Sheet Metal Working Unit With Moving Tool for Low-Force Profiling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing machines for working sheet metal, such as bending presses and profiling lines, face issues with high tool costs, complexity, inflexibility, and high deformation forces, which are proportional to the length and thickness of the sheet metal piece, leading to inefficient and costly production.
Innovation Solution
A machine with a frame supporting retention means and working units, featuring adjustable tools mounted on carriages that can translate and rotate, allowing precise control of tool positions and movements to deform or cut sheet metal with reduced force and tool numbers, enabling flexible production of complex profiles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If bending presses with prismatic tools are used to deform sheet metal along the entire length, then the desired profile shape can be reproduced, but the deformation force increases proportionally with the length of the sheet metal piece and the tool cost increases
Solution Approach 1:
The invention divides the sheet metal piece into multiple zones along its length, with at least one zone being worked upon at a time. The tool acts only on a localized portion of the sheet metal rather than the entire length simultaneously, thereby reducing the deformation force required while maintaining profile accuracy through sequential processing of different zones
Solution Approach 2:
The invention employs dynamic positioning of the tool along the sheet metal piece, allowing the tool to move sequentially between different zones. This dynamic approach enables the same tool to work on different portions of the sheet metal at different times, reducing the required deformation force compared to static tools that must accommodate the entire length
2Manufacturing precision
If prismatic tools with dedicated profiles are used in bending presses, then specific profile shapes can be reproduced accurately, but the tool cost increases and production flexibility decreases
Solution Approach 1:
The invention employs a single multi-functional tool that can be positioned and oriented in different ways to produce various profile shapes. Instead of requiring dedicated prismatic tools for each profile type, the same tool can be dynamically positioned to create different profiles, thereby reducing tool cost and increasing production flexibility while maintaining manufacturing precision
3Force
If the structure of bending presses is designed to accommodate long sheet metal pieces, then the required deformation force can be applied, but the structure becomes subject to flexing and requires increased sizing
Solution Approach 1:
By segmenting the working process into zones along the sheet metal length and processing them sequentially rather than simultaneously, the invention reduces the span over which the press structure must maintain rigidity. This allows for a more compact, less expensive press structure that is less susceptible to flexing, while still achieving the required deformation force on each localized zone
4Productivity
If profiling lines use a train of rollers with complex profiles to deform sheet metal progressively, then high productivity can be achieved, but the number of rollers increases and processing time increases
Solution Approach 1:
The invention replaces the static train of rollers with a dynamic tool that can be quickly repositioned between zones. This dynamic approach reduces the number of processing steps required compared to progressive deformation through multiple fixed rollers, thereby reducing processing time and increasing productivity while maintaining the ability to achieve complex profile shapes
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 machine achieves flexible and efficient production of diverse sheet metal profiles with lower tool costs and deformation forces, independent of sheet metal dimensions and complexity, using a single set of tools and reducing structural loads and costs.
Implementation Method 1
The tool (18) is designed for contact with a face of the sheet metal piece (13) and for deformation or cutting of the sheet metal piece by action of the tool against the sheet metal piece
Implementation Method 2
at least one unit (14) for the working of said sheet metal piece (13)... configured to support a tool (18) designed for contact with a face of the sheet metal piece (13) and for deformation or cutting of the sheet metal piece
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A machine (10) for working sheet metal and the like, comprising a frame (11) for supporting means (12) for the retention of a piece of sheet metal (13) or the like and at least one unit (14, 114, 214, 314) for the working of the sheet metal piece (13). The working unit (14, 114, 214, 314) is at least able to translate on the frame (11) along a direction that is parallel to the plane of arrangement of the sheet metal piece (13) and is adapted to support at least one tool (18, 118, 218, 318) designed for contact with one face of the sheet metal piece (13).