Twist-Retaining Support Points for Die-Free Panel Shaping
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Solution Overview
Problem
Existing methods for shaping large, complexly curved metallic sheets like aircraft wings using peen forming require costly and space-consuming press jigs, and rely on operator skill for reproducibility, while die members can interfere with reinforcement members in integral skins.
Innovation Solution
A plate-like-workpiece twisting and retaining apparatus with movable support and pressing points that can be independently positioned and controlled to twist and shape the workpiece without a die member, allowing for adjustable deformation and precise control of twisted or curved shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a press jig is used to elastically deform a plate-like workpiece, then the workpiece can be twisted and retained in a desired shape, but a huge press jig is necessary which is costly to manufacture and requires large storage space
Solution Approach 1:
The patent divides the continuous pressing surface of a traditional press jig into discrete, localized pressing points. These pressing points are distributed across the workpiece surface and can be independently activated, transforming a monolithic complex device into a segmented system that requires less material and space while maintaining shaping precision.
Solution Approach 2:
The pressing points are designed to be movable rather than fixed, allowing them to be repositioned according to the specific twisting requirements. This dynamic configuration enables a single apparatus to handle multiple workpiece shapes and sizes, eliminating the need for multiple huge press jigs for different models and areas.
2Device complexity
If a clamping-type retaining apparatus or hydraulic jack is used without a press jig, then the apparatus complexity is reduced, but the stroke adjustment and shape management depend on operator skill which reduces reproducibility
Solution Approach 1:
The patent incorporates a control system that monitors and adjusts the pressing points based on feedback about the workpiece state. This automated feedback mechanism replaces operator skill with systematic control, ensuring consistent and reproducible results across different operations and operators while maintaining the simplified apparatus structure.
Solution Approach 2:
The pressing points are designed to automatically position and apply force based on pre-programmed parameters, making the system self-regulating rather than dependent on operator intervention. This self-service capability ensures that the same pressing pattern can be repeatedly applied with consistent results, improving product consistency without adding complexity.
3Shape
If a die member such as a jig or template is used to give an integral skin a twisted or curved shape, then the workpiece can be shaped, but the die member interferes with the stringers in the integral skin
Solution Approach 1:
The patent extracts the shaping function from a physical die member that contacts the entire workpiece surface and concentrates it into discrete pressing points. This extraction allows the shaping action to occur at specific locations away from the stringers, eliminating interference while still achieving the desired curved shape through coordinated pressing at multiple points.
Solution Approach 2:
Instead of applying shaping force from one dimension (a die member contacting the surface), the patent uses pressing points that can operate from multiple dimensions and angles. This multi-dimensional approach allows the pressing points to apply force through or around the stringers without direct interference, achieving shape change without physical conflict with the reinforcement members.
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 the simple and versatile shaping of plate-like workpieces, including integral skins, with improved reproducibility and reduced processing time by eliminating the need for die members and allowing for complex shapes without interference with reinforcement members.
Implementation Method 1
the plate-like workpiece is elastically deformed by forcedly making the plate-like workpiece conform to a press jig
Implementation Method 2
blasting the plate-like workpiece with steel particles called shot having a diameter of about 0.5 mm to 4 mm at high speed so as to make the steel particles collide therewith with large momentum, thereby generating plastic strain
Data Source
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AI summary
Provided are a highly versatile device for maintaining twist in panel-shaped workpieces, a method for maintaining twist, and a method for creating twist, which are applicable to integral skins, and by which, through a simple and versatile constitution that does not employ a die member, a panel-shaped workpiece may be freely imparted with a twisted shape and a curved shape. This device (1) for maintaining twist is equipped with: at least two support points (25a) which are capable of contacting one surface of a panel-shaped workpiece (W) within a twisting process area (P); a plurality of pressure points (40) which are capable of contacting the other surface within the same twisting process area (P), and which are situated straddling a line connecting the at least two support points (25a) in plan view of the panel-shaped workpiece (W); and an extension/retraction driving means (support unit (23), pressure unit (33)) for extending and retracting at least the support points (25) and/or the pressure points (40) in the thickness direction of the panel-shaped workpiece (W).