Tiltable Shaping Rollers for Complex Sheet Metal Forming

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Solution Overview

Problem

Existing sheet metal forming machines are unable to form complex shapes due to limited adjustability and constraints in roller orientation, which restricts the formation of intricate geometries and waves in the material.

Innovation Solution

A sheet metal forming machine with coplanar drive rollers that are adjustable about the z-axis for varying material thickness and tiltable shaping rollers that are not constrained to a parallel orientation, allowing for independent adjustment of their ends to apply varying bending forces and form complex shapes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If shaping rollers are constrained to parallel orientation, then machine structure is simple, but ability to form complex shapes is limited

Engineering Contradiction:

Improveability to form complex shapesVSAvoidroller orientation constraints

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The shaping rollers are made dynamically adjustable in their orientation rather than being fixed in a parallel configuration. Each shaping roller can be independently tilted about the z-axis, allowing the machine to adapt to different complex shape requirements while maintaining a relatively simple structural framework.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The shaping roller system is segmented into independently controllable units. Each shaping roller can be tilted independently about the z-axis, allowing differential adjustment of bending forces across different sections of the sheet metal, thereby enabling formation of complex three-dimensional shapes.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If drive rollers are fixed in position, then machine structure is simple, but adaptability to varying material thickness is limited

Engineering Contradiction:

Improveaccommodation of varying material thicknessVSAvoiddrive roller adjustability

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The drive rollers are equipped with adjustable positioning mechanisms that allow them to move along the x-axis. This dynamic adjustability enables the machine to accommodate sheet metal of varying thicknesses by modifying the distance between drive rollers, while the overall structural framework remains relatively simple.

Inventive Principle:

Principle #15Dynamics

3Manufacturing precision

If shaping rollers are constrained to limited adjustment, then machine operation is simple, but manufacturing precision for complex shapes is limited

Engineering Contradiction:

Improveprecision control over bending forcesVSAvoidoperation complexity

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

The shaping rollers incorporate adjustable tilt mechanisms about the z-axis, providing precise control over bending forces applied to different sections of the sheet metal. This dynamic adjustment capability enables high manufacturing precision for complex three-dimensional shapes while maintaining straightforward operational procedures.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS11267026B2Sheet metal rolling machine for forming complex shapes

Publication Date: 2022.03.08 METAL DESIGN SYSTEMS INC

AI summary

First drive roller and second drive roller are coplanar and adjustable about an axis to increase or decrease the distance between the same to accommodate varying thicknesses in material. A first shaping roller and a second shaping roller that are also coplanar are provided with ends tiltable on an axis with respect to each other. While the first drive roller and the second drive roller remain parallel with respect to each other, the first shaping roller and the second shaping roller are not constrained in a parallel orientation, but rather can tilt with respect to each other to form sheet metal with complex shapes.