Ring Component Contouring with Staggered Forming Roller Sets
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Solution Overview
Problem
Conventional contour roll forming and vertical roll forming processes face challenges in defining complex and intricate profiles on ring-shaped components, particularly due to access limitations for welding and the need for frequent removal and reinstallation of the component for heat treatment and roller set changes.
Innovation Solution
A system comprising a frame with multiple forming roller sets, each set having inner and outer rollers that are adjustable and staggered in engagement timing, allowing for the formation of diverse profiles on a ring component without the need for post-forming welding or frequent heat treatment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a complex and/or intricate profile is formed on the metal strip before bending, then the desired profile shape is achieved, but the weld head cannot access the profile for welding due to insufficient space created by bends or features
Solution Approach 1:
The patent inverts the conventional sequence by performing welding on the straight metal strip before bending and profile formation. The opposing ends of the straight strip are welded together to form a continuous loop, and only then is the complex profile formed. This inversion eliminates the accessibility problem entirely, as welding occurs on flat, accessible surfaces rather than constrained bent sections.
Solution Approach 2:
The welding operation is performed as a preliminary action before the profile forming process. By completing the welding of opposing ends while the strip is still straight and accessible, the patent ensures weld quality is not compromised by subsequent bending operations that would create access difficulties.
2Adaptability or versatility
If the ring-shaped component is repeatedly removed and reinstalled for heat treatment and roller set changes, then different profiles can be formed, but manufacturing time and costs increase
Solution Approach 1:
The patent merges multiple profile forming operations into a single continuous pass through the roll forming machine. Multiple roller sets with different profiles are arranged in series along the production line, allowing the metal strip to receive sequential profile formations without being removed or reinstalled. This combining of operations eliminates downtime and maintains continuous production flow.
Solution Approach 2:
The production process maintains continuity by keeping the metal strip moving continuously through the roll forming machine. The strip passes through multiple roller sets in sequence, receiving different profile formations without interruption, removal, or reinstallation. This continuous action eliminates idle time and maximizes production efficiency.
3Shape
If the metal strip is bent to form a ring-shaped structure before profile addition, then the ring structure is established, but frequent removal and reinstallation is required for subsequent profiling
Solution Approach 1:
The patent inverts the conventional sequence by forming the ring structure through welding of straight strips before profile formation, rather than bending first. This allows profile forming to occur on straight, accessible material in a continuous process, eliminating the need for repeated removal and reinstallation that would reduce productivity.
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 enables the cost-effective and time-efficient manufacturing of ring components with complex profiles, eliminates the need for post-forming welding, and reduces the frequency of heat treatment and roller set changes, thereby improving manufacturing efficiency and reducing costs.
Implementation Method 1
a forming process, such as, a contour roll forming process or a vertical roll forming process, may be used to define a profile on a component
Implementation Method 2
The system may include a heating element configured to locally heat a portion of the ring component disposed between the at least two forming roller sets
Implementation Method 3
each forming roller set comprising an inner forming roller and an outer forming roller... upon an engagement with the ring component, each forming roller set is configured to form a profile
Data Source
AI summary
A system includes a plurality of forming roller sets comprising an inner forming roller and an outer forming roller, each inner forming roller rotatable about an inner forming roller axis, each outer forming roller rotatable about an outer forming roller axis, each forming roller set being adjustable between an engagement configuration and a disengagement configuration, each forming roller set forming a profile on the ring component based on a forming roller set profile of the forming roller set, the system also including an actuating unit which controls the engagement and a disengagement of the forming roller sets with the ring component.