Variable Thickness Plate Roll Forming Device
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Solution Overview
Problem
Conventional roll forming systems face challenges in controlling the gap between upper and lower forming rolls when processing materials with varying thicknesses, leading to forming pressure imbalances and defective products due to difficulty in accurately adjusting the gap in real time.
Innovation Solution
A roll forming device with a spring unit that absorbs forming reaction forces and adjusts the gap between the upper and lower forming rolls using a worm wheel, worm gear, and adjustment screw, maintaining a uniform forming pressure by varying the position of the upper forming roll based on material thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a fixed gap is set between the upper and lower forming rolls, then the device structure is simple, but the forming pressure becomes unbalanced when material thickness varies
Solution Approach 1:
The upper forming roll is made movable instead of fixed, allowing it to adjust its position dynamically in response to material thickness variations. The roll can move vertically along the shaft axis, enabling real-time adaptation of the gap between upper and lower rolls to maintain balanced forming pressure across variable thickness materials.
Solution Approach 2:
The gap parameter between the upper and lower forming rolls is made variable rather than fixed. By allowing the upper roll position to change, the system adapts the gap parameter according to material thickness, ensuring consistent forming pressure despite variations in material dimensions.
2Manufacturing precision
If a servo motor is used to control the gap in real time, then the forming pressure can be maintained, but the device complexity and control difficulty increase
Solution Approach 1:
The system uses self-service through elastic deformation of the upper forming roll. When material with varying thickness passes through, the roll automatically deforms elastically to absorb reaction forces, maintaining gap consistency without requiring external control systems. This eliminates the need for servo motors and complex control mechanisms.
Solution Approach 2:
Instead of using active control systems, the patent changes the physical state parameter of the upper forming roll by allowing elastic deformation. This passive parameter change approach replaces complex active control, simplifying the device while maintaining precision.
3Stability of the object's composition
If the upper forming roll position is fixed, then the device is stable, but gap deviation occurs when material thickness varies
Solution Approach 1:
The upper forming roll transitions from a fixed static position to a dynamic position that can adjust vertically. This dynamic capability allows the roll to maintain stable contact with the material while adapting to thickness variations, preserving both stability and gap consistency.
Solution Approach 2:
The system prepares for thickness variations in advance by designing the upper roll mounting to allow vertical movement. This preliminary design consideration enables the roll to automatically compensate for thickness changes before they cause gap deviations, maintaining consistent forming conditions.
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 real-time control of the gap between the forming rolls, preventing deviations and maintaining a consistent forming pressure, thus optimizing the roll forming process and improving the quality of variable thickness plates by minimizing distortions caused by pressure differences.
Implementation Method 1
a spring unit that is disposed between the adjustment screw and the upper sliding block within each sliding groove of the both-side stand frames, absorbs a forming reaction force that is applied to the upper forming roll according to a thickness variation of a plate that is to be formed
Implementation Method 2
a worm wheel and a worm gear are operated in an adjustment block of each upper portion of the both-side stand frames and an adjustment screw that is screw-engaged to a center of the worm wheel in an up and down direction adjusts an up-down direction position of the both-side upper sliding blocks
Data Source
AI summary
A roll forming device for forming a variable thickness plate is disclosed. A roll forming device for forming a variable thickness plate according to one or a plurality of exemplary embodiments may include both-side stand frames that are disposed at a left side and a right side on a process base at a predetermined distance from each other and in which a sliding groove is formed at a center portion in an up and down direction, a lower forming roll unit in which a lower forming roll is fixed on a lower rotation shaft such that both end portions are rotatably disposed on a lower sliding block that is fixed to a lower portion of each sliding groove on the both-side stand frames, an upper forming roll unit in which an upper forming roll is fixed on an upper rotation shaft such that both end portions are rotatably disposed at an upper sliding block that is disposed on each sliding groove of the both-side stand frames to be slidably moved in an up and down direction at an upper portion of the lower forming roll unit, a forming roll gap adjustment unit that adjusts an initial gap between the lower forming roll and the upper forming roll, wherein a worm wheel and a worm gear are operated in an adjustment block of each upper portion of the both-side stand frames and an adjustment screw that is screw-engaged to a center of the worm wheel in an up and down direction adjusts an up-down direction position of the both-side upper sliding blocks, and a spring unit that is disposed between the adjustment screw and the upper sliding block within each sliding groove of the both-side stand frames, absorbs a forming reaction force that is applied to the upper forming roll according to a thickness variation of a plate that is to be formed, and simultaneously maintains a forming pressure of the upper forming roll within a predetermined range.