Roll-Forming Curvature Control for Variable-Width Arc Parts
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Solution Overview
Problem
Conventional roll forming devices fail to produce arc-shaped roll-formed parts with specific curvature configurations, such as an outer contour with a constant curvature and an inner contour with varying curvature, or vice versa, when dealing with workpieces of varying widths, as they lack effective roll control methods for achieving desired shapes.
Innovation Solution
A roll-formed part production device and method that utilize a transfer roll, support roll, and bending roll, with a roll driver and circuitry to adjust the rolls' movement based on the workpiece's width dimension and position, allowing for precise control of the outer and inner contours' curvatures through a combination of contact movement and origin shift, enabling the production of arc-shaped parts with predetermined curvature configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional roll forming devices are used to produce arc-shaped parts with varying width, then the workpiece can be formed with varying width, but the outer and inner contours cannot achieve precise predetermined curvature configurations
Solution Approach 1:
The patent implements dynamic roll control where the positions of multiple rolls (transfer roll, support rolls, bending rolls) are adjusted in real-time based on the workpiece position and width variations. The control system calculates required roll positions dynamically to maintain precise curvature control throughout the forming process, transforming static roll positions into dynamic adjustable positions that adapt to varying workpiece geometries.
Solution Approach 2:
The system changes multiple parameters simultaneously including roll positions, workpiece transfer speed, and forming forces to achieve desired curvature configurations. The control method adjusts these parameters based on real-time workpiece width measurements and position data, enabling precise control of both outer and inner contour curvatures even as workpiece width varies along its length.
2Adaptability or versatility
If the workpiece width varies in the longitudinal direction, then complex geometries can be formed, but conventional bending techniques cannot achieve the desired outer and inner contour curvatures
Solution Approach 1:
The patent divides the workpiece into multiple segments along its longitudinal direction, with each segment having specific width characteristics. The control system processes each segment independently, calculating the appropriate roll positions and forming parameters for that specific segment. This segmentation approach allows the system to handle varying width profiles while maintaining precise curvature control for each individual segment.
Solution Approach 2:
The system applies local quality control by adjusting roll positions and forming parameters specifically for each workpiece segment based on its local width characteristics. Rather than using uniform forming parameters throughout, the control method tailors the forming conditions to match the local geometry requirements, enabling precise curvature control at each position along the workpiece length.
3Manufacturing precision
If multiple rolls are used to control curvature, then precise shape control is achieved, but the coordination of roll movements becomes complex
Solution Approach 1:
The patent implements a feedback control system that continuously monitors workpiece position, width variations, and roll positions. Based on this feedback information, the control method calculates and adjusts the optimal positions for all rolls in real-time. This closed-loop feedback mechanism simplifies the coordination complexity by automatically determining the required roll configurations based on actual workpiece conditions rather than requiring manual coordination of multiple rolls.
Data Source
AI summary
A device and method for producing an arc-shaped roll-formed part having an outer contour with a predetermined constant curvature and an inner contour with a varying curvature, having an outer contour with a varying curvature and an inner contour with a predetermined constant curvature, or having an outer contour with a varying curvature and an inner contour with a varying curvature. Circuitry obtains a third amount of movement corresponding to a sum of first and second amounts of movement of a bending roll as an amount by which the bending roll moves in a width direction during roll bending.