Segmented Roller Tool for Sheet Metal Bent Deformation
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Solution Overview
Problem
Existing roller tools for sheet metal deformation are unable to create bent deformations due to limitations in generating tension and shearing forces.
Innovation Solution
A roller tool comprising multiple independently rotating roller discs that form a seamless profile, allowing differential rotation to generate bent deformations, and a counterbody with independently rotating rollers to facilitate linear deformation, along with a lubrication system for sustained operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single roller body is used for sheet deformation, then the structure is simple, but bent deformations cannot be generated
Solution Approach 1:
The roller body is divided into multiple independently rotating roller discs (at least three) that can rotate around the shaft independently of each other. This segmentation allows different roller discs to rotate at different speeds, enabling the generation of bent deformations while maintaining a relatively simple overall structure.
2Adaptability or versatility
If roller discs rotate at different speeds to create bent deformations, then bent deformations can be generated, but tension forces and shearing forces occur
Solution Approach 1:
The roller discs are designed to rotate dynamically at different speeds around the shaft, with the inner roller disc rotating more slowly than the outer roller disc. This dynamic differential rotation creates bent deformations while distributing forces more evenly, reducing the harmful tension and shearing forces that would occur with rigid differential mechanisms.
3Adaptability or versatility
If multiple roller discs are used to enable bent deformations, then versatility improves, but the structure becomes more complex
Solution Approach 1:
Multiple roller discs are merged into a single integrated roller body structure that shares a common shaft and support system. This combining approach allows the system to achieve bent deformation capability through the coordinated rotation of multiple discs while avoiding the complexity of completely separate deformation mechanisms.
4Manufacturing precision
If a seamless profile is formed by multiple roller discs, then bead quality improves, but manufacturing complexity increases
Solution Approach 1:
The roller body is segmented into multiple roller discs with outer surfaces that complete a surrounding profile when adjacent. This segmentation allows each disc to be manufactured separately with precise profile features, then assembled to form a seamless overall profile, improving bead quality while managing manufacturing complexity through modular construction.
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 the creation of bent deformations in sheet metal by allowing differential rotation of roller discs and counterbody rollers, ensuring consistent and seamless bead formation across straight and curved sections, with automated lubrication ensuring prolonged operation.
Implementation Method 1
The roller disc on the inside of the bend can then rotate more slowly than the roller disc on the outside of the bend so that tension forces and shearing forces which so far did not allow the generation of bent deformations with the known roller tools do no longer occur.
Implementation Method 2
the press roller and the counterbody together are guidable in a linear manner relative to a sheet to be processed which lies between them to create the deformation of the sheet
Implementation Method 3
A lubricating facility for lubricating the roller body and/or the counterbody facilitates an automated lubrication of the roller body and/or of the counterbody
Data Source
AI summary
A roller tool is used within a sheet deformation facility for the linear deformation of sheet metal. The roller tool comprises a press roller having a shaft and a roller body rolling around the same as well as a counterbody. The press roller and the counterbody can be jointly moved in a linear manner relative to a sheet positioned between them that is to be processed for performing the sheet metal deformation. The roller body has a plurality of roller discs which are adjacent to each other, which together form the section of the roller body that can be placed onto the sheet to be processed and which can rotate around the shaft independently of each other. The sheet deformation facility is furthermore provided with a roller tool support and a drive for pivoting the roller tool support around an axis perpendicular to the sheet that is to be processed.