Variable Cutoff Device for Roll Formers
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Solution Overview
Problem
Existing cutoff devices struggle to handle the rapid and substantial oscillating movement of continuous beams with multiple/different sweeps as they exit the roll former, especially at high line speeds, leading to inaccuracies in cutting beam segments with desired lengths and sweeps.
Innovation Solution
A rapidly-adjustable power sweep unit and a cutoff unit with an extendable pin and guillotine-type cutting blade, controlled by a coordinated controller, which includes a pickup device with a shock absorber to engage and cut the beam segments accurately, accommodating the beam's dramatic position changes and ensuring precise cutting of beam segments with desired lengths and sweeps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a traditional fixed cutoff device is used to cut continuous beams with multiple sweeps, then the device structure is simple, but it cannot handle the rapid and substantial oscillating movement of the beam at high line speeds, leading to cutting inaccuracies
Solution Approach 1:
The cutoff device is transformed from a fixed structure to a dynamic one. The pickup device with extendable pickup member can temporarily engage with the continuous beam and move along with it during the cutting operation. This dynamic capability allows the cutoff device to accommodate the oscillating movement of multi-swept beams while maintaining cutting accuracy at high line speeds
Solution Approach 2:
The pickup device acts as an intermediary between the stationary cutoff device and the moving continuous beam. By engaging the beam with the extendable pickup member and moving with it temporarily, the pickup device bridges the gap between the fixed device structure and the oscillating beam, enabling accurate cutting without requiring the entire cutoff device to be complex and mobile
2Productivity
If the roll former operates at high line speeds to increase productivity, then production efficiency improves, but the continuous beam with multiple sweeps oscillates more dramatically, making accurate cutting difficult
Solution Approach 1:
The cutoff device adopts a dynamic design where the pickup device can temporarily engage with the continuous beam and move along with its oscillations. This allows the system to maintain cutting accuracy even when operating at high line speeds that cause dramatic beam oscillations, resolving the trade-off between productivity and precision
3Manufacturing precision
If a pickup device with extendable pickup member and shock absorber is used to engage and track the continuous beam, then cutting accuracy is maintained despite beam oscillation, but the device complexity increases
Solution Approach 1:
The pickup device serves as an intermediary that temporarily engages with the continuous beam using an extendable pickup member. This intermediary approach allows the stationary cutoff device to accurately track and cut the oscillating beam without requiring the entire device to be complex and mobile, achieving precision through a focused, specialized component rather than system-wide complexity
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
The solution allows for accurate cutting of beam segments with desired lengths and multiple sweeps, even at high line speeds, reducing secondary processing and maintaining tight dimensional standards, enabling the production of beam segments with precise curvature and length accuracy.
Implementation Method 1
A shock absorber is provided to reduce impact when the pickup member engages the continuous beam and first begins to move therewith
Data Source
AI summary
A cutoff unit for cutting a variably swept continuous beam extending from a roll forming mill includes a pickup subassembly for tracking a shape of the continuous beam, and a cutoff subassembly that engages and supports sides of the continuous beam while a blade slices transversely through the continuous beam. A controller connected to the roll forming mill and to the cutoff unit controls the cutoff unit to allow pass through of the continuous beam, and is configured to actuate the pickup and then actuate the blade to cut the continuous beam into longitudinally symmetrical beam segments, each having a center section (swept or not) and with mirror-image equally-swept end sections.