Three-Punch Sheet Metal Bending Machine with Adjustable Die Width
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Solution Overview
Problem
Conventional bending machines with two lower bending punches coupled in a pivoting mechanism can only bend sheet metal legs symmetrically, posing safety risks and limiting flexibility, especially with large workpieces, and cannot adjust the die width or minimize surface damage during the bending process.
Innovation Solution
A bending machine with at least three bending punches, each with parallel working edges, where the second punch has three degrees of freedom and the third punch has rotational and translational freedom, allowing for flexible path curves that minimize relative movement and energy input, enabling one leg to remain in the starting plane and adjusting the die width.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If two lower bending punches are coupled in a pivoting mechanism, then both legs of the sheet metal are bent up symmetrically, but this creates safety risks and limits flexibility for large workpieces
Solution Approach 1:
The bending machine divides the bending function into three independent bending punches instead of two coupled punches. Each bending punch can be independently controlled, allowing one leg to remain stationary while the other is bent, thus eliminating the safety hazard of both legs swinging open simultaneously while maintaining precise control over the bending process
Solution Approach 2:
The invention intentionally creates an asymmetric bending configuration where one bending leg remains in the starting plane (stationary) while the other leg is bent. This asymmetric approach resolves the safety issue by preventing both legs from moving, while still achieving the desired bending function with improved operator safety
2Device complexity
If two bending punches are pivotally mounted on a common axis, then the bending process is simplified, but the distance between bending punches cannot be adjusted to change die width
Solution Approach 1:
The bending punches are designed with dynamic positioning capabilities, allowing their positions to be adjusted along the sheet metal width direction. This enables the die width to be changed by repositioning the bending punches, providing versatility for different workpiece sizes while maintaining the simplicity of the pivoting mounting mechanism
Solution Approach 2:
The bending machine is designed with universal bending punches that can be positioned at different locations to accommodate various die widths and workpiece sizes. The same bending punch structure serves multiple functions by being movable along the width direction, eliminating the need for dedicated tools for different bending configurations
3Productivity
If conventional bending processes are used, then the bending function is achieved, but surface damage occurs and energy input is high due to large relative movement
Solution Approach 1:
The bending process is designed to minimize relative movement between the bending punch and the sheet metal surface from the beginning of the operation. By positioning the bending punch optimally and controlling its movement path, the method reduces friction and rubbing that cause surface damage, while still achieving the required bending function efficiently
Data Source
Figure 1~3
Figure 4a~5e
Figure 6~8
AI summary
The invention relates to a bending machine (1) for bending a sheet metal workpiece (2), comprising at least three bending punches (4, 5, 6) which respectively have working edges (7, 8, 9) which are aligned parallel to each other. With respect to an outlet plane (3), on which a bending section (10) of the sheet metal workpiece (2) lies, the third bending punch (6) is positioned on one side of the first and the second bending punch (4, 5) and on the opposite side of the outlet plane (3). The working edge (9) of the third bending punch (6) can be adjusted between the working edges (7, 8) of the first and second bending punches (4, 5). The third bending punch (6) comprises at least one rotary and one translatory degree of freedom in a reference plane oriented at a right-angle to the working edges (7, 8, 9). The second bending punch (5) comprises three degrees of freedom in the reference plane (19).