Triangulated Sheet Metal Lofting with Adjustable Bend Zones
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for creating transitional sheet metal shapes are inefficient, as they require manual triangulation and lack flexibility in bend line adjustment, leading to inaccurate and time-consuming manufacturing processes, especially when converting smooth designs into manufacturable patterns.
Innovation Solution
A computer-implemented graphics program that allows users to create simple profiles, automatically generate triangulated shapes, and adjust bend zones to reflect the manufacturing process, producing accurate manufacturing data for numerical control devices, including bend line positions and angles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If smooth transitions are used in design, then ease of design is improved, but manufacturing accuracy deteriorates
Solution Approach 1:
The smooth transitional surface is segmented into multiple planar facets by automatically generating triangulation networks. This divides the continuous smooth surface into discrete manufacturing zones that can be accurately fabricated using standard bend operations, while maintaining the overall transitional shape.
Solution Approach 2:
The patent introduces an intermediary computational process that acts as a bridge between the smooth design model and the triangulated manufacturing model. This intermediary automatically generates the triangulation network and calculates bend parameters, eliminating the need for manual intervention while ensuring manufacturing accuracy.
2Manufacturing precision
If manual triangulation is performed, then manufacturing accuracy is improved, but productivity deteriorates
Solution Approach 1:
The system performs self-service by automatically generating triangulation networks and calculating all necessary bend parameters without requiring manual intervention. The software autonomously processes the smooth design model, generates the manufacturable triangulated model, and produces flat pattern layouts, eliminating time-consuming manual operations.
Solution Approach 2:
The patent replaces the manual mechanical process of triangulation with an automated computational system. The software algorithmically generates the triangulation network and calculates bend parameters, substituting human labor and manual calculation with automated digital processing that is both faster and more accurate.
3Ease of manufacture
If cosmetic bend lines are used, then ease of manufacture is improved, but manufacturing precision deteriorates
Solution Approach 1:
The system transitions from static cosmetic bend lines to dynamic, adjustable bend zones. Each bend zone can be independently configured with specific parameters such as bend radius, angle, and position, allowing the model to adapt to actual manufacturing requirements while maintaining ease of manufacture through automated generation.
4Manufacturing precision
If triangulated shapes are manually created, then manufacturing precision is improved, but loss of time increases
Solution Approach 1:
The system performs preliminary action by automatically generating the triangulation network and calculating bend parameters before the actual manufacturing process. This pre-computation ensures manufacturing precision is built into the model from the outset, eliminating the need for time-consuming manual adjustments during production setup.
Data Source
AI summary
A method, apparatus, and article of manufacture provide the ability to generate a lofted sheet metal model. User input is accepted that obtains two input profiles. A triangulated lofted shape is generated that transitions between the two profiles. The triangulated lofted shape is adjusted to reflect a manufacturing process. A manufacturable lofted sheet metal shape is then generated based on the adjusted triangulated lofted shape.