Roll-Formed Intermediate Profiles for Higher Throughput Splitting
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Solution Overview
Problem
Existing roll forming processes are complex, expensive, and have limited throughput due to the need for high forces, which restricts the efficiency of producing profile end products from metal flat products.
Innovation Solution
The process involves forming an intermediate profile product through roll forming and then dividing it into multiple end profile products, reducing cycle times and allowing for increased throughput by combining several work steps, with the use of symmetrical cross-sections to reduce component stresses and roller loading, and employing cutting rollers to achieve precise and efficient separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high forces are used for roll forming, then the desired profile shape is achieved, but the throughput is limited and the device complexity increases
Solution Approach 1:
The profile production process is segmented into two stages: first producing an intermediate profile product with the complete cross-sectional shape, then dividing it into multiple end profile products. This segmentation allows the roll forming process to focus on creating the complex shape once, while the division step multiplies output without requiring additional high-force forming operations.
Solution Approach 2:
The intermediate profile product is formed in advance with the complete cross-section geometry, including features that will later be divided. This preliminary action of creating the full profile shape once allows subsequent division into multiple products without repeating the complex forming process, thereby increasing throughput while maintaining manufacturing precision.
2Manufacturing precision
If multiple profile end products are produced separately, then each product meets specifications, but the cycle time is long and productivity is low
Solution Approach 1:
Multiple profile end products are merged into a single intermediate profile product during the roll forming process. By forming one intermediate product that contains the geometry for multiple end products, the cycle time is reduced significantly compared to producing each end product separately through the entire roll forming process.
Solution Approach 2:
The intermediate profile product is subsequently segmented into multiple end profile products through a dividing process. This segmentation step occurs after the time-consuming roll forming is complete, allowing multiple finished products to be obtained from a single forming cycle, thereby reducing overall cycle time while maintaining specification compliance.
3Stability of the object's composition
If symmetrical intermediate profile products are used, then component stresses are reduced and roller loading is decreased, but the design flexibility is limited
Solution Approach 1:
While the intermediate profile product itself is designed with symmetry to reduce stresses and roller loading, the method accommodates asymmetric end profile products through the division process. The symmetric intermediate profile is configured so that when divided, it produces the required asymmetric end products, thus maintaining design flexibility while benefiting from the mechanical advantages of symmetry during forming.
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 significantly increases throughput by reducing cycle times by half, allows for precise and cost-effective production of profile end products with high flexural rigidity, and reduces the risk of corrosion by protecting uncoated edges, while also enabling flexible production and packaging strategies.
Implementation Method 1
the flat metal product comes into contact with the burnishing rollers in such a way that the specialist metal product is deformed at least in sections through contact with the burnishing rollers
Data Source
Figure 1
Figure 2A
Figure 2B~2C
AI summary
A rolling process for producing profile end products (11, 11') from a flat metal product (8) by means of roll forming is described and illustrated. In order to achieve a higher throughput without disproportionate effort, it is provided that the flat metal product (8) is transported in a rolling direction (RR) along a plurality of rolling rolls (3) arranged one behind the other, that the flat metal product (8) comes into contact with the rolling rolls (3) in such a way that the flat metal product (8) is formed at least section by section by the contact with the rolling rolls (3), that the flat metal product (8) is gradually formed into an intermediate profile product (10, 10') by the contact with the rolling rolls (3), and that the intermediate profile product (10, 10') is divided longitudinally into at least two final profile products (11, 11').