Gripper Alignment for Wheel Rim Blank Welding
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Solution Overview
Problem
The quality of welding cylindrical wheel rim blanks is dependent on the preparation of the blanks, particularly the cutting and coiling processes, and high-strength steels are difficult to weld effectively due to their inherent properties and the need for precise geometry and uniformity of the gap between longitudinal edges.
Innovation Solution
A forming apparatus comprising a coiling station and a flattening press with a gripper system that allows for separate clamping and aligning movements of the longitudinal edge portions, ensuring precise parallelism and alignment for improved welding joints, using a combination of fluidic actuators and movable clamp assemblies to prevent edge damage and ensure symmetrical edge alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional gripper with simultaneous clamping and aligning movements is used, then the device complexity is reduced, but the manufacturing precision of the longitudinal edge alignment deteriorates
Solution Approach 1:
The gripper is divided into two independent clamp assemblies (first and second clamp assemblies), each capable of independent movement. The first clamp assembly performs clamping movement while the second performs aligning movement, allowing separate control of each function to achieve precise edge alignment without increasing overall system complexity
Solution Approach 2:
The clamp assemblies are designed with movable connections to the support frame, allowing dynamic adjustment during operation. The first clamp assembly moves in a first direction for clamping, while the second moves in a second direction for aligning, enabling adaptive positioning that maintains precision despite variations in blank geometry
2Reliability
If the longitudinal edges are not precisely aligned and parallel, then the forming process is simpler, but the welding quality deteriorates
Solution Approach 1:
The gripper performs preliminary alignment of the longitudinal edges before the forming process begins. By pre-aligning the edges to be substantially parallel and in substantial alignment, the system ensures optimal welding conditions are established before any deformation or welding operations occur
Solution Approach 2:
The patent replaces conventional mechanical alignment methods with a controlled dual-directional clamping system. Instead of relying on fixed mechanical guides, the system uses independently controllable clamp assemblies that can adjust their position and orientation to achieve precise edge alignment through controlled movement in different directions
3Reliability
If the cut edges are not protected during forming, then the ease of manufacture is improved, but the reliability of the welding joint deteriorates due to edge damage
Solution Approach 1:
The gripper applies different types of contact and force to different parts of the blank. The clamp assemblies are designed to contact and hold the longitudinal edges in a manner that prevents damage during forming, while allowing the rest of the blank to be freely formed. This localized protective action ensures edge integrity without complicating the overall forming process
Data Source
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AI summary
Apparatus for forming wheel rim blanks comprising: - a coiling station (A) for coiling blanks (20) of strip material into the form of a cylinder with the longitudinal edges (20b', 20c') of the coiled blank (20') defining a longitudinal gap, and - a flattening press (B) for flattening longitudinal edge portions (20b', 20c') on the coiled blank (20'), wherein the flattening press includes a gripper (50) for clamping the coiled blank (20'), said gripper comprising two pair of jaws (51, 52; 53, 54), each pair of jaws (51, 52; 53, 54) being adapted to engage opposite side edges (20b1, 20b2; 20c1, 20c2) of the coiled blank (20') near to a respective longitudinal edge portion (20b', 20c') of the coiled blank (20'), wherein each pair of jaws (51, 52; 53, 54) is carried by a respective movable clamp assembly (61, 63), wherein said gripper comprises a clamping drive for moving the jaws (51, 52; 53, 54) of the respective clamp assembly (61, 63) toward each other to clamp the respective longitudinal edge portion (20b', 20c') of the coiled blank (20'), and an aligning drive for moving the clamp assemblies (61, 63) in longitudinal direction to align the longitudinal edge portions (20b', 20c') of the coiled blank (20') to each other.