Magnetic Bending System for Angled Flange Formation
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Solution Overview
Problem
Current bend tools for forming angled flanges are often heavy, large, and inflexible, making them difficult to transport and use on moving assembly lines, and are typically specific to certain types of parts, leading to increased costs and inefficiencies in manufacturing.
Innovation Solution
A magnetic bending system comprising a retaining portion and a magnetic portion with a locking magnet that allows the first section of a workpiece to bend relative to a second section while keeping the second section fixed, using a clamping magnet and a rigid elongate member to maintain the workpiece's planarity and facilitate the formation of angled flanges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional bend tools are used to form angled flanges, then the flanges can be formed with proper strength and precision, but the tools become heavy and large, making them difficult to transport and use on moving assembly lines
Solution Approach 1:
The bend tool is divided into multiple separate components: a positioning device that remains stationary, a magnetic bending device that applies force, and a support structure. This segmentation allows the heavy magnetic component to be used only when needed at the stationary positioning station, rather than moving the entire tool assembly along the assembly line.
Solution Approach 2:
A stationary positioning device with fixtures and guides acts as an intermediary between the moving workpiece and the magnetic bending device. This intermediary holds the workpiece in the correct position and orientation, allowing the magnetic device to apply bending force without needing to move with the assembly line.
2Manufacturing precision
If larger bend tools are used to ensure stability and precision during bending, then the bending precision can be maintained, but the tools block heat and draw heat away from the part during heating operations
Solution Approach 1:
The bending system is segmented into a stationary positioning component and a separate magnetic bending component. The magnetic component can be removed or deactivated during heating operations, leaving only the minimal positioning fixtures in place. This reduces the mass blocking heat transfer to the workpiece during thermal processing.
Solution Approach 2:
The magnetic bending device is designed to be dynamically applied only when bending is needed, rather than being permanently attached. During heating or curing operations, the magnetic device can be removed or its force reduced, allowing thermal energy to efficiently reach the workpiece without being blocked by large tooling mass.
3Manufacturing precision
If custom bend tools are designed for specific part types, then the bending precision for those parts can be optimized, but the cost increases when forming objects with multiple part types requiring angled flanges
Solution Approach 1:
The positioning device incorporates adjustable fixtures, guides, and clamps that can be reconfigured to accommodate different part geometries and bending requirements. The magnetic bending device itself is universal, applying magnetic force regardless of part type. This allows a single positioning device to serve multiple part types while maintaining precision for each.
Solution Approach 2:
The positioning device features dynamic, adjustable elements such as movable guides, adjustable clamps, and reconfigurable fixtures. These elements can be quickly adjusted or repositioned to match different part configurations, allowing the same device to precisely position various part types without requiring custom tooling for each.
4Strength
If heavier bend tools are used to provide sufficient bending force, then the bending strength can be ensured, but the energy needed to heat and cure the part increases
Solution Approach 1:
The magnetic bending device replaces traditional mechanical bending mechanisms (such as hydraulic presses or mechanical levers) with a magnetic field-based system. Magnetic fields can exert substantial force on ferromagnetic materials without requiring heavy mechanical structures, thereby reducing the mass of the bending device that would otherwise block or absorb thermal energy during heating operations.
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 system enables efficient and cost-effective formation of angled flanges on various parts, improving portability and adaptability, reducing energy consumption, and allowing for use in constrained environments like ovens or autoclaves without heat interference.
Implementation Method 1
a locking magnet configured to exert an attractive force that causes the magnetic portion of the structure to move towards the second section of the workpiece
Implementation Method 2
the magnetic portion of the structure is positioned at a first side of the workpiece
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A method and apparatus comprising a structure and a locking magnet. The structure comprises a retaining portion and a magnetic portion. The retaining portion of the structure is configured to receive a first section of a workpiece such that a second section of the workpiece is positioned at an angle relative to the magnetic portion of the structure. The magnetic portion of the structure is positioned at a first side of the workpiece. The locking magnet is configured to exert an attractive force that causes the magnetic portion of the structure to move towards the second section of the workpiece when the locking magnet is positioned at a second side of the workpiece.