Tube Free-Bending Clamp Layout With Adjustable Deformation Zone
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Solution Overview
Problem
Existing free bending forming devices for metal tubes are limited to processing tubes with fixed dimensional specifications, requiring mold replacement for different outer diameters, which reduces efficiency and increases costs, and lack the ability to adjust the A value, affecting forming quality and application range.
Innovation Solution
A free bending forming device with a variable A value, utilizing a spherical bearing, clamping and fixing modules, and adjustable clamping mechanisms to clamp tubes of different diameters, allowing for 'one-die-for-multiple-tubes' processing by regulating the A value through radial and axial positions of arc-shaped limiting blocks and clamping support seats.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single device is used to process tubes with fixed dimensional specifications, then the device structure remains simple and stable, but the adaptability to process tubes with different outer diameters is poor
Solution Approach 1:
The patent implements adjustable clamping mechanisms that can dynamically adapt to different tube outer diameters. The clamping mechanisms include adjustable clamping arms and clamping force control, allowing the device to accommodate various tube sizes without requiring structural changes to the entire device, thus improving adaptability while maintaining relatively simple device structure
Solution Approach 2:
The patent enables adjustment of the A value (distance from rotation axis to tube center) and clamping force parameters to match different tube specifications. By changing these parameters rather than the physical structure, the device can process tubes with different outer diameters efficiently, resolving the contradiction between adaptability and structural complexity
2Productivity
If mold replacement is performed for different tube outer diameters, then the processing precision for each specific tube size is ensured, but the production efficiency decreases and manufacturing costs increase
Solution Approach 1:
The patent designs a universal bending device with adjustable clamping mechanisms that can process multiple tube outer diameters using a single device configuration. The universal clamping system eliminates the need for mold replacement while maintaining forming quality through parameter adjustment, thereby improving production efficiency without sacrificing manufacturing precision
Solution Approach 2:
The patent implements preliminary adjustment of clamping mechanisms and A value parameters before each bending operation. This preliminary configuration ensures that the device is optimally set for the specific tube dimensions, maintaining high forming quality while avoiding time-consuming mold replacement operations, thus resolving the contradiction between productivity and manufacturing precision
3Manufacturing precision
If the A value is fixed in the device design, then the device structure remains simple and stable, but the forming quality for tubes with different specifications cannot be optimized
Solution Approach 1:
The patent implements an adjustable A value mechanism that allows the distance from the rotation axis to the tube center to be dynamically changed according to different tube specifications. This dynamic adjustment capability enables optimization of forming quality for various tube sizes while maintaining relatively simple device structure through modular adjustment components
Solution Approach 2:
The patent enables change of the A value parameter to match different tube outer diameters and bending requirements. By making the A value adjustable rather than fixed, the device can optimize forming quality for different tube specifications without requiring complete structural redesign, thus resolving the contradiction between manufacturing precision and device complexity
Data Source
AI summary
Disclosed is a free bending forming device having a variable length of a bending deformation zone (defined as A value) capable of processing tubes of different outer diameters, including a bending forming module, clamping and fixing modules and a spherical bearing. Clamping mechanisms of the bending forming module and the clamping and fixing modules possess integrated radial freedom of motion and circumferential freedom of motion of clamping jaws, meeting the requirements for clamping tubes with different outer diameters. Positions of arc-shaped limiting blocks and clamping support seats are adjusted through the clamping and fixing modules to change a magnitude of A value during the forming process. According to the present disclosure, the efficient “one-die-for-multiple-tubes” processing of the free bending forming device for tubes is realized, saving the time and cost associated with die replacements.