Multi-Axis Sweep Unit for Structural Beam Forming
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Solution Overview
Problem
Existing roll forming apparatuses are limited to forming structural beam components in a single plane and direction, leading to complexity, tolerance issues, and maintenance problems when attempting to form beams with multiple directional sweeps, especially with high-strength steel, which requires precise dimensional consistency and high impact strength.
Innovation Solution
A multi-axis sweep unit integrated with a roll former that can selectively sweep beams in both vertical and horizontal directions, using programmable logic control for coordinated operation, and featuring hydraulic cylinder-driven components for precise positioning and force management, allowing for the formation of non-linear shapes with varying radii and planes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple moving components are added to sweep in multiple directions, then multi-directional sweeping capability is improved, but device complexity and maintenance problems increase
Solution Approach 1:
The patent combines multiple sweeping functions into a single integrated sweep unit that can perform sweeps in multiple directions (vertical, horizontal, and angled) using one coordinated mechanism rather than separate moving components for each direction, thereby reducing overall device complexity while maintaining multi-directional capability
Solution Approach 2:
The sweep unit is designed as a universal device capable of performing multiple sweeping operations in different directions and planes through coordinated movement of its components, eliminating the need for direction-specific mechanisms and reducing maintenance requirements
2Strength
If high strength steel is used, then beam strength is improved, but loads and stress on machine components become very high
Solution Approach 1:
The patent performs preliminary roll forming of the high strength steel beam to achieve the desired cross-sectional shape and structural integrity before the sweeping operation, so that the beam is pre-stabilized and requires less force during sweeping, reducing stress on machine components
Solution Approach 2:
The sweep unit uses dynamically adjustable forming members that can move and apply force adaptively during the sweeping process, allowing optimized force distribution that reduces peak loads on machine components while effectively forming high strength steel
3Shape
If beam is bent in multiple directions, then complex shapes are achieved, but flat wall sections collapse and/or undulate
Solution Approach 1:
The patent divides the beam into multiple zones during the sweeping process, with different forming members acting on different sections (e.g., sweeping the beam while maintaining other sections in line), allowing complex multi-directional shapes to be achieved while keeping wall sections stable through localized control
Solution Approach 2:
The patent uses an intermediary support structure or mandrel system that temporarily supports the beam during multi-directional sweeping, preventing wall collapse and undulation, and ensuring dimensional consistency is maintained throughout the complex forming operation
4Productivity
If small radii sweeps are formed at high line speeds, then productivity is improved, but forces on components become extraordinarily high
Solution Approach 1:
The patent maintains continuous motion of the beam through the roll former and sweep unit at high line speed, avoiding stopping or slowing down during sweeping operations, which reduces the peak forces required to achieve small radius sweeps while maintaining high productivity
Solution Approach 2:
The patent employs hydraulic or pneumatic actuation systems in the sweep unit that can deliver extremely high forces rapidly and controllably, enabling small radius sweeps to be achieved at high line speeds without exceeding component force limits through precise force management
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
Enables the production of structural beams with complex non-linear shapes while maintaining dimensional consistency and reducing maintenance needs, allowing for the use of a single set of tooling for different vehicle models, thereby reducing production costs and setup time.
Implementation Method 1
The sweep unit is hydraulic cylinder-driven, at least in part
Implementation Method 2
a sweep unit... for selectively sweeping a roll formed continuous beam... in multiple different directions
Data Source
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AI summary
An apparatus and method include a roll former with rolls configured to form a structural beam from sheet material, and a sweep unit for longitudinally sweeping a beam in any of vertical, horizontal, or combination directions. The sweep unit has a first pair of forming rolls positioned to engage first opposing sides of the structural beam and has a second pair of forming rolls positioned to engage second opposing sides of the structural beam. The sweep unit movably supports the first and second pairs of forming rolls so that any selected one of the forming rolls continuously engages an associated side of the structural beam while an associated one of the forming rolls opposing the selected one forming roll moves downstream and around the selected one forming roll. This provides a very stable beam-bending condition promoting dimensional stability during the sweeping process, and hence dimensional accuracy and repeatability.