Integrated Tube Bending and Notching for Precise Alignment
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Solution Overview
Problem
Conventional tube processing systems require separate devices for bending and notching, leading to accuracy and precision issues, increased costs, reduced processing speed, and space inefficiency due to the need for multiple machines and their supports.
Innovation Solution
A single machine system that integrates both bending and notching capabilities, featuring a cutting head and positioning system for notching, and a rotationally driven bending die with a clamp, allowing for precise alignment and operation within a unified setup.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate devices are used for bending and notching tubes, then each device can be specialized and simple in design, but accuracy and precision of alignment between bend and notch deteriorate
Solution Approach 1:
The patent combines the bending device and notching device into a single integrated tube processing system. The bending mechanism and notching mechanism share a common frame, support structure, and tube positioning system, allowing both operations to be performed on the same tube without transfer between machines. This integration ensures that the bend and notch are accurately aligned relative to each other while eliminating the complexity of managing multiple separate devices.
2Productivity
If two separate machines are used to bend and notch tubes, then functional versatility is achieved, but processing speed and convenience deteriorate due to transfer time
Solution Approach 1:
The integrated system allows the tube to remain in position while both bending and notching operations are performed sequentially or simultaneously on the same workpiece. This eliminates the time-consuming transfer operation between separate machines and reduces setup time, thereby improving processing speed and operational convenience.
Solution Approach 2:
The system enables continuous processing where the tube is clamped once and both bending and notching operations are performed without removing or repositioning the workpiece. This continuous action eliminates idle transfer time and maintains productive operation throughout the processing cycle.
3Area of stationary object
If separate machines are used for bending and notching, then each machine can have dedicated supports, but space consumption increases due to duplicate support structures
Solution Approach 1:
The integrated system employs a universal support structure that serves both the bending operation and the notching operation. The same frame, supports, and clamping mechanisms are used for both functions, eliminating the need for duplicate support structures and reducing the overall space required for the equipment while maintaining adequate support for both operations.
Data Source
AI summary
Tube processing systems for bending and notching a tube fed from a feed position. The tube processing system includes a notching system and a bending system. The notching system is configured to cut a notch in the tube. The bending system is disposed between the notching system and the feed position and is configured to bend the tube. The notching system includes a cutting head and a positioning system. The cutting head is configured to cut a notch in the tube. The positioning system movably supports the cutting head and is configured to move the cutting head relative to the tube to a selected cutting position. The bending system includes a bending die and a clamp. The bending die is rotationally driven to bend the tube. The clamp is configured to secure the tube to the bending die.