Sequential Lead Bending Rollers for Uniform Component Forming
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Solution Overview
Problem
Existing methods for bending leads of lead components often result in uneven bending and excessive stress on the components due to simultaneous bending of multiple leads at the same time.
Innovation Solution
A bending device and method that bends multiple leads of a lead component one by one in the same direction at different timings, utilizing a tape feeder with bending rollers arranged at different heights to distribute the bending load and reduce reaction forces on the component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple leads are bent simultaneously at the same time, then the bending process is completed quickly, but uneven bending and excessive stress occur on the component
Solution Approach 1:
The bending device divides the simultaneous bending action into sequential segments, where each lead is bent individually by separate bending rollers at different positions. The leads are bent one by one in sequence rather than all at once, which maintains productivity while ensuring uniform bending for each lead.
2Productivity
If multiple leads are bent simultaneously at the same time, then the bending process is completed quickly, but excessive stress and component damage occur
Solution Approach 1:
The bending load is segmented and applied sequentially to each lead rather than simultaneously to all leads. This distribution of bending actions over time reduces the peak stress on the component body, preventing damage while maintaining efficient production.
Solution Approach 2:
The bending device applies preliminary bending actions to individual leads in sequence before completing the full bending process. By bending leads one by one in a predetermined sequence, the component is gradually deformed without experiencing excessive instantaneous stress.
3Device complexity
If bending rollers are arranged at the same position, then the device structure is simple, but uneven bending occurs
Solution Approach 1:
The bending rollers are arranged in the vertical dimension at different heights rather than at the same horizontal position. This vertical stacking of bending rollers at different elevations allows each roller to bend a different lead sequentially, achieving uniform bending while maintaining a compact and relatively simple device structure.
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 allows for appropriate bending of leads, reducing the risk of component damage by distributing the bending load and simplifying the bending process, while also reducing costs through a simplified structure.
Implementation Method 1
A bending device and method that bends multiple leads of a lead component one by one in the same direction at different timings, utilizing a tape feeder with bending rollers arranged at different heights to distribute the bending load and reduce reaction forces on the component.
Data Source
AI summary
A bending device to bend leads of a component one by one in the same direction at different timings. The bending device including a support block below the component that is movable in a vertical direction; a pair of support members fixed to the support block, the pair of support members contacting and supporting the leads of the component from below; a pair of clamp arms swingably held to the support block, the pair of clamp arms contacting and clamping the leads of the component from above; and a pair of bending rollers arranged above the leads of the component that bend the leads at the different timings.