Pre-rounding Element with Actuation for Sheet Metal Rounding
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Solution Overview
Problem
Existing rounding apparatuses face inefficiencies due to variations in sheet metal properties, leading to inconsistent rounding radii and edge overlaps during the welding process, resulting in production line stoppages and reduced efficiency.
Innovation Solution
A pre-rounding element with a solid flexure hinge and electrically controllable actuation allows for real-time adjustment of pressurization on sheet metal blanks, using measurement data from properties like thickness or elastic limit to maintain a constant rounding radius, even during operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual adjustment of the pre-rounding wedge is performed based on sheet metal properties, then rounding consistency can be improved, but production downtime increases and efficiency decreases
Solution Approach 1:
The pre-rounding wedge is made dynamically adjustable during operation through an electrically controllable actuator that can change the wedge position and pressurization force in real-time based on measured sheet metal properties, eliminating the need for manual adjustments and production stoppages
Solution Approach 2:
A measurement device continuously monitors sheet metal properties (thickness, elastic limit) and feeds this information to a control system that automatically adjusts the pre-rounding wedge position, creating a closed-loop control system that maintains consistent rounding without manual intervention
Solution Approach 3:
The manual mechanical adjustment system is replaced with an electrically controlled actuation system that uses electrical signals to adjust the pre-rounding wedge position, enabling automatic and precise control during operation without manual intervention
2Manufacturing precision
If the pre-rounding wedge is adjusted for different sheet metal qualities, then rounding precision can be maintained, but machine stoppages occur and downtime costs increase
Solution Approach 1:
The measurement and adjustment processes are integrated into the continuous operation of the rounding apparatus, allowing the pre-rounding wedge to be adjusted on-the-fly without stopping the machine, ensuring continuous production while maintaining precision
Solution Approach 2:
The system performs self-adjustment through automatic measurement of sheet metal properties and corresponding modification of pre-rounding wedge position by the control system, eliminating the need for operator intervention and machine stoppages
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 solution ensures consistent rounding radii and reduced downtime by allowing for automatic adaptation to different sheet metal properties, enhancing the efficiency and reliability of the production line.
Implementation Method 1
The joint or hinge, respectively, which connects the upper part 20 and the wedge 22 is in this case a flexible solid hinge consisting of a solid part with a dimension that allows deformation within its elastic range by the force of the actor 23
Data Source
AI summary
A pre-rounding element (14) is used in a rounding apparatus (4) for rounding can body blanks from sheet metal blanks. The lower element part (22) of the pre-rounding element (14) is displaceable by an actuation element (23). This allows the adjustment of the pre-rounding element even during operation of the rounding apparatus. Preferably a measurement of sheet metal blank properties takes place. The measurement may include a thickness measurement and/or a strength measurement of blanks. The pre-rounding element is controlled in dependency of the measurement result. This allows a constant rounding result even with varying sheet metal properties.