Radial Profile-Bending Machine for Exact Diameter Control
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Solution Overview
Problem
Existing profile-bending machines struggle to achieve exact curvature due to the elasticity of profiles and tolerances in bar thickness, resulting in approximate and not exact radii or diameters.
Innovation Solution
A profile-bending machine utilizing a two- or three-roller bending die with radial guides, profile-supporting skates, and a length-adjustable guide arm to ensure precise curvature by coordinating the position of the skates and bending die through a mechanism like an umbrella-like system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a traditional three-roller bending machine is used, then the bending operation can be performed, but the accuracy of the radius or diameter is insufficient due to profile elasticity and thickness tolerances
Solution Approach 1:
The bending process is divided into multiple sequential bending zones along the profile length, with each zone having its own rollers that can be independently positioned. This allows progressive bending that accounts for elastic recovery at each stage, achieving cumulative precision that overcomes the limitation of single-stage bending.
Solution Approach 2:
The profile is pre-positioned on support skates before bending begins, and the bending rollers are pre-adjusted to account for expected elastic recovery. The machine performs preliminary positioning and alignment operations to ensure the profile starts in the correct configuration, compensating for anticipated elasticity effects.
2Manufacturing precision
If traditional bending machines are used, then bending operation is possible, but the equipment cannot accommodate varying bar thickness tolerances to achieve exact diameters
Solution Approach 1:
The bending rollers and support skates are mounted on adjustable mechanisms that allow dynamic repositioning during operation. The roller positions can be adjusted along the profile thickness dimension to accommodate varying bar thicknesses while maintaining the correct bending geometry, enabling exact diameter achievement despite thickness tolerances.
Solution Approach 2:
The machine allows adjustment of critical parameters including roller separation distance, roller position along the profile, and support skate positioning. These parameters can be modified based on the actual bar thickness being processed, enabling the system to adapt to thickness variations and maintain precise diameter control.
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 machine achieves precise bending of profiles by ensuring the skates and bending die maintain identical positions, allowing for accurate definition and attainment of the target diameter, overcoming the limitations of elasticity and tolerances.
Implementation Method 1
the latter must bend. Depending on the distance, the diameter or radius of curvature is larger or smaller
Implementation Method 2
However, the elasticity of the profile means that the accuracy of that radius or diameter is less than desirable. The profile more or less recovers its position
Implementation Method 3
a length-adjustable guide arm concentric with the guides, and freely rotatable about the centre point of the guides, with an adjustable guide
Implementation Method 4
the skates and the bending die are connected to each other by a mechanism for coordinating the position thereof on the respective guide
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a profile-bending machine comprising a series of radial guides (2) centred on a point, with a bending die (4) mounted on one guide (2) and profile-supporting skates (3) disposed on the remaining guides (2). The machine also comprises a length-adjustable guide arm (5) concentric with the guides (2). The skates (3) and the bending die (4) are connected by a mechanism for coordinating the position thereof on the respective guide (2), such that they are all equidistant from the centre point.