Roller Hemming Device Axial Transition Bending
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Solution Overview
Problem
Existing roller hemming devices often result in a wave-shaped flange due to the large circumferential ratio and small radius of curvature on the tapered surface of the preliminary bending roller, leading to interference with obstacles during regular bending, which can prevent proper bending processes.
Innovation Solution
A roller hemming device featuring a large diameter roller with a tapered surface for preliminary bending and a small diameter roller with a cylindrical surface for regular bending, where the small diameter roller is coaxially positioned and axially movable, allowing for smooth transition and avoidance of obstacles, ensuring both preliminary and regular bending can be performed effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a small diameter roller with a tapered surface is used for preliminary bending, then the roller can be accommodated in the regular bending roller, but the flange becomes wave-shaped due to large circumferential ratio and small radius of curvature
Solution Approach 1:
The bending process is segmented into two distinct stages: preliminary bending using a small diameter roller with tapered surface, and regular bending using a large diameter roller with cylindrical surface. This segmentation allows each roller to be optimized for its specific function, resolving the contradiction between compactness and surface quality.
Solution Approach 2:
The system dynamically switches between two rollers during the bending process. The small diameter roller is used first for preliminary bending, then the large diameter roller is engaged for regular bending. This dynamic transition allows the system to achieve both compact preliminary bending and high-quality final bending without interference from obstacles.
2Manufacturing precision
If a large diameter roller is used for regular bending, then the roller can accommodate the preliminary bending roller, but the roller interferes with obstacles such as protruding inner panels
Solution Approach 1:
The preliminary bending action is performed first using the small diameter roller to create initial curvature in the flange. This preliminary action prepares the workpiece for the subsequent regular bending while avoiding interference with obstacles that would block the larger roller.
Solution Approach 2:
The small diameter preliminary bending roller is nested within the large diameter regular bending roller. This nesting arrangement allows both rollers to coexist in the same space, with the small roller used first and then retracted to accommodate the large roller for the final bending operation.
3Volume of moving object
If a small radius of curvature is used on the tapered surface, then the roller fits in the regular bending roller, but the flange develops wave shape
Solution Approach 1:
Different regions of the bending process use different roller characteristics: the preliminary bending uses a small radius tapered surface appropriate for initial curvature, while the final regular bending uses a large radius cylindrical surface appropriate for smooth, wave-free finishing. Each stage applies the locally appropriate roller geometry.
Data Source
AI summary
A roller hemming device includes a large diameter roller having a large tapered surface and a small diameter roller having a small cylindrical surface. The small diameter roller is coaxially disposed with the large diameter roller. The small diameter roller and the large diameter roller enable to relatively move in an axial direction. The outer diameter of the small cylindrical surface is smaller than the minimum outer diameter of the large tapered surface.