Roll-Forming Machine With Laterally Displaceable Rollers
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Solution Overview
Problem
Conventional roll-forming machines are limited in producing beams with complex profiles, such as those needed for vehicle components like the beam above the windshield, which require bending in two planes and cannot achieve angles greater than 90 degrees, necessitating the use of molding techniques.
Innovation Solution
A roll-forming machine with frames that have laterally displaceable rollers, pivotable intermediate pieces, and vertically movable axle pins, allowing for extensive variation in roller positioning and orientation to form complex profiles, including twisted and double-bent shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional roll-forming machines with fixed roller positions are used, then the structure is simple and easy to manufacture, but the ability to produce complex profiles such as double-bent beams is limited
Solution Approach 1:
The patent implements dynamic adjustability by making the intermediate piece pivotable around a vertical axis and tiltable laterally, and by making the carriers of roller pairs laterally displaceable on the intermediate piece. This allows the roller positions and orientations to be dynamically changed during operation, enabling the production of various complex profiles including double-bent beams, while maintaining a relatively simple base structure.
Solution Approach 2:
The machine structure is segmented into independent movable components: the frame, the intermediate piece mounted on the frame, and the carriers of roller pairs mounted on the intermediate piece. Each segment can move independently, providing flexibility in positioning rollers to create complex profiles without requiring complete redesign of the entire machine structure.
2Adaptability or versatility
If molding technique is used to produce beams with complicated profiles, then complex shapes can be achieved, but the manufacturing process is less flexible and more complex compared to roll-forming
Solution Approach 1:
The roll-forming machine is transformed from a static device to a dynamic one with multiple degrees of freedom. The intermediate piece can be pivoted and tilted, and carriers can be laterally displaced, allowing continuous adjustment of roller configurations. This dynamic capability enables the production of complex profiles through progressive forming rather than requiring complex molding processes.
3Adaptability or versatility
If roller positions are made highly adjustable to produce varied profiles, then adaptability increases, but the device complexity and number of components increases
Solution Approach 1:
The patent adds lateral displacement capability to the carriers of roller pairs, introducing a new dimension of adjustment beyond simple rotation. The carriers can be moved laterally on the intermediate piece, providing an additional degree of freedom for positioning rollers without requiring complex multi-axis mechanisms for each individual roller.
Data Source
AI summary
A method is provided for roll-forming a sheet metal strip (35) by driving the sheet metal strip through a row of forming stations (17, 18) having pairs of rollers (19, 20; 29, 30) directed towards each other and both holding the sheet metal strip therebetween and forming the sheet metal strip over roller edges. In every second forming station (12), two angles (41, 42) are gradually formed and in every second forming station two other angles (43, 44) are gradually formed.