Lateral Press Tool Assembly for Uniform Profile Groove Deformation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing machines for assembling profiles with thermally insulating sections suffer from irregular plastic deformation due to local tolerance differences, leading to inconsistent connection quality, requiring complex and time-consuming setup, and are not adaptable to diverse profile types, resulting in low productivity and increased costs.
Innovation Solution
A machine with movable press tools that can exert adjustable and controlled force laterally to deform grooves uniformly, allowing for flexible assembly of various profile types with minimal operator skill, and automated operation to compensate for tolerance differences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If press tools are kept at a fixed lateral distance from the central axis during pressure operation, then the machine structure is simple, but irregular plastic deformation occurs due to local tolerance differences
Solution Approach 1:
The press tools are made movable in the lateral direction rather than fixed, allowing them to dynamically adjust their position during the pressure operation. This enables the press tools to compensate for local tolerance differences in profile sections while maintaining a relatively simple machine structure.
Solution Approach 2:
The lateral position of the press tools is made adjustable during operation, changing the spatial parameter of tool placement. This allows adaptation to different profile sections with varying tolerances, ensuring uniform plastic deformation without requiring complex machine architecture.
2Manufacturing precision
If press tools are moved laterally to compensate for tolerance differences, then connection quality becomes consistent, but the machine complexity increases
Solution Approach 1:
The press tools are designed with lateral mobility, enabling them to move and adjust their position dynamically during operation. This dynamic capability ensures consistent connection quality across different profile sections while avoiding the need for complex adjustment mechanisms.
Solution Approach 2:
The press tools can apply force at different lateral positions tailored to the local characteristics of each profile section. This localized adaptation ensures optimal deformation and connection quality for each specific area without requiring overall machine complexity.
3Manufacturing precision
If multiple adapted tools are provided for diverse profile types, then assembly quality is maintained, but device complexity and cost increase
Solution Approach 1:
The press tools are designed with universal adaptability through lateral movement capability, allowing a single tool design to handle multiple profile types and configurations. This eliminates the need for numerous specialized tools while maintaining high assembly quality across diverse applications.
Solution Approach 2:
The press tools can dynamically reposition themselves laterally to accommodate different profile geometries and groove locations. This dynamic adaptability enables one tool design to perform multiple functions across various profile types, reducing overall device complexity.
4Manufacturing precision
If complex setup procedures are used to adjust press tools, then assembly precision is improved, but productivity decreases
Solution Approach 1:
The press tools automatically adjust their lateral position during operation based on the profile section being processed, eliminating the need for complex manual setup procedures. This self-adjusting capability maintains high assembly precision while maximizing productivity by reducing setup time.
Solution Approach 2:
The dynamic lateral adjustment capability is integrated into the normal operation of the press tools, allowing precision adaptation to occur automatically during assembly rather than requiring separate setup phases. This eliminates productivity losses associated with complex setup procedures.
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 machine ensures consistent quality of connections over the profile length by controlling deformation force independently, improving productivity and reducing material waste and assembly time, while being adaptable to different profile types and tolerances.
Implementation Method 1
plastically deform one or several walls of the grooves by means of pressing or rolling and to clamp the thermally insulating sections in the grooves
Data Source
AI summary
Machine (1) for the assembly of profiles (2) formed of at least a first profile section (3) and a second profile section (4) connected by means of one or several thermally insulating sections (5,6), whereby the machine (1) is provided with press means (58) exerting an adjustable pressure on press tools (48) in a lateral direction (HH′) and towards the profile sections (3,4) to be assembled so as to be able to exert an adjustable force on corresponding walls (18) of grooves (17, 20, 31, 33, 82, 90) of the profile sections (3,4) in order to achieve a plastic deformation thereof.