Ring Component Contouring with Sequential Forming Roller Sets
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Solution Overview
Problem
Conventional contour roll forming and vertical roll forming processes face challenges in defining complex profiles on ring components due to limited weld head access and the need for frequent removal and reinstallation of ring components for heat treatment and roller set changes, leading to increased time and costs.
Innovation Solution
A system and method that combines contour roll forming and vertical roll forming, allowing multiple forming roller sets to apply different profiles sequentially without removing the ring component, using an actuating unit for precise engagement and disengagement of roller sets and optional heating elements to enhance ductility and prevent spring back.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If contour roll forming process is used to define complex profiles on ring component, then profile shape complexity is improved, but weld head accessibility deteriorates due to bends and features in sheet metal
Solution Approach 1:
The ring component is welded into a closed loop configuration before the contouring process begins. This preliminary welding action eliminates the need for post-forming welding operations, as the welding is performed on the flat metal strip when full weld head accessibility is available, before any profile-forming bends are created
2Adaptability or versatility
If vertical roll forming process is used with multiple roller sets, then profile versatility is improved, but manufacturing time increases due to frequent removal and reinstallation of ring component
Solution Approach 1:
The vertical roll former is divided into multiple independent roller sets, each capable of being selectively engaged or disengaged from the ring component. This segmentation allows different roller sets with different profiles to be used without requiring complete disassembly and reassembly of the entire forming system
Solution Approach 2:
The roller sets are made dynamically adjustable through selective engagement mechanisms that allow them to be moved into or out of contact with the ring component during the forming process. This dynamic capability enables profile changes without removing the ring component from the machine, maintaining continuous production
3Manufacturing precision
If ring component is repeatedly removed for heat treatment and roller set changes, then profile accuracy is improved, but manufacturing cost increases due to increased time
Solution Approach 1:
The system maintains continuous forming action by keeping the ring component in place and selectively engaging different roller sets as needed. Heat treatment operations are integrated into the continuous process flow rather than requiring complete removal and reinstallation, eliminating idle time and maintaining continuous productive action throughout the manufacturing sequence
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 reduces manufacturing time and costs by enabling the creation of complex profiles without post-forming welding and eliminating the need for frequent ring component removal, ensuring precise profile formation across the entire circumference while maintaining material constraint and ductility.
Implementation Method 1
The system includes a heating element configured to heat a portion of the ring component
Implementation Method 2
each forming roller set is configured to form a profile on the ring component based on the forming roller set profile
Data Source
Figure 1
Figure 2A
Figure 2B~2C
AI summary
A system (100) includes a plurality of forming roller sets (106-1, 106-2, 106-3, 106-4, 106-5) comprising an inner forming roller (120-1, 120-2, 120-3, 120-4, 120-5) and an outer forming roller (122-1, 122-2, 122-3, 122-4, 122-5). Each inner forming roller (120-1, 120-2, 120-3, 120-4, 120-5) rotates about an inner forming roller axis (A1-1, A1-2, A1-3, A1-4, A1-5). Each outer forming roller (122-1, 122-2, 122-3, 122-4, 122-5) rotates about an outer forming roller axis (A2-1, A2-2, A2-3, A2-4, A2-5). Each forming roller set is adjustable between an engagement configuration and a disengagement configuration. Each forming roller set forms a profile (130) on the ring component based on a forming roller set profile (118-1, 118-2, 118-3, 118-4, 118-5) of the forming roller set. The system also includes an actuating unit (110). The actuating unit controls the engagement and a disengagement of the forming roller sets with the ring component.