Roll Bending Frame Control for Transition-Zone Curvature Accuracy
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Solution Overview
Problem
The roll bending process faces challenges in achieving dimensional accuracy and productivity due to arbitrary curvature values in the transition zone, which can result in design curvature mismatches.
Innovation Solution
A roll bending apparatus with a movable roll set frame and a bending frame featuring adjustable bending rolls, which rotate on the roll set frame to precisely control the curvature of the material in the transition zones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a bending roll rotates continuously during the roll bending process, then productivity is improved, but the curvature in the transition zone becomes arbitrary and dimensional accuracy deteriorates
Solution Approach 1:
The bending roll is designed to rotate dynamically rather than continuously. The rotation is activated only when the material enters the bending zone, and stopped when the material exits. This dynamic operation mode allows the bending roll to provide precise curvature control during the bending process while maintaining productivity by minimizing idle rotation time.
Solution Approach 2:
The system incorporates a control mechanism that monitors the material position and bending progress. Based on this feedback, the bending roll rotation is precisely timed - starting when needed and stopping when the bending is complete. This feedback control ensures that the curvature in the transition zone matches the design requirements while maintaining efficient production节奏.
2Manufacturing precision
If the bending roll is stopped to control curvature precisely, then dimensional accuracy is improved, but productivity deteriorates due to frequent stopping and starting
Solution Approach 1:
Instead of static stopping and starting, the bending roll operates in a dynamic manner - rotating only during the brief period when material passes through the bending zone. This dynamic approach eliminates the need for frequent complete stops, thereby maintaining production efficiency while achieving precise curvature control through timed rotation.
Solution Approach 2:
The bending roll operates periodically - rotating during the material passage and remaining stationary during idle periods. This periodic operation pattern ensures that the bending roll provides precise curvature control exactly when needed, while minimizing the time spent in non-productive states, thus balancing accuracy and 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
The solution improves both productivity and dimensional accuracy by allowing for precise adjustment of bending rolls during the roll bending process, ensuring that the material follows the desired shape and curvature.
Implementation Method 1
a screw bolt rotated by a motor member; a support block fixed to the moving frame and rotatably supporting the screw bolt; a moving block moving according to rotation of the screw bolt
Data Source
AI summary
The present invention provides a roll bending machine comprising: a roll set frame mounted to be movable; and a bending frame which has a plurality of bending rolls for bending material and in which, while rotating on the roll set frame, the positions of the plurality of bending rolls are controlled.