Modular Bending Tool Inserts for Fast Geometry Changeovers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Bending machines require a large investment in multiple tool parts for various bending geometries, leading to delays and high costs when switching between different diameters and bending radii, as existing systems lack flexibility and efficiency in configuring tools for diverse bending operations.
Innovation Solution
A modular tool set with interchangeable components, including base bodies and tool inserts, allows for configuration of two-part bending tools with different effective geometries, ensuring compatibility and flexibility by adhering to specific selection criteria based on wire or tube diameter and desired bending geometry, thereby reducing the need for multiple tool sets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple complete tool sets are maintained for different bending geometries, then bending precision and reliability are maintained, but tooling costs and storage requirements increase significantly
Solution Approach 1:
The bending tool is divided into modular components: base bodies and tool inserts. Each base body can accept different tool inserts, and each insert can be used with different base bodies. This segmentation allows a limited set of components to create multiple bending geometries, reducing the total number of tool components needed while maintaining the ability to perform various bending operations reliably
Solution Approach 2:
The base bodies are designed with universal engagement sections that can work with multiple different tool inserts. Each base body serves multiple functions by accommodating various inserts with different effective radii. This multi-functionality allows a single base body to be used for different bending geometries, reducing the need for multiple complete tool sets
2Manufacturing precision
If multiple complete tool sets are maintained for different bending geometries, then bending precision is maintained, but investment costs increase
Solution Approach 1:
By segmenting the tool into base bodies and interchangeable inserts, the system maintains precision through dedicated inserts for each bending geometry while sharing common base bodies. This reduces the total number of components needed compared to maintaining complete separate tool sets for each geometry, thereby reducing investment costs while preserving bending precision
Solution Approach 2:
The universal base bodies provide a common platform that works with multiple inserts, reducing the need to purchase multiple complete tool sets. Each insert maintains its specific geometry precision, while the shared base bodies reduce overall tooling investment
3Manufacturing precision
If complete tool sets are changed for different bending geometries, then bending accuracy is maintained, but switching time and productivity decrease
Solution Approach 1:
The segmentation into base bodies and interchangeable inserts allows for rapid tool changeover by simply swapping inserts rather than changing entire tool sets. The base body remains in place, and only the insert needs to be changed, significantly reducing switching time while maintaining bending accuracy through the use of precision inserts
Solution Approach 2:
The system provides dynamic adaptability by allowing quick interchange of inserts on the same base body. This dynamic configuration capability enables rapid adjustment between different bending geometries without the downtime associated with changing complete tool sets, thereby improving productivity while maintaining accuracy
4Adaptability or versatility
If a modular tool set with interchangeable components is used, then adaptability and switching speed improve, but device complexity increases
Solution Approach 1:
The segmentation into standardized base bodies and inserts with defined engagement interfaces provides adaptability through combination while controlling complexity through standardization. Each component has a specific function, and the standardized interfaces simplify the configuration process despite the modular nature, making the system easier to manage than fully custom solutions
Data Source
Figure 1~2
Figure 3~4
Figure 5A~6
AI summary
A tool set comprises a variety of tool components for configuring two-part bending tools (500) of different working geometries for use in a bending head (200) of a bending machine (100). The bending head (200) has a first tool carrier (210) and a second tool carrier (220), wherein the first tool carrier (210) is rotatable about a bending head axis (202) by means of a first drive and has a first tool holder (215) for receiving a first tool part (300) of a bending tool (500), and the second tool carrier (310) is rotatable about the bending head axis (202) relative to the first tool carrier by means of a second drive and has a second tool holder (225) arranged eccentrically to the bending head axis for receiving a second tool part (400) of the bending tool.The tool set comprises at least one first base body (310) which has a mounting section suitable for the first tool holder and a base body axis which, when the first base body is mounted in the first tool holder, runs coaxially to the bending head axis (202), wherein the first base body (310) further comprises an insert carrier section (315) on which, eccentric to the base body axis, a first insert receptacle for receiving a first tool insert (330-1) and, angularly offset thereto, a second insert receptacle for receiving a second tool insert (330-2) are formed; and at least one second base body (410) which has a mounting section suitable for the second tool holder (225) and an insert carrier section (415) on which a third insert receptacle for receiving a third tool insert (430-3) is formed.The tool set includes at least three tool inserts (330-1, 330-2, 430-3), each of which has a fastening section for attaching the tool insert to one of the insert receptacles and an attack section (315-1, 315-2, 415-3) with a circumferential surface for engaging a wire or tube to be bent, wherein the circumferential surface has an effective radius with respect to an attack section axis.