Press Brake Lower Beam Recess Layout for Bending Accuracy
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Solution Overview
Problem
Existing bending machines face issues with lower beam deflection during bending operations, which can lead to inaccuracies and reduced mechanical stability, particularly due to high manufacturing costs associated with active crowning methods and rigidity reduction in prior solutions like slot-provided lower beams.
Innovation Solution
The bending machine design features a lower beam constructed with a central element and side elements, where recessed regions reduce bending stiffness at the edges, allowing for controlled deformation and maintaining mechanical stability by distributing force through a central region and free regions, ensuring uniform bending along a straight line.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If active crowning techniques are used to counteract lower beam deflection, then bending accuracy is improved, but manufacturing costs increase due to required sensors and drives
Solution Approach 1:
The patent replaces expensive active crowning systems with simple, inexpensive recessed regions that are integrated into the lower beam structure. These recessed regions passively accommodate beam deflection without requiring sensors, actuators, or complex control systems, thereby significantly reducing manufacturing costs while maintaining bending accuracy.
Solution Approach 2:
The lower beam structure is designed to self-accommodate deflection through the recessed regions, eliminating the need for external active crowning systems. The beam itself provides the necessary compliance through its geometric design, making the system self-regulating without additional components.
2Manufacturing precision
If slots are provided in the lower beam to maintain parallel deformations, then bending line accuracy is improved, but mechanical stability deteriorates due to reduced rigidity
Solution Approach 1:
Instead of providing slots throughout the lower beam which would compromise overall rigidity, the patent applies recessed regions only locally at the ends of the tool holder where deflection occurs. This localized approach maintains the parallelism of the bending line while preserving the mechanical stability and rigidity of the majority of the beam structure.
Solution Approach 2:
The lower beam is functionally segmented into different regions: the central region maintains full rigidity for mechanical stability, while the end regions with recessed regions provide controlled compliance for bending accuracy. This segmentation allows each part to fulfill its specific function without compromising the other.
3Manufacturing precision
If recessed regions are provided at the ends of the tool holder, then bending accuracy is improved by allowing controlled deformation, but beam rigidity is reduced
Solution Approach 1:
The recessed regions are provided only at the end portions of the tool holder where deflection occurs during bending, while the central region of the lower beam maintains full rigidity. This localized reduction in stiffness allows controlled deformation at critical locations without compromising the overall mechanical stability of the beam structure.
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 design effectively counteracts lower beam deformation without compromising mechanical stability, resulting in improved bending accuracy and reduced manufacturing costs by allowing for symmetrical force introduction and controlled deformability.
Implementation Method 1
Each end of the tool holder, lying in the width direction, is associated with a recessed region, which is formed in the lower beam overlapping with the respective end in the width direction. The recessed region serves to reduce the bending stiffness of the lower beam at the edges of the tool holder.
Data Source
AI summary
A bending machine for bending workpieces is disclosed. The bending machine includes a lower beam and an upper beam for forming a workpiece by bending along a bending line. A tool holder for receiving bending tools is provided on the lower beam and each end of the tool holder is associated with a recessed region which is formed in the lower beam overlapping with the respective end. The lower beam includes a central element and at least one side element arranged adjacent to one another in the thickness direction of the lower beam. Recessed regions are provided in the central element and/or in the width direction adjacent to the central element. The lower beam also includes a central region in which, during a bending operation of a workpiece, a force is introduced via the tool holder both into the central element and into the at least one side element.