Robot Roller Hemming with Reference Surface Guidance
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Solution Overview
Problem
Existing robot roller hemming systems face issues with panel bending, wrinkling, or external bending due to inaccurate movement and insufficient pressure application during the hemming process, particularly in the first pass, which can lead to poor hem quality.
Innovation Solution
A hemming apparatus with a hemming die featuring an angle between the hemming bed and outer periphery ranging from 110 to 130 degrees, incorporating a roller with a chamfered surface that contacts a reference surface during the first pass to guide and apply increased pressure, ensuring precise folding of panel edges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a robot roller hemming system is used to automate the hemming process, then productivity increases, but manufacturing precision deteriorates due to inaccurate movement and insufficient pressure application
Solution Approach 1:
A reference surface is introduced as an intermediary element between the robot roller and the workpiece. The reference surface provides a stable geometric基准 that the roller can follow, ensuring consistent pressure application and accurate movement along the hemming path, thereby maintaining high manufacturing precision while using automated robotic equipment
Solution Approach 2:
The system adjusts operational parameters including the angle of the reference surface (110-130 degrees), roller position, and pressing force to optimize both automation performance and hemming quality. By dynamically controlling these parameters, the system achieves high productivity without sacrificing precision
2Productivity
If the robot moves the hemming roller with high speed to increase productivity, then manufacturing time decreases, but manufacturing precision deteriorates due to panel bending and wrinkling
Solution Approach 1:
The reference surface acts as a guide that constrains the roller's movement path and pressure application points. This intermediary structure ensures that even at high speeds, the roller applies force at the correct locations and angles, preventing panel bending and wrinkling while maintaining high hemming speed
Solution Approach 2:
The reference surface is pre-positioned and fixed before the hemming operation begins. This preliminary setup establishes the correct geometric relationship between the roller and workpiece, allowing the robot to move quickly without risking precision loss during the actual hemming process
3Manufacturing precision
If multiple passes are used to ensure proper folding and prevent defects, then manufacturing precision improves, but loss of time increases
Solution Approach 1:
The reference surface enables the roller to apply precise, controlled pressure in a single pass by providing a stable geometric基准. This eliminates the need for multiple corrective passes, as the first pass achieves the desired hem quality directly, thereby reducing total processing time while maintaining high precision
Solution Approach 2:
All necessary geometric constraints and pressure application points are pre-established by the reference surface before hemming begins. This preliminary configuration allows the robot to complete the entire hemming operation in one accurate pass, avoiding the time loss associated with multiple passes
Data Source
AI summary
A hemming apparatus having a hemming die that includes a seat configured to support a first panel and a second panel relative to one another; a hemming bed positioned between the seat and an outer periphery of the hemming die; and a reference surface between the hemming bed and outer periphery of the hemming device, wherein a robot is configured to move the roller about the outer periphery of the hemming die in a manner where the roller simultaneously contacts each of a first terminal edge of the first panel and the reference surface to fold the first terminal edge of the first panel over a second terminal edge of the second panel to create a flange that secures the first panel to the second panel.