Spiral Sheet Transitioning for Accurate Tubular Roll Forming
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Solution Overview
Problem
In spiral forming manufacturing, transitions between sheets used to form structures like wind turbine towers pose challenges in meeting manufacturing tolerances and efficient material use due to issues with dimples and errors during the rolling process.
Innovation Solution
The method involves controlling the relative orientation and shape of planar sheets and the position of a roll bender to curve the sheets into desired configurations, using a 'T'-shaped seam intersection to align and weld the sheets, reducing the likelihood of errors and improving dimensional tolerance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If sheets are continuously roll-formed into desired shapes, then productivity is improved, but manufacturing precision deteriorates due to dimples and errors during rolling
Solution Approach 1:
The sheets are pre-formed with specific edge configurations (mating edges, alignment edges, and nonlinear paths) before the rolling process. This preliminary preparation ensures that when the sheets are continuously roll-formed, the pre-established geometric relationships guide the forming process to maintain dimensional accuracy while preserving high productivity.
Solution Approach 2:
Different regions of the sheet are given different geometric properties: mating edges are designed to interface with specific features, alignment edges are configured for precise positioning, and nonlinear paths are created in specific areas. This localized differentiation allows the rolling process to maintain precision in critical areas while maintaining overall productivity.
2Ease of manufacture
If sheets are joined along spiral edges to form tubular structures, then ease of manufacture is improved, but manufacturing precision deteriorates at transitions between sheets
Solution Approach 1:
The sheets are pre-configured with mating edges and alignment edges that establish the correct geometric relationships before joining. The nonlinear paths are pre-formed to anticipate the spiral joining process, ensuring that when sheets are joined along spiral edges, the transitions maintain high precision without requiring complex adjustments during the joining process.
Solution Approach 2:
The alignment edges and mating edges act as intermediaries that facilitate precise joining. These specially designed edge features mediate between the spiral joining process and the final tubular structure, ensuring that transitions between sheets achieve high manufacturing precision while maintaining the ease of the spiral joining process.
3Manufacturing precision
If the curved configuration of stock material is controlled through transitions between sheets, then manufacturing precision is improved, but device complexity increases due to roll bender positioning control
Solution Approach 1:
The sheets are pre-configured with specific edge geometries and nonlinear paths that encode the desired curved configuration information. This preliminary preparation allows the roll bender to follow a predetermined path, reducing the complexity of real-time control while maintaining high manufacturing precision in the curved configuration.
Solution Approach 2:
The invention changes the geometric parameters of the sheets themselves (edge configurations, nonlinear paths) to embed the curvature information directly in the material. This shifts the control burden from the roll bender positioning system to the pre-formed sheet geometry, thereby reducing device complexity while maintaining manufacturing precision.
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 facilitates the formation of tubular structures with improved dimensional accuracy and efficient material use by minimizing errors and ensuring proper alignment of sheets, thus meeting manufacturing tolerances.
Implementation Method 1
controlling a position of a roll bender used to curve the planar form of the stock material into the curved configuration
Implementation Method 2
continuously joining the curved, roll-formed material along a spiral edge
Data Source
AI summary
Spiral forming devices, systems, and methods can be used to join edges of a of a stock material, in a curved configuration, along one or more joints to form tubular structures, such as conical and/or cylindrical structures (e.g., frusto-conical structures). A planar form of the stock material can be formed from a plurality planar sheets coupled to one another in an abutting relationship. By controlling relative orientation and shapes of the plurality of planar sheets forming the stock material and/or by controlling a position of a roll bender used to curve the planar form of the stock material into the curved configuration, the curved configuration of the stock material can be controlled through transitions between sheets to facilitate rolling the sheets to a desired diameter with a reduced likelihood of dimples or other errors and to facilitate fit up between adjacent sheets in the curved configuration.