Method of aligning a flat or profiled metal sheet
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Solution Overview
Problem
Current HVAC duct fabrication processes require manual or mechanical alignment of profiled metal sheets between rollformers and folders, leading to inefficiencies in space, time, labor, and cost due to the need for transfer tables and additional manpower.
Innovation Solution
A method utilizing sensors, controllers, and hydraulic motors to align the first fold line of the metal sheet with the folding line of the mechanical folder, eliminating the need for transfer tables and manual alignment by controlling the rollers' speed and direction to ensure precise alignment before folding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual alignment or mechanical transfer table is used to align the profiled metal sheet before folding, then the alignment accuracy is improved, but the production time increases and labor cost increases
Solution Approach 1:
The system uses sensors to automatically detect the position of the metal sheet and controllers to automatically adjust the roller speeds, enabling the system to self-align without manual intervention or transfer tables, thus improving both alignment accuracy and production efficiency
Solution Approach 2:
The patent replaces the mechanical transfer table and manual alignment mechanisms with a sensor-based detection system and controller-based roller speed regulation system, eliminating complex mechanical alignment equipment while achieving precise alignment
2Manufacturing precision
If manual alignment or mechanical transfer table is used to align the profiled metal sheet before folding, then the alignment accuracy is improved, but the labor cost increases
Solution Approach 1:
The system automatically detects sheet position using sensors and self-regulates roller speeds through controllers, eliminating the need for manual alignment operations and complex mechanical transfer tables, thereby reducing both labor requirements and system complexity
Solution Approach 2:
The patent extracts and eliminates the unnecessary mechanical transfer table and manual alignment operations from the system, keeping only the essential sensor detection and controller regulation components, thus simplifying the overall system while maintaining alignment precision
3Manufacturing precision
If mechanical transfer table is used to transfer and align the metal sheet, then the alignment is improved, but the space requirement increases
Solution Approach 1:
The patent merges the alignment function directly into the folder by using sensors mounted on the folder to detect sheet position and controllers to regulate roller speeds, eliminating the need for a separate mechanical transfer table and reducing space requirements
Solution Approach 2:
The patent removes the mechanical transfer table from the production line entirely, extracting its alignment function and redistributing it across the sensor-detector and controller-regulator components already present in the system, thereby freeing up production space
4Adaptability or versatility
If the rollformer and folder are separated without direct linkage, then the equipment flexibility is improved, but the alignment process becomes more complex requiring additional equipment
Solution Approach 1:
The system uses sensors to continuously detect the position of the metal sheet as it moves from the rollformer to the folder, and feeds this information back to the controllers which automatically adjust the roller speeds to achieve proper alignment, eliminating the need for complex mechanical linkages or transfer tables
Solution Approach 2:
The patent replaces complex mechanical linkage systems with an electronic control system based on sensor feedback, allowing the separated rollformer and folder to work together efficiently without requiring physical connection or complex alignment mechanisms
Data Source
AI summary
A method of aligning a flat or profiled metal sheet with preformed notches on the two sides of the metal sheet when the sheet enters into a bender or folding machine directly from a roll forming machine linked or joined to the folder. The metal sheet has to be effectively aligned on the folder before folding to avoid potential damages to the metal sheet of not being properly squared or angled on bending while reducing the times to produce the folded products. Moreover, this method according to the invention allows the metal sheet to feed directly into the folder from the rollformer without having to pass through an intermediary transfer table or aligning device/machine before entering the folder for folding or manual alignment in the folder.