Offset Deformation Head for Machining Bent Tube Ends
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Solution Overview
Problem
Current machines for deforming tubes with complex shapes and multiple curves, common in the automotive industry, face challenges in correctly positioning the tube for machining due to its shape, leading to manual, labor-intensive, and costly processes that are not versatile enough to handle all required shapes.
Innovation Solution
A machine with a deformation unit that is rotatable and protrudes laterally from the support frame, featuring offset actuator and head axes, and additional misalignment lengths, allowing for flexible positioning and automated machining of tubes with complex shapes by preventing collisions and accommodating a wide range of tube geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the tube is repeatedly bent to assume a desired shape, then the tube can meet miniaturization needs and compact shape requirements, but the tube shape and curvatures cause collisions with machine parts that prevent correct positioning for machining
Solution Approach 1:
The deformation unit is configured to protrude laterally from the support frame in a direction substantially perpendicular to the tube axis, enabling the machining head to approach the tube end from a lateral dimension rather than along the tube axis. This dimensional change allows the deformation unit to access tube ends even when the tube has complex curvatures that would block axial approach, thereby resolving the positioning problem while maintaining the ability to create desired tube shapes
Solution Approach 2:
The deformation unit is made rotatable about an axis substantially parallel to the tube axis, allowing dynamic adjustment of the machining head orientation. This rotational capability enables the system to adapt to different tube configurations and curvature arrangements, maintaining ease of operation across various tube shapes while preserving the ability to create compact forms
2Adaptability or versatility
If manual tools are used for deformation of tube and/or component, then all tube shapes can be handled, but the process requires skilled labor, extremely long machining time and high costs
Solution Approach 1:
The deformation unit combines multiple functions in a single automated device: the thrust group performs deformation operations while the support head provides positioning and stabilization. The lateral protrusion configuration and rotational capability enable this universal machine to handle all tube shapes that previously required different specialized manual tools, thereby maintaining versatility while dramatically improving productivity through automation
Solution Approach 2:
The patent replaces manual mechanical operations with an automated deformation unit driven by a thrust actuator. The controlled thrust group applies precise deformation forces without requiring skilled manual intervention, eliminating the need for expert operators while maintaining the ability to process all tube shapes and reducing machining time from extremely long durations to automated cycle times
3Device complexity
If the deformation unit is positioned coaxially with the tube axis, then the machine structure is simple, but tubes with complex shapes and curvatures cannot be correctly positioned for machining
Solution Approach 1:
The deformation unit is positioned to protrude laterally from the support frame rather than being coaxial with the tube axis. This lateral offset creates a different spatial relationship between the machining head and tube, allowing the head to approach the tube end from the side. This dimensional repositioning enables the machine to handle complex tube shapes with multiple curves while adding only moderate structural complexity through the lateral support frame configuration
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 automated, efficient, and cost-effective deformation machining of tubes with complex shapes, overcoming the limitations of existing machines by allowing for precise positioning and handling of tubes with multiple bends, thus reducing manual labor and increasing production efficiency.
Implementation Method 1
a thrust group (7) movable by an actuator (70) along an actuator axis (C)
Implementation Method 2
The machine (1) comprises a deformation unit (6) configured to perform deformation machinings of an end (21) of the tube (2), and/or deformation of a component (3) to be mounted to the tube (2)
Data Source
AI summary
A machine for deformation machinings of a tube and/or of a component to be mounted to said tube, including a support frame, a bracket projecting in a cantilever manner from the support frame and a deformation unit engaged rotationally free with the bracket, the deformation unit in turn including a thrust group and a support head, the thrust group having a thrust actuator extending along an actuator axis, where the support head faces the thrust group and is suitable to support a tube portion during the machining, where the thrust group further includes a deformation head extending along a head axis offset with respect to the actuator axis, the offsetting between the actuator axis and the head axis is suitable to allow the deformation of the tube and/or of the component also when an end of the tube is close to a curvature of the tube itself.