Vacuum Bending Apparatus for Metal Plate Curvature Control
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Solution Overview
Problem
Current methods for bending metal plates into cylindrical shapes for aircraft outer shells are inefficient due to the need for multiple adjustments, large-sized forming machines, and difficulty in maintaining accuracy, especially with the formation of pocket grooves and curvature, leading to long production times and reduced efficiency.
Innovation Solution
A bending apparatus and method using suction devices and expandable/contractable servo screw jacks to deform metal plates into cylindrical shapes without filling pocket grooves, allowing for precise control and forming without large machines, enabling efficient and accurate bending with a simple configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If cardboard fillers are embedded in pocket grooves and three-point bending is performed repeatedly, then the outer-plate can be formed into a cylindrical shape with predetermined curvature, but the production time increases significantly and requires multiple manual adjustments
Solution Approach 1:
The invention removes the cardboard fillers from the pocket grooves before bending, eliminating the need for their embedding and adjustment. This extraction of the filler material simplifies the process while maintaining forming capability through direct vacuum application to the plate surface.
Solution Approach 2:
The invention replaces the mechanical three-point bending system with a distributed vacuum bending system. Instead of using a punch and die with mechanical force applied at three points, the system uses vacuum suction distributed across the plate surface to achieve bending, eliminating the need for repeated mechanical adjustments.
2Length of moving object
If a large-sized press brake is used for tip forming, then the large outer-plate workpiece can be bent, but the device size and complexity increase
Solution Approach 1:
The invention segments the bending process into multiple small suction zones distributed across the plate surface. Instead of using a single large press brake, the system divides the workpiece into regions, each handled by individual suction cups that can be independently controlled, enabling processing of large workpieces with simpler, more manageable equipment.
Solution Approach 2:
The invention transitions from one-dimensional mechanical pressing (single punch movement) to two-dimensional distributed vacuum application. By applying suction forces across the entire surface area of the plate rather than at a single point, the system achieves the same bending effect with much smaller, less complex equipment.
3Manufacturing precision
If cardboard fillers are used to maintain uniform thickness, then the outer-plate can be formed, but the operation complexity increases and requires skilled workers
Solution Approach 1:
The vacuum system directly applies suction to the outer surface of the plate, allowing the plate itself to serve as the forming surface without requiring additional filler materials. The plate's own structure and the distributed vacuum pressure work together to achieve uniform thickness and accurate curvature without manual intervention for filler placement.
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
This approach allows for efficient and accurate bending of metal plates into cylindrical shapes with reduced production time and energy requirements, improving the forming process by eliminating the need for complex adjustments and large machines, while maintaining high accuracy and flexibility in curvature control.
Implementation Method 1
a suction device configured to suck a surface of a plate-shaped metal workpiece
Implementation Method 2
forming the plate-shaped metal workpiece under bending deformation by expanding and contracting the plurality of expansion and contraction devices
Data Source
AI summary
Provided is a bending apparatus for a plate-shaped metal workpiece, including: a suction device (suction pad) configured to suck a surface of a plate-shaped metal workpiece in a removable manner; a plurality of expansion and contraction devices (servo screw jacks) each including the suction device mounted on a distal end thereof and being capable of expanding and contracting a length ranging from a proximal end thereof to the suction device; and an apparatus base (bed) on which the proximal end of each of the expansion and contraction devices is mounted. The bending apparatus is configured to form the plate-shaped metal workpiece under bending deformation by expanding and contracting the expansion and contraction devices under a state in which the suction device sucks the surface of the plate-shaped metal workpiece.