Spacer Profile Bending Machine with Synchronous Support Arm
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Solution Overview
Problem
Existing methods for bending and calendering spacer profiles for insulating glazing units face challenges due to inertial, gravitational, and frictional forces, leading to reduced productivity and quality issues, particularly with the use of denser and more varied materials and larger sizes.
Innovation Solution
A machine and method utilizing an oscillating arm with a sliding carriage and clamps to maintain the formed frame portion, employing a polar system that synchronizes with the bending/calendering head to counteract these forces, ensuring stable frame production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the bending and calendering rate is increased to improve productivity, then the productivity increases, but the geometric and aesthetic regularity of the frame deteriorates due to inertial, gravitational, and frictional forces
Solution Approach 1:
The patent employs a support system that actively counteracts gravitational, inertial, and frictional forces acting on the profile during bending and calendering. The support means includes elements positioned to balance the weight of the profile and compensate for inertial effects during acceleration and deceleration, thereby maintaining geometric precision even at higher production speeds
Solution Approach 2:
The support means is designed to be dynamic rather than static, adjusting its position and force application in real-time during the bending and calendering process. This dynamic support system adapts to the changing forces (gravity, inertia, friction) as the profile moves through the forming head, ensuring consistent quality at increased speeds
2Manufacturing precision
If manual guiding is used to maintain quality, then the geometric regularity is improved, but the productivity decreases due to operator intervention between bends
Solution Approach 1:
The system implements self-service through automated support means that continuously guide and support the profile without operator intervention. The support system automatically adjusts to maintain the profile in the correct position throughout the bending and calendering process, eliminating the need for manual guiding while sustaining high production speeds
Solution Approach 2:
The patent introduces an intermediary support system between the profile and the forming head that acts as a mediator to maintain geometric regularity. This intermediary mechanism provides continuous support and guidance, replacing manual operator intervention with an automated system that operates at high speeds
3Manufacturing precision
If the profile is supported downstream of the bending head, then the geometric precision is improved, but the device complexity increases due to additional support mechanisms
Solution Approach 1:
The support means is designed with multi-functionality, serving multiple purposes: supporting the profile weight, counteracting inertial forces, maintaining geometric precision, and guiding the profile through the forming process. By consolidating these functions into a single integrated system rather than separate mechanisms, the patent reduces overall device complexity while achieving high precision
Solution Approach 2:
The patent merges the support functions into the existing bending and calendering head structure rather than adding completely separate support mechanisms. The support means is integrated with the forming head, combining multiple support and guidance functions into a unified system that minimizes additional complexity
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 significantly increases productivity from 120 frames/hour to approximately 200 frames/hour and enhances the geometric and aesthetic quality of the finished frames.
Implementation Method 1
the profile downstream of the bending/calendering head, which is subject to gravity, inertia and friction actions
Implementation Method 2
the profile downstream of the bending/calendering head, which is subject to gravity, inertia and friction actions
Implementation Method 3
the profile downstream of the bending/calendering head, which is subject to gravity, inertia and friction actions
Data Source
Figure 1A~1E
Figure 2a~2d
Figure 3
AI summary
An automatic machine for bending and/or calendering spacer profiles (1) comprising a carriage (300) provided with clamps and having an intermittent and bidirectional action for moving the spacer profile (1); a bending head (400) having jaws and a punch (402); a bending lever (403) directly downstream of the punch (402) that is provided with a rotary motion (ω); downstream of the bending head (400) there is arranged a mechanism (100) that mates with and retains a portion (2) of the spacer frame (3, 3', 3"), configured for supporting the portion (2) and movably guiding the portion (2) during all the operating steps of bending and/or calendering along a path that is synchronous with the geometric position described by the portion (2) of the spacer frame during the forming of the spacer frame (3, 3', 3") performed by the carriage (300) and by the bending head (400), in order to compensate the loads produced by the force of gravity and by inertial and friction reactions, wherein the mechanism (100) comprises at least one arm (101) rotatable by means of a motor (102) and a support/carriage (110) slidable along the arm (101), wherein the support/carriage (110) comprises clamps (117f, 117g) for selectively coupling and uncoupling the spacer frame (3, 3', 3") to the support/carriage (110).