Offset Jig Bending Apparatus for Wire Shape Control
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Solution Overview
Problem
Existing bending apparatuses and machines face challenges in accurately bending metal wires and rods without causing material displacement or damage, particularly when bending multiple portions simultaneously, due to issues like material pull-in and difficulty in maintaining dimension control.
Innovation Solution
A bending apparatus with first and second jigs coupled to rotate relative to each other, featuring a suppressing section to prevent material displacement and a bending section offset from the rotary center, ensuring the material is not displaced during bending, and a bending machine design that allows for simultaneous bending at multiple portions using a series arrangement of these jigs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the bending jig is rotated on the material to wind the material around it, then the material can be bent, but the mechanism becomes complicated and cannot perform accurate bending
Solution Approach 1:
The bending jig is divided into two separate jigs (first jig and second jig) that rotate in opposite directions. This segmentation simplifies each individual jig's mechanism while maintaining the overall bending capability through coordinated rotation of both jigs.
2Ease of operation
If the bending center and rotary center coincide, then the jigs can rotate smoothly, but the material is displaced relative to the jigs causing pull-in and damage
Solution Approach 1:
The bending center of the material is intentionally offset from the rotary center of the jigs. This asymmetric positioning creates a controlled displacement that prevents material pull-in while maintaining smooth rotation, resolving the contradiction between operational ease and positioning accuracy.
3Productivity
If great back tension is exerted to prevent material pull-in during simultaneous bending at two portions, then the material can be bent, but it becomes difficult to control dimensions and perform accurate bending
Solution Approach 1:
The offset between bending center and rotary center acts as a counterbalancing mechanism that naturally compensates for material displacement during bending. This eliminates the need for excessive back tension, allowing simultaneous bending at multiple portions while maintaining dimensional control and accuracy.
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 solution enables accurate bending without material damage, prevents pull-in, and allows for complex shapes to be formed efficiently, reducing manufacturing costs by minimizing the number of joining portions and maintaining dimensional accuracy.
Implementation Method 1
bending a prescribed material attached to the first jig and the second jig as the first and second jigs rotate relatively to each other
Data Source
AI summary
A bending apparatus for performing accurate non-destructive bending of material includes first and second jigs that are rotatable about a rotary shaft and that bend the material attached to the jigs as they rotate relative to each other. The first jig includes a bending section that is arranged offset from a rotary center to a rotating side of the material and that has a partially cylindrical surface with a radius of curvature corresponding to the radius of curvature of an inner peripheral surface of the material. Each of the first and second jigs has a suppressing section for suppressing displacement of the material, and a bending center of the material is arranged such that the material is not displaced relative to the first and second jigs when the material is bent.