Running Cutter Sheet Roll Forming for Curved Beams

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Solution Overview

Problem

In sheet roll forming methods, the cutting process often results in crushed cutting edges, dust, and noise, and may require stopping the roll forming process, leading to reduced productivity and product quality.

Innovation Solution

A sheet roll forming method that includes an uncoiling, straightening, piercing, sheet roll forming, and bending process, utilizing a running cutter synchronized with feeding speed for precise cutting and a round bender with adjustable rollers to form curved beams, eliminating the need for post-processing cutting and reducing environmental disturbances.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a cutting press is used to cut the shaped beam, then the cutting can be performed, but the cutting edge may be crushed and product quality deteriorates

Engineering Contradiction:

Improvecutting capabilityVSAvoidcutting edge quality

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent applies preliminary action by performing the blanking operation on the coil material before it enters the roll forming process. This means the material is cut to length while still in a flat, unformed state, avoiding the crushing problem that occurs when cutting already-formed shaped beams. The running cutter performs this preliminary cutting action upstream in the process sequence.

Inventive Principle:

Principle #10Preliminary action

2Ease of manufacture

If a wheel cutter is used for cutting, then the cutting can be performed, but dust and noise deteriorate the work environment

Engineering Contradiction:

Improvecutting capabilityVSAvoidwork environment quality

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the wheel cutter mechanical system with a running cutter system that uses a different cutting mechanism. The running cutter appears to use a shearing or guillotine-style cut rather than abrasive wheel cutting, which eliminates or significantly reduces dust generation and noise, thereby improving the work environment while maintaining cutting capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If the roll forming process is stopped during cutting, then the cutting can be performed, but productivity is reduced

Engineering Contradiction:

Improvecutting capabilityVSAvoidproduction continuity

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent implements continuity of useful action through the running cutter that moves synchronously with the coil material feed. The cutting operation occurs continuously as material passes through, rather than requiring the line to stop. The running cutter maintains a constant cutting speed matched to the material feed rate, enabling uninterrupted production flow and maintaining high productivity.

Inventive Principle:

Principle #20Continuity of useful action

Data Source

PatentUS10449591B2Sheet roll forming method, and running cutter and round bender applied thereto

Publication Date: 2019.10.22 SUNG WOO HITECH

AI summary

A sheet roll forming method includes an uncoiling step for uncoiling a coil by an uncoiler provided at a start of a process line, a straightening step for straightening the coil from the uncoiler to be a flat panel, a piercing step for forming holes for various purposes in the panel fed from the straightening step by a piercing press, a sheet roll forming step for cutting the panel to be a sheet with a predetermined dimension by a running cutter and for successively bending the cut sheet to be a shaped beam by a multi-stage roll forming unit, and a bending step for curvature forming the shaped beam to be a shaped product by a round bender.