Roll Bending Profiles via Dynamic Roller Alignment
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Solution Overview
Problem
Conventional roll-bending methods and devices are inadequate for producing three-dimensionally bent profiles with continuous processes, especially for irregular non-circular cross-sections, as they require sectioning of profiles, lead to surface damage, and are inefficient in avoiding twisting and surface marking.
Innovation Solution
A method and device for roll-bending profiles that involve translating and rotating sets of bending rollers in a specific time sequence and spatial alignment to achieve desired curved shapes without twisting, ensuring gentle guidance and maintaining surface quality, allowing for three-dimensional bending of profiles as a continuous process without prior cutting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional bending rollers are used to bend profiles three-dimensionally, then the profile can be bent, but the profile must be separated into sections and twisted, which increases production complexity and time
Solution Approach 1:
The bending device employs dynamically adjustable bending rollers that can be positioned and oriented in multiple directions. The rollers are mounted on adjustable arms that can be moved along the profile length and angled to create complex three-dimensional bending paths, eliminating the need for section separation and twisting operations
Solution Approach 2:
The invention extends conventional two-dimensional bending by adding a third spatial dimension through adjustable roller orientation. The bending rollers can be angled relative to the profile axis and positioned at different heights, enabling spatial curves and helical bends to be created in a single continuous operation
2Productivity
If powered drive and bending rollers are used to bend the profile, then the bending operation is efficient, but visible marks are left on the outer surface of the profile
Solution Approach 1:
A polished guide surface is introduced as an intermediary element between the powered drive rollers and the profile. This smooth surface guides the profile through the bending zone without direct contact from the drive rollers, preventing surface marks while the rollers efficiently bend the profile through controlled pressure
Solution Approach 2:
The invention replaces direct mechanical contact from powered rollers with a friction-based guide surface system. The profile is driven by friction against the smooth guide surface rather than direct roller contact, eliminating visible marks while maintaining bending efficiency through controlled mechanical pressure from positioned rollers
3Shape
If the profile is twisted during bending to achieve three-dimensional shape, then complex shapes can be formed, but irregular non-circular cross-sections are adversely affected by crushing
Solution Approach 1:
The bending device applies localized support and pressure through individually adjustable rollers positioned at specific locations along the profile. Each roller can be independently positioned to support particular cross-sectional features, preventing crushing of irregular shapes while enabling three-dimensional bending through targeted local forces
Solution Approach 2:
The adjustable roller positions and orientations allow the device to dynamically adapt to different cross-sectional geometries. The rollers can be repositioned along the profile length and angled to match the specific shape requirements, maintaining cross-sectional integrity while creating complex three-dimensional curves
4Adaptability or versatility
If sections of the profile are separated beforehand for three-dimensional bending, then the bending operation can be performed, but the continuous production process is interrupted
Solution Approach 1:
The bending device is designed to handle continuous profiles without interruption. The adjustable rollers can be positioned along the entire length of the profile, and the device accommodates continuous feeding and bending operations, maintaining uninterrupted production flow while achieving complex three-dimensional shapes
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
Enables economical, labor-saving, and material-saving production of dimensionally accurate bent profiles with undamaged surfaces, avoiding the limitations of conventional methods such as twisting and surface marking, and allowing for flexible bending of non-round profiles.
Implementation Method 1
moving the second set of bending rollers (5) relative to the first set of bending rollers (4) in such a way that the second set of bending rollers (5) along at least a first spatial direction (11) and one to this non-parallel second spatial direction (14) and rotated about at least a first axis of rotation (12) and a second axis of rotation (15) non-parallel thereto, whereby the profile (1) about a first bending axis (13) and about a bending axis (13') non-parallel second bending axis (16) is bent
Data Source
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AI summary
The method involves moving a bending roller set (5) relative to another bending roller set (4) such that the former roller set is translated along spatial directions (11, 14) and rotates around rotational axes (12, 15) during inserting and guiding a profile (1). The profile is bent around bending axes. A translation (T1) and rotations (R1, R2) of the former roller set are performed temporally and simultaneously and/or in a preset sequence temporally offset relative to each other. An armoring is partially embedded in a plastic material. Independent claims are also included for the following: (1) a profile (2) a method for manufacturing a bent profiled workpiece by an extrusion and roll bending line (3) a bent profiled workpiece (4) a device for roll bending of a profile (5) an extrusion and roll bending line.