Magnetic Drive Roller Cleaning for Hemming Tools
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for cleaning machining rollers, particularly in roller hemming processes, face challenges such as contamination transfer and reduced process reliability due to reliance on frictional contact for rotary drive, which can lead to incomplete cleaning and equipment interference.
Innovation Solution
A method and device where the processing roller is coupled with a drive rotor external to the processing tool through a positive drive engagement, ensuring consistent peripheral speed without frictional contact, allowing for effective cleaning without contaminant transfer and enabling cleaning even when the roller is not rotationally driven.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If frictional contact is used to drive the processing roller during cleaning, then the roller can be rotated for cleaning, but contamination can be transferred from the friction wheel to the roller and drive reliability is reduced
Solution Approach 1:
The patent replaces the friction-based mechanical drive system with a magnetic field-based drive system. The processing roller is equipped with a permanent magnet, and the drive wheel contains electromagnetic coils that generate a magnetic field to rotate the roller without physical contact. This substitution eliminates contamination transfer while maintaining reliable drive operation.
2Speed
If frictional contact is used to drive the processing roller, then rotation can be achieved, but the peripheral speed cannot be precisely controlled
Solution Approach 1:
The patent incorporates a sensor that detects the rotational position and speed of the processing roller, feeding this information back to the control unit. The control unit adjusts the electromagnetic coil activation to maintain the required peripheral speed, ensuring consistent cleaning quality while adapting to varying operating conditions.
3Volume of moving object
If the processing tool is made compact, then space is saved, but there is insufficient space for integrated cleaning devices
Solution Approach 1:
The patent separates the cleaning function from the main processing tool by making the processing roller itself self-contained with integrated magnetic drive and cleaning capabilities. The roller can be independently rotated and cleaned without requiring space for external cleaning mechanisms, thus maintaining compact tool design while ensuring cleaning functionality.
4Reliability
If contact pressure against the processing roller is increased to ensure clean rolling, then rolling reliability improves, but the risk of contaminant transfer and roller damage increases
Solution Approach 1:
The patent replaces mechanical friction-based contact with a magnetic field-based contactless drive system. The electromagnetic coils generate a magnetic field that interacts with the permanent magnet in the roller, producing rotational force without physical contact. This eliminates contaminant transfer while maintaining sufficient drive force for reliable operation.
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
This approach enhances cleaning reliability by ensuring the roller moves at the required speed for cleaning, reduces contamination risk, and allows for flexible positioning of the drive engagement, improving the cleanliness and operational efficiency of the machining roller.
Implementation Method 1
the drive wheel (16) has, arranged on its inner circumference, electromagnetic coils (26) which, in interaction with a permanent magnet (62) on the processing roller (1), are set up to rotationally drive the processing roller (1)
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The method involves coupling a processing roller with an external drive rotor (16) in a drive engagement in relation to a processing tool. The drive rotor is rotated in the drive engagement of the processing roller. The processing roller is cleaned by a cleaning tool (11,12) during rotary operation. A carbon di-oxide pellet cleaning process is utilized during cleaning. An independent claim is included for a device for cleaning a processing roller of a processing tool.