Roll Forming Metal Frames for Modular Buildings
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Solution Overview
Problem
Current methods for manufacturing metal frames for building panels are inefficient, leading to increased processing time and costs, and do not ensure proper fitting for structural integrity and thermo-acoustic insulation.
Innovation Solution
A method involving a roll forming machine with specific molding shafts and support rollers to shape and cut galvanized steel frames into standardized components, reducing production time and costs while ensuring precise fitting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional forming processes are used to manufacture metal frames, then the manufacturing process can be completed, but the processing time increases and production efficiency decreases
Solution Approach 1:
The forming process is divided into multiple sequential stages, each handled by a dedicated forming die (first forming die, second forming die, third forming die). Each die performs a specific forming operation on the metal sheet, allowing parallel processing and reducing overall manufacturing time while maintaining precision.
Solution Approach 2:
The metal sheet undergoes preliminary forming operations before final assembly. The first forming die creates initial folds and shapes, the second forming die adds intermediate structures, and the third forming die completes the final configuration. This preliminary action ensures that all forming operations are completed in advance, reducing on-site assembly time.
2Ease of manufacture
If traditional forming processes are used, then manufacturing can proceed, but the conformation of metal sheet becomes more difficult and manufacturing complexity increases
Solution Approach 1:
The complex conformation process is segmented into three distinct forming stages, each handled by a specialized die. The first forming die handles initial folding, the second forming die manages intermediate shaping, and the third forming die completes the final conformation. This segmentation simplifies each individual step while achieving the overall complex shape.
Solution Approach 2:
Multiple forming dies act as intermediaries between the raw metal sheet and the final frame structure. Each die transforms the metal sheet incrementally, making the complex conformation process more manageable and easier to control at each stage.
3Manufacturing precision
If metal frames are not manufactured with precision, then production costs are reduced, but the structural integrity and fitting quality of buildings deteriorates
Solution Approach 1:
The precision forming process is divided into three controlled stages, each with dedicated forming dies that ensure accurate geometry at every step. This segmentation allows for quality control at each stage while maintaining overall manufacturing efficiency and frame precision.
Solution Approach 2:
Each forming die is designed with specific geometric parameters and forming forces optimized for its particular operation. The first forming die uses specific fold angles and pressures, the second forming die applies different parameters for intermediate shaping, and the third forming die uses optimized parameters for final precision conformation, ensuring high-quality results throughout.
Data Source
AI summary
A method of making a metal frame that will be used to make metal panels that will be used to fabricate modular metal buildings. Currently, the metal frames are manufactured through forming processes, however, the steps adopted end up generating greater difficulty in the conformation of the metal sheet, and, consequently, increase in the manufacturing time; as well as, they cannot achieve a higher degree of quality, which reduces the added value of the metal frame and can lead to greater difficulty of assembly, lower productivity and higher labor cost. The ideal method, comprises of modular plates (1) that are formed by galvanized sheet frames (2), which are manufactured by the method with 22 forming steps through a roll forming machine (7) with profiling rolls (9) with specific frames (10), and each step has a roll (9) and a set of support rollers (12) for each forming step.