Roll Forming System Synchronized Stretch Bending Thick Beams
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Solution Overview
Problem
Conventional roll forming systems struggle to manufacture shaped beams with thicknesses greater than 50 mm, as they often result in deformation and buckling due to inadequate curvature bending, requiring a synchronized stretch bending process that is challenging to integrate with the forming speed.
Innovation Solution
A roll forming system and method that incorporates a bending unit with synchronizing, clamping, position conversion, cutting, and bending means to simultaneously perform cutting and stretch bending in sync with the forming speed, using a cutting wheel and stretch bending tool to achieve the desired curvature without prior cutting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional roll forming system is used for shaped beams with thickness greater than 50 mm, then the beam can be manufactured, but deformation and buckling occur at the inner surface of curvature
Solution Approach 1:
The invention performs cutting and stretch bending operations after roll forming but before final assembly. The stretch bending unit applies preliminary deformation control to thick beams (greater than 50 mm) by stretching and bending them in a controlled manner, preventing buckling at the inner surface of curvature that would occur with conventional post-forming bending operations.
2Manufacturing precision
If stretch bending method is applied to conventional roll forming system, then thick beams can be formed with predetermined curvature, but process speed synchronization becomes challenging
Solution Approach 1:
The invention incorporates a control unit that receives position information from the roll forming unit and uses this feedback to synchronize the stretch bending unit's operations with the forming speed. This closed-loop control ensures that the stretch bending process maintains predetermined curvature accuracy while operating at synchronized process speeds with the roll forming unit.
3Ease of manufacture
If cutting is performed before stretch bending in conventional system, then process sequence is maintained, but integration with roll forming speed becomes complex
Solution Approach 1:
The invention merges the cutting unit and stretch bending unit into a single integrated system that operates after roll forming. The control unit coordinates both cutting and stretch bending operations simultaneously, maintaining process sequence simplicity while reducing system integration complexity compared to separate pre-cutting and post-forming operations in conventional systems.
Data Source
AI summary
A roll forming system and a roll forming method are disclosed. The roll forming system according to an exemplary embodiment of the present invention includes a bending unit provided with synchronizing means moving a synchronizing table in keeping pace with a forming speed of a shaped beam along a process line, clamping means clamping both sides of the shaped beam, position conversion means converting a position of the shaped beam between a cutting position and a bending position, cutting means cutting one side of the shaped beam by a cutting wheel, and a bending means stretch-bending the shaped beam to have a predetermined curvature.