Rolling Metal Strut Mounts with Pre-formed Flanges
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Solution Overview
Problem
Conventional methods for forming metal strut mounts are time-consuming and costly due to the need for multiple die presses and machines, resulting in inefficient manufacturing processes that require significant space and resources.
Innovation Solution
A rolling machine with a support, pair of rollers, and a mandrel with a C-shape cross-section is used to shape a metal sheet with pre-formed flanges into a metal strut mount, allowing for single-machine formation with improved part tolerances and circular strut openings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple die presses and machines are used to form metal strut mounts, then manufacturing precision can be achieved, but manufacturing time increases and productivity decreases
Solution Approach 1:
The patent combines multiple die press operations into a single rolling machine that performs all forming operations in one continuous rolling process. The rolling machine integrates the functions of multiple separate machines, allowing the metal sheet to be formed into the final strut mount configuration without traveling through multiple stations, thereby maintaining precision while dramatically improving productivity.
Solution Approach 2:
The metal sheet is prepared with pre-formed flanges before entering the rolling machine. This preliminary action allows the rolling process to focus solely on shaping the main body of the strut mount, reducing the number of operations required and enabling faster production while maintaining manufacturing precision.
2Manufacturing precision
If multiple die presses and machines are used to form metal strut mounts, then manufacturing precision can be achieved, but device complexity and floor space requirements increase
Solution Approach 1:
The patent consolidates multiple separate die press machines into a single rolling machine with integrated forming capabilities. This merging reduces device complexity by eliminating the need for multiple independent machines and their associated control systems, while maintaining manufacturing precision through the coordinated action of the rolling components.
Solution Approach 2:
The rolling machine is designed as a universal device that performs multiple forming operations that previously required different specialized machines. The single machine can execute all necessary forming steps to create the strut mount, reducing overall system complexity while preserving manufacturing precision through its multi-functional capabilities.
3Manufacturing precision
If multiple die presses and machines are used to form metal strut mounts, then manufacturing precision can be achieved, but manufacturing costs increase
Solution Approach 1:
The patent combines multiple expensive die press machines into a single rolling machine, reducing capital equipment costs and operational expenses. The consolidated machine requires less maintenance, consumes less energy, and reduces tooling costs while maintaining manufacturing precision through its integrated forming process.
Solution Approach 2:
This principle does not apply to this patent as there are no color changes or visual indicators involved in the manufacturing process.
4Productivity
If a single rolling machine is used to form metal strut mounts, then manufacturing time decreases and productivity increases, but achieving consistent part tolerances becomes more challenging
Solution Approach 1:
The metal sheet is pre-formed with flanges before entering the rolling machine, establishing consistent starting conditions for each part. This preliminary action ensures that variations in the rolling process do not propagate back to affect flange dimensions, allowing the single machine to maintain both high productivity and consistent tolerances across all parts.
Solution Approach 2:
The rolling machine incorporates control systems that monitor and adjust rolling parameters in real-time to maintain consistent part tolerances. Through feedback mechanisms, the machine compensates for material variations and wear, ensuring uniform quality across all produced parts while maintaining high production speed.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces manufacturing time and costs while producing more consistent and efficient metal strut mounts, enabling faster production and reduced operational complexity.
Implementation Method 1
The pair of rollers can then press the metal sheet down against the mandrel while the pair of flanges move towards one another to roll the metal into the shape of the strut mount
Implementation Method 2
press the metal sheet down against the mandrel while the pair of flanges move towards one another to roll the metal into the shape of the strut mount
Data Source
AI summary
The aspects of the present disclosure provide an apparatus for forming a metal strut mount having a C-shape cross-section and a pair of flanges extending therefrom and a method of forming a metal strut mount utilizing a rolling machine.