Profile Disk Forming via Adjustable Connecting Rods
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Solution Overview
Problem
Existing methods for producing longitudinal grooves in cylindrical workpieces, such as disk carriers and toothed belt pulleys, are limited by the need for circular movement paths, which restrict the ability to achieve soft penetration and rapid lifting movements, leading to potential jamming and inefficiencies in the forming process.
Innovation Solution
The use of at least two connecting rods, with adjustable lengths and bearing axes, allows for non-circular movement paths, enabling soft immersion and rapid lifting of profile discs during the forming process, thereby preventing jamming and optimizing the forming sequence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If circular movement paths are used for profile disks, then the device structure is simple, but the ability to achieve soft penetration and rapid lifting movements is restricted
Solution Approach 1:
The profile disk movement is changed from a fixed circular path to a dynamically controllable path using connecting rods with adjustable lengths. The connecting rods enable the profile disk to follow optimized movement curves that adapt to different forming requirements, achieving both soft penetration and rapid lifting movements while maintaining a mechanically simple structure.
Solution Approach 2:
The length of the connecting rods is made adjustable, allowing modification of the movement path parameters. This enables optimization of the profile disk trajectory for different workpiece geometries and forming requirements without changing the fundamental device structure, thus improving adaptability while controlling complexity.
2Reliability
If circular movement paths are used, then the device structure is simple, but jamming of the component on the profile disc occurs
Solution Approach 1:
The connecting rod mechanism enables dynamic adjustment of the profile disk movement path, allowing rapid lifting movements that prevent material jamming on the profile disc surface. The optimized movement curve ensures the profile disk can quickly exit the deformation zone, eliminating jamming issues while maintaining reliable operation.
3Length of moving object
If profile disks rotate around a single center of rotation, then the device structure is simple, but larger rotational paths are required
Solution Approach 1:
The profile disk mounting is segmented from a single center of rotation to multiple spaced-apart bearing axes. This segmentation allows the profile disk to follow a shorter, more efficient movement path while being supported by multiple connecting rods attached to different bearing axes, reducing the overall rotational path length required.
Solution Approach 2:
The profile disk movement is transitioned from a two-dimensional circular path around a single axis to a three-dimensional optimized trajectory controlled by multiple bearing axes. This dimensional change enables shorter effective movement paths while providing more flexible control over the profile disk motion.
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 approach results in improved dimensional accuracy, reduced holding and working forces, and smaller forming paths, eliminating the need for additional gas pressure or hydraulic cushions, while enabling the creation of complex profiles like undercuts and gaps, enhancing the quality of the formed components.
Implementation Method 1
Each profile disk (4) is guided in its rolling movement by two connecting rods (1, 2) which are arranged at a distance from one another
Implementation Method 2
the profiled discs (4) are carried along in the direction of the arrow 20 by frictional engagement and roll off the outer circumference of the component in a deforming manner, with the introduction of radially inward-pointing longitudinal grooves
Implementation Method 3
the profiled discs (4) are carried along in the direction of the arrow 20 by frictional engagement
Data Source
Figure 1
Figure 2~4
Figure 5
AI summary
The device has a roller stamp (7) arranged at a lower end of an upper stamp (9), and carrying a cylindrical component (11). Multiple profile disks (4) are arranged opposite to a housing (25) for implementing shifting movement of the component in a radially inward direction. A movement guide is rotatably mounted on a housing-firm bearing shell (3). The disks are movably driven by piston rods (1, 2) that are arranged at a distance from each other. One of ends of the piston rods is held in a recess in the profile disk and other end of the rod is rotatably mounted over a bearing axis on the shell. An independent claim is also included for a method for producing longitudinal slots in a cylindrical workpiece.