Tank Inner Rib Forming Without a Complex Inner Mandrel
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing gas or liquid tanks with internal profiles are economically inefficient, particularly for larger diameters, as they require complex and costly inner mandrels for forming both internal and external profiles.
Innovation Solution
A method involving a rotatably supported profiling roller that forms an internal profile with longitudinal ribs on the internal side of a drum-shaped circumferential wall in a non-cutting manner, allowing for precise meshing without the need for a matching inner mandrel, with the option to synchronize workpiece and roller rotation for efficient deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a complex inner mandrel is used to form both internal and external profiles, then the internal profile can be formed precisely, but the device complexity and manufacturing cost increase significantly
Solution Approach 1:
The forming process is segmented into two independent operations: first forming the external profile, then forming the internal profile using a separate profiling roller. This eliminates the need for a complex inner mandrel that must simultaneously match both internal and external profiles, reducing device complexity while maintaining precision.
Solution Approach 2:
Instead of forming the internal profile from the outside using a complex inner mandrel, the invention inverts the approach by forming the internal profile from the inside using a profiling roller that matches only the internal contour. This inversion simplifies the forming tool while achieving the same precision.
2Manufacturing precision
If a profiled inner mandrel is used for forming, then the internal profile is formed, but the external contour of the workpiece is unavoidably deformed
Solution Approach 1:
The forming operations are separated into distinct steps: external profiling followed by internal profiling. The internal profiling roller is designed to match only the internal contour, not the external contour, allowing internal profile formation without deforming the external shape.
Solution Approach 2:
The profiling roller is designed with local quality - its surface profile matches only the internal contour requirements. This localized matching allows the roller to form the internal profile precisely while leaving the external contour unaffected, as the roller does not contact or conform to the external surface.
3Manufacturing precision
If an inner mandrel with matching counter-profile is produced, then precise internal and external profiles are achieved, but the manufacturing cost increases for larger diameters
Solution Approach 1:
The invention extracts the requirement for a complex counter-profile from the inner mandrel design. By using a profiling roller that matches only the internal contour, the counter-profile requirement is eliminated, significantly reducing manufacturing cost for large-diameter workpieces while maintaining precision.
Solution Approach 2:
The profiling roller is a simpler, more economical forming tool compared to a complex inner mandrel. It can be easily manufactured and replaced if needed, making it a cost-effective solution for producing large-diameter tanks with precise internal profiles.
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 production of larger, thin-walled gas or liquid tanks with internal longitudinal ribs, providing structural reinforcement while maintaining a stable external profile, thus achieving efficient and cost-effective manufacturing.
Implementation Method 1
the at least one profiling roller is fed to an internal side of the circumferential wall and that the at least one profiling roller circulates relative to the internal side of the circumferential wall, wherein the internal profile is formed in a non-cutting manner
Data Source
AI summary
The invention relates to a method for shaping a workpiece having a drum-type peripheral wall, on the inner face of which an inner profile featuring longitudinal ribs is formed by feeding at least one profiling roll to said inner face. According to the invention, at least one rotatably mounted profiling roll is fed to an inner face of the peripheral wall of the workpiece, and said at least one profiling roll rotates relative to the inner face of the peripheral wall such that the inner profile is formed in the inner face in a non-cutting manner.