Platform Lift Rail Forming With Integrated Rack Flange
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Solution Overview
Problem
Conventional manufacturing methods for platform lift rails require separate bending and joining processes, resulting in complex and costly production, especially for curved rails, which lack efficiency and stability.
Innovation Solution
A method involving plastic forming of sheet metal to create a tubular profile with a projecting flange, allowing for a one-piece rail production without additional materials, using processes like bending and high-pressure forming, and incorporating positive engagement means through material removal, enabling the use of various materials and improved stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate bending and joining processes are used for conventional rail manufacturing, then the rail can be assembled from pre-fabricated components, but the manufacturing complexity and cost increase significantly
Solution Approach 1:
The patent merges the tube and rack into a single integrated component formed from one piece of sheet metal. The sheet metal is formed into a tubular profile with the rack integrated as part of the same continuous structure, eliminating the need for separate bending and joining processes while reducing manufacturing complexity and cost
2Productivity
If separate tube and rack components are joined by welding, then the rail can be assembled from standard components, but the joining process becomes complex and time-consuming
Solution Approach 1:
The tube and rack are merged into a single integrated component formed from one piece of sheet metal through plastic forming processes. This eliminates the need for separate joining operations such as welding, thereby significantly improving manufacturing efficiency and reducing the time required for rail production
3Device complexity
If a one-piece rail is manufactured without additional joining processes, then the manufacturing cost and complexity are reduced, but the structural stability must be ensured through material and design choices
Solution Approach 1:
The tube and rack are merged into a single integrated component formed from one piece of sheet metal, eliminating joints and potential weak points while maintaining structural stability through the continuous material structure and optimized geometric design
Solution Approach 2:
The patent utilizes plastic forming processes to permanently deform the sheet metal into the desired tubular profile with integrated rack features. This permanent deformation creates a stable, rigid structure that ensures rail reliability without requiring additional joining processes
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
This method simplifies the manufacturing process, reduces costs, and enhances stability by eliminating the need for additional joining processes, allowing for flexible rail configurations that can adapt to curved paths while maintaining cross-sectional integrity.
Implementation Method 1
plastic forming the sheet metal so as to form a tubular profile
Implementation Method 2
The applied manufacturing processes are in particular bending, high pressure forming, rolling
Data Source
Figure 1a~2
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Figure 7~9
AI summary
Method for manufacturing a rail (2) for a platform lift (1), the platform lift (1) has a rail (2) and a drive unit (6) driving along the rail (2), the rail (2) comprising - a tubular section (11) for supporting the drive unit (6), - a rack section (12) adapted for positively engaging with driving means of the drive unit (6), the method comprising: providing a sheet metal (20), first step of plastic forming the sheet metal (20) so as to form a tubular profile (21), thereby closing the tubular profile (21) and forming a projecting flange (22), in particular by connecting opposite faces (25) of the sheet (20), permanently fixing the flange, in particular by joining the opposite faces (25) in the area of the projecting flange (22), creating positive engagement means (13, 23) into the projecting flange (22).