Roller Hemming System for Vehicle Panels Using Interchangeable Dies
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Solution Overview
Problem
Conventional roller hemming systems for vehicle panels require expensive molds and complex equipment setups, making it difficult to efficiently produce various vehicle models, leading to high initial investment costs and reduced productivity.
Innovation Solution
A roller hemming system utilizing a marriage jig, clamping pad, transfer rails, hemming dies, and hemming robots with interchangeable dies, allowing for high-speed hemming of inner and outer panels of different vehicle models without the need for specific molds for each model, using a robot-based process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a press type device with molds is used for hemming, then hemming quality is improved, but initial investment cost and device complexity increase significantly
Solution Approach 1:
The patent replaces the conventional press type mechanical hemming system with a roller-based mechanical system. Instead of using complex press molds that require high initial investment, the invention uses rollers with hemming tools that can be easily exchanged, thereby reducing device complexity and initial cost while maintaining hemming quality through the rolling action and clamping mechanism.
Solution Approach 2:
The patent creates a universal hemming system where the same roller hemming apparatus can process multiple vehicle panel types by simply exchanging the hemming tools on the rollers. This multi-functional design eliminates the need for dedicated press molds for each panel type, reducing both device complexity and initial investment while preserving manufacturing precision across different applications.
2Manufacturing precision
If press type devices with molds are used for hemming, then hemming quality is improved, but productivity decreases due to mold replacement time
Solution Approach 1:
The patent introduces dynamic tool exchange capability where hemming tools on rollers can be quickly replaced during production. Unlike static press molds that require complete mold changes, the roller system allows for rapid tool exchange, maintaining hemming quality while significantly reducing downtime and improving overall productivity through dynamic adaptability.
Solution Approach 2:
The patent prepares multiple hemming tools in advance that can be quickly swapped on the roller system. This preliminary preparation of interchangeable tools ensures that when a tool needs replacement, the changeover is minimal, thus maintaining both hemming quality and high productivity without the lengthy mold replacement processes of conventional press systems.
3Productivity
If roller hemming method is used, then productivity is improved, but initial investment and equipment complexity increase
Solution Approach 1:
The patent segments the roller hemming system into modular components where each roller can be independently equipped with specific hemming tools. This segmentation allows the system to achieve high productivity through automated roller operation while reducing overall equipment complexity by breaking down the system into manageable, interchangeable modules rather than requiring a completely complex automated press line.
4Manufacturing precision
If multiple specific molds are manufactured for various vehicle models, then hemming quality for each model is improved, but initial investment cost increases
Solution Approach 1:
The patent creates a universal roller hemming platform that can process multiple vehicle models by exchanging tools on the rollers rather than requiring dedicated molds for each model. This multi-functional approach maintains hemming quality for each specific vehicle model while dramatically reducing the quantity of expensive mold components needed, thereby lowering initial investment costs.
Solution Approach 2:
The patent uses standardized roller components that can be replicated and exchanged across different vehicle model productions. Instead of investing in multiple unique expensive molds, the system uses copyable, interchangeable roller tools that maintain consistent hemming quality across different models while reducing the total investment through component standardization and reusability.
Data Source
AI summary
Disclosed is a roller hemming system for panels of a vehicle that may include: a marriage jig adapted to load thereon a part having an outer panel and an inner panel joined together; a clamping pad releasably mounted at a front end of an arm of a first handling robot, and adapted to clamp the part loaded on the marriage jig by a plurality of clamping means; a plurality of transfer rails adapted to intersect with each other at a center; a plurality of hemming dies, each being disposed on a predetermined transfer rail, being adapted to reciprocate on the transfer rail between the center and an initial position, and being adapted to receive thereon the part clamped by the clamping pad; and a plurality of hemming robots being disposed corresponding to each hemming die and provided with a hemming roller unit adapted to hem an edge of the part.