Round Bar Forming Roll Adjustment Without Mold Disassembly
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Solution Overview
Problem
Existing devices for forming round bars into variable shapes require frequent disassembly and reassembly of mold frames and forming rolls to adjust passage holes for different diameters, leading to inefficiencies and potential breakages, and often result in incomplete forming at corners due to uneven surface dimensions.
Innovation Solution
A device with a main body featuring a circular plate portion, radial plate protrusions, and a turn gear system that allows for adjustable passage hole diameters and step formation in forming rolls, enabling precise control of forming processes without disassembly, and using slide molds with varying heights to prevent corner incompleteness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If forming rolls are fixed to prevent movement during drawing, then forming stability is improved, but adjustment of passage hole for different diameters requires disassembly and reassembly, increasing time consumption and risk of breakage
Solution Approach 1:
The mold frame is designed with movable adjusting components that allow the passage hole dimensions to be changed dynamically without disassembly. The forming rolls are mounted on adjustable supports that can be repositioned along guide rails, enabling continuous adjustment of the passage hole for different bar diameters while maintaining forming stability during operation
Solution Approach 2:
The mold frame is divided into modular sections with independent adjusting mechanisms. Each forming roll assembly can be adjusted separately, allowing partial reconfiguration without complete disassembly. This segmentation enables efficient adjustment of passage hole dimensions while maintaining the overall structural integrity and forming stability
Data Source
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AI summary
The present invention relates to a device for forming a round bar into variable shapes, comprising: a main body provided with a plate portion with a circular shape having a plate hole formed in a center thereof, having six plate protrusions protruding to the plate portion in a radial shape, and a turn gear connecting portion formed at an outer circumference surface of the plate portion; a round bar forming portion coupled between the plate protrusions and having six slide molds seated on the plate portion and forming rolls coupled to the respective slide molds to rotate; a turn gear having a donut shape where two main gears are connected to an outer surface thereof, provided with six turn gear protruding portions with a circular arc shape having different diameters from a center in an inner surface thereof, and disposed between the slide molds and the turn gear connecting portion; a main body cover connected to a front portion of the main body and provided with two deceleration motor connecting portions in a front side thereof; and a deceleration motor coupled to the deceleration motor connecting portions and having a pinion gear which is rotatably interlocked with the main gears at a driving axis. When forming round bars with different sizes, the size of the passage hole between forming rolls can be controlled efficiently. It is unnecessary to dissemble and re-assemble a mold frame and the forming rolls to adjust the passage hole, or replace with the mold frame with a passage hole meeting a size requirement, in order to adjust the interval of the passage hole, whenever the round bar having different diameters are formed. Thus, it may be possible to substantially reduce the time and cost for processing and prohibit a breakage of a component upon replacing the components, thereby remarkably ensuring reliability and durability.