Traveling Tube Insertion for Long 3D Bending Dies
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for producing bent pipes from thermoplastic resin tubes require manual handling of hot tubes, posing safety risks and making it difficult to insert long tubes or those with complex three-dimensional shapes into bending dies.
Innovation Solution
A device with a traveling body that moves along the bending die, equipped with guide mechanisms, drive wheels, and an inserting roll, allows for automatic insertion of tubes into bending dies, even for shapes exceeding two meters in length, using a three-dimensional printing technique to create the bending die with a smooth, continuous profile.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual handling is used to insert tubes into bending dies, then操作简单 (operation simplicity) is maintained, but safety risks increase and long tubes cannot be inserted
Solution Approach 1:
The tube insertion device automatically feeds and inserts tubes into the bending die without manual intervention. The feeding mechanism grasps the tube end and pushes it through the die, while the tube itself guides the insertion process by following the die's internal path, achieving self-service operation that eliminates safety risks associated with manual handling of hot tubes
Solution Approach 2:
The patent replaces the manual mechanical insertion process with an automated mechanical system. The tube insertion device uses a feeding mechanism with grippers and pushers that automatically insert tubes into the bending die, substituting human hands and operations with mechanical automation to eliminate safety hazards while maintaining operational simplicity
2Device complexity
If manual insertion is used, then device complexity is low, but productivity decreases and long tubes cannot be processed
Solution Approach 1:
The automated tube insertion device performs the complete insertion process autonomously without requiring manual intervention for each tube. The feeding mechanism automatically grasps, positions, and pushes tubes into the bending die, enabling continuous high-speed operation that dramatically increases productivity while the self-guiding mechanism keeps the device structure relatively simple
Solution Approach 2:
The tube insertion device is designed with universal functionality to handle various tube lengths and configurations. The feeding mechanism can process tubes of different lengths using the same basic structure, and the bending die's internal guide path accommodates complex three-dimensional tube shapes, enabling the device to produce diverse products without requiring complex reconfiguration
3Manufacturing precision
If three-dimensional printing is used to create bending dies, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent employs three-dimensional printing technology to manufacture bending dies with precise control over geometric parameters. The printing process allows for accurate reproduction of complex internal channels and surface features that define the tube bending path, achieving high manufacturing precision while the additive manufacturing process itself simplifies the overall device structure by integrating multiple components into a single printed part
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables safe and efficient automatic insertion of tubes into bending dies, facilitating the production of complex shapes without manual handling, thus improving workability and enabling the creation of long, intricately shaped products.
Implementation Method 1
heats up, for example, a thermoplastic resin tube
Implementation Method 2
hardens the thermoplastic resin tube
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An object of the present invention is to propose a device capable of automatically insetting a tube into a bending die instead of doing so manually, even if the shape of a product exceeds two meters in length, the device comprising a bending die 1 having a tube insetting portion 2, and a traveling body 21 that includes a guide mechanism 29 guiding a tube 20 to an upper portion of the tube insetting portion, an auxiliary guide mechanism 22a keeping the tube in the upper portion of the tube insetting portion, a insetting roll 30 insetting the tube in the tube insetting portion, a pair of drive wheels 23 rolling along lower rails 18, and a drive mechanism 25, wherein the traveling body 21 moves and insets a tube 20A into the bending die while having the auxiliary guide mechanism and the drive wheels grip the bending die.