Segmented Bending Roller for Stamping Machine Tabs
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Solution Overview
Problem
Existing sheet metal working machines are limited in producing formings with varying widths and cannot efficiently create adjacent deformations like tabs without requiring specialized tools, and they risk damaging the workpiece by hitting the stationary bending roller.
Innovation Solution
The tool features a bending punch and roller segmented to reduce unnecessary punching area, allowing for multiple deformations in one stroke and preventing workpiece collision with the bending roller through adjustable spacer segments and ejectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single bending punch and bending roller are used, then the structure is simple, but only one deformation can be produced at a time and adjacent tabs cannot be formed
Solution Approach 1:
The bending punch is divided into multiple first bending segments (25) that can be independently positioned, and the bending roller is divided into multiple second bending segments (31'). Each segment can independently form a deformation, allowing multiple tabs to be created in a single stroke while maintaining manageable structural complexity through modular design.
Solution Approach 2:
The segmented bending tool is designed to perform multiple functions: it can form adjacent tabs, create deformations of different widths, and produce various shaping operations on plate-shaped workpieces using the same tool structure, eliminating the need for multiple specialized tools.
2Reliability
If the bending roller remains stationary, then the structure is simple, but the workpiece may hit the bending roller causing damage
Solution Approach 1:
The bending roller is transformed from a stationary component to a dynamic one that can rotate about its axis. This rotation is controlled by ejectors that pivot the second bending segments, allowing the workpiece to be lifted clear of the bending roller during formation and preventing damage while maintaining structural simplicity.
Solution Approach 2:
The ejectors are positioned to act on the actuating sections of the second bending segments before the workpiece completes its movement, preliminarily pivoting the bending segments to lift the workpiece clear of the bending roller and prevent potential collision damage.
3Loss of substance
If a full-length bending punch and roller are used, then the tool is robust, but large areas must be punched free creating material waste
Solution Approach 1:
Both the bending punch and bending roller are segmented into multiple independent sections that can be positioned only where deformations are required. This allows the tool to engage only the necessary portions of the workpiece, minimizing the area that needs to be punched free and reducing material waste while maintaining sufficient structural strength at the active deformation zones.
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
Enables efficient production of formings with different widths and spacings, reducing material waste and preventing workpiece damage by allowing for precise control over deformation positions and sizes.
Implementation Method 1
sections of a plate-shaped workpiece (10) are pressed by means of a bending punch (24) onto a bending roller (30), so that the sections are deformed in a bending manner
Implementation Method 2
a restoring element (49) acts on the second bending segments (31') or second spacer segments (32') in such a way that the bending roller (30) is sprung back into its initial position
Data Source
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AI summary
A tool for a punching machine (1), for forming at least one section of a plate-shaped workpiece (10), comprising a first tool part (21) and a second tool part (28), is provided. The first tool part (21) has a first device (22) for receiving it in a first tool holder (6) of the punching machine (1) and a bending punch (24) with a bending edge (34). The second tool part (28) has a second device (29) for receiving it in a second tool holder (5) of the punching machine (1) and a bending roller (30) that interacts with the bending punch (24) and is rotatable about a rotational axis (33) extending in the direction of the bending edge (34).The bending roller (30) has a sector-shaped recess (38) along the axis of rotation (33) with a bending leg (39) and a second leg (44) as well as an actuating section (40) which can be actuated during a relative movement of the bending punch (24) and the bending roller (30) in the form of a working stroke of the punching machine (1), so that the bending roller (30) can be deflected from a rest position during a forming process during a bending deformation of the workpiece (10) by the interaction of the bending punch (24) and the bending roller (30), wherein the bending roller (30) has several second bending segments (31', 31") in the direction of the axis of rotation (33).