating device for calibrating an extruded profile, wherein the lamella block includes a carrier structure and a lamella structure, and wherein the lamella structure has a plurality of lamellae, which are spaced apart from each other by grooves and arranged in a longitudinal direction (L) of the carrier structure. Neighboring lamellae of the lamella block are arranged laterally offset to each other in the longitudinal direction (L). Also provided is a method for manufacturing the lamella block mentioned above, as well as a calibrating device, which includes a plurality of the lamella blocks mentioned above. Further provided is a system for additively manufacturing the lamella block mentioned above, a corresponding computer program and a corresponding dataset.