Panel Hemming Roller Structure for Low-Cost Flexible Roof Panel Forming
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Solution Overview
Problem
Existing hydraulic equipment for panel hemming in automotive manufacturing is costly, requires significant space, and is inefficient for small-quantity production due to complex setup and long equipment replacement times.
Innovation Solution
A panel hemming device with a simple configuration, utilizing a fixing die, hemming shaft, rotary shaft, and hemming rollers with guide grooves and protrusions, which allows for easy adjustment and replacement, eliminating the need for hydraulic equipment, enabling cost-effective and efficient hemming of various vehicle types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hydraulic equipment is used for panel hemming, then hemming function is achieved, but device complexity and construction cost increase
Solution Approach 1:
The patent extracts and eliminates the hydraulic system from the hemming equipment, replacing it with a simple mechanical structure consisting of a press, die, and hemming tool. This removal of the hydraulic subsystem directly reduces device complexity while maintaining the core hemming function through mechanical force application.
Solution Approach 2:
The patent employs simple, inexpensive mechanical components instead of expensive hydraulic equipment. The hemming device uses basic mechanical elements like presses, dies, and tools that are cheaper to manufacture and replace, aligning with the principle of using cost-effective, simpler components for the task.
2Reliability
If hydraulic equipment is used for panel hemming, then hemming function is achieved, but space requirement increases
Solution Approach 1:
By removing the hydraulic system with its pumps, reservoirs, hoses, and control mechanisms, the patent significantly reduces the space required for equipment operation. The compact mechanical press and die assembly occupy much less floor space compared to a full hydraulic setup.
3Reliability
If hydraulic equipment is used for panel hemming, then hemming function is achieved, but equipment replacement time increases
Solution Approach 1:
The hemming device is segmented into modular components (press, die, hemming tool) that can be independently adjusted or replaced. This segmentation allows for quick changes between different vehicle types by simply swapping or repositioning specific components rather than replacing entire hydraulic systems.
Solution Approach 2:
The patent incorporates adjustable and reconfigurable mechanical components that can be dynamically adapted to different hemming requirements. The die and tool positions can be adjusted, and components can be quickly swapped, enabling rapid reconfiguration for different vehicle models without lengthy replacement procedures.
4Reliability
If hydraulic equipment is used for panel hemming, then hemming function is achieved, but construction cost increases
Solution Approach 1:
The patent replaces expensive hydraulic equipment with inexpensive mechanical components. The press, die, and hemming tools are simple mechanical elements that cost significantly less to manufacture and install, directly reducing construction costs while performing the required hemming function.
5Ease of manufacture
If simple mechanical device is used for hemming, then construction cost is reduced, but manufacturing precision may worsen
Solution Approach 1:
The patent incorporates preliminary positioning and alignment features in the mechanical design, such as guide rails,定位 pins, and pre-set die positions. These preliminary actions ensure that components are correctly positioned before hemming begins, maintaining manufacturing precision despite the simplicity of the mechanical system.
Solution Approach 2:
The patent allows for adjustment of key parameters such as press force, die position, and tool alignment to optimize hemming quality for different panel types and thicknesses. This parameter adjustability ensures consistent manufacturing precision across various applications using the simple mechanical device.
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 allows for low-cost manufacturing of jigs and efficient hemming of automotive roof panels, suitable for small-quantity production, improving quality by preventing manual deformation and reducing production time.
Implementation Method 1
A rotary roller that generates friction force for hemming between the rotary shaft and the fixing die in contact with the bottom of the fixing die when fixed may be formed at the second side of the rotary shaft.
Data Source
AI summary
A panel hemming device includes: a fixing die on which a panel is placed and having a supporting surface stepped upward to be parallel with an end of the panel; a hemming shaft having a first side coupled to a tool and having a second side to which a hemming roller, which contacts a top of the supporting surface when fixed to the fixing die, is coupled; a rotary shaft having a first side coupled to the first side of the hemming shaft to receive torque and having a second side, which contacts a bottom of the fixing die when fixed to the fixing die; and a case supporting an outer surface of the hemming shaft disposed through the case and coupled to a first end of the rotary shaft such that the rotary shaft can rotate upward or downward with respect to the first end.