Magnesium Component Truing by Fixed-Datum Controlled Bending
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Solution Overview
Problem
Vehicle manufacturers face challenges in producing vehicle components made from lighter materials like magnesium or aluminum that are warped and do not meet dimension and tolerance requirements, necessitating a method to accurately bend and true these components to comply with regulatory standards.
Innovation Solution
A truing machine and process that includes holding devices to secure components at fixed datums, bending devices to apply forces at specific locations, and a control system to evaluate and manipulate the components into compliance with manufacturer specifications, using a combination of measurement systems and controlled force applications to achieve precise bending and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If lighter weight materials (magnesium or aluminum) are used to replace traditional materials, then vehicle weight is reduced, but the components become warped and fail to meet dimension and tolerance requirements
Solution Approach 1:
The patent applies preliminary action by performing bending adjustments on magnesium or aluminum components after casting or stamping but before final assembly. The system measures warpage dimensions and pre-applies corrective bending forces to compensate for anticipated dimensional deviations, ensuring components meet tolerance requirements before being installed in the vehicle.
Solution Approach 2:
The patent utilizes parameter changes by applying controlled bending forces that alter the physical shape parameters of the component. The system adjusts bending position, force magnitude, and duration to transform warped components into compliant ones, changing the geometric parameters to meet specification requirements.
2Manufacturing precision
If a truing machine is used to bend components into compliance, then dimension and tolerance requirements are met, but the device complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the bending process into discrete, controllable segments. The system uses multiple independently actuated bending elements that can apply force at different positions and with different magnitudes, allowing complex warpage correction through sequential or simultaneous localized bending operations.
Solution Approach 2:
The patent implements feedback by measuring the actual dimensions of bent components and using this information to adjust subsequent bending operations. The system continuously monitors component geometry and modifies bending force application to achieve target dimensional specifications, creating a closed-loop control system.
3Manufacturing precision
If multiple bending devices are used to correct warpage, then manufacturing precision improves, but the time required for the bending process increases
Solution Approach 1:
The patent applies periodic action by implementing a systematic sequence of bending operations. The system performs measurements, applies bending forces at specific intervals, releases, and re-measures in repeated cycles until dimensional compliance is achieved. This periodic measurement-adjust-correct cycle ensures precision while managing process time through efficient iteration.
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 truing machine effectively brings magnesium or aluminum components into compliance with dimension and tolerance requirements, ensuring they meet vehicle manufacturer standards, thereby addressing the issue of warping and improving the manufacturing efficiency and quality of vehicle components.
Implementation Method 1
The at least one bending device is configured to apply an upward and downward force to plastically deform the component
Data Source
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AI summary
A machine (100) for bending a cast or stamped component (10) into compliance with dimension and tolerance requirements, includes a base (101) and at least one fixed holding device (120) coupled to the base (101) and configured to hold a corresponding datum (20) of the component (10). The machine (100) further includes at least one bending device (130) coupled to the base (101) and configured to engage a corresponding bending datum (30) of the component, and a control system (200) configured to control the at least one fixed holding device (120) and the at least one bending device (130) during a manipulation routine. The at least one fixed holding device (120) is configured to hold the component (10) in a predetermined spatial orientation relative to the base (101). The at least one bending device (130) is configured to plastically deform the component (10).