English wheel (EW) forming is a process that allows to form compound curves from sheet metal. The shapes can be generated without part specific tools, like dies, and hence allows the flexible and economic manufacture of prototypical and low volume metal parts with short lead times. Conventional EW forming solely relies on a human worker whose movements of the metal sheet between two wheels, which are mounted on a frame that is fixed to the ground, determines the shape of the formed sheets. The need for repeatability, reduction in human labor costs and the scarcity of skilled workers have led to the research of robotic EW forming. These initial endeavors have kept the design and use of the EW the same as with the conventional process and only replaced the worker with a robot or multiple robots, i.e., the frame holding the two wheels was still fixed to the ground with only the sheet metal being handled robotically. This paper explores the other options that exist in moving a metal sheet relative to the wheels, without the constraint of the conventional approach. Those are enabled by using the EW as an end-effector for the robot flange and using its degrees of freedom for the forming process, either solely or assisted by optional degrees of freedom from the system holding the sheet metal.

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English Wheel Forming Using Robot-Mounted Wheel End-Effectors for Increased Flexibility

  • Christopher Ehrmann,
  • Yanrong Zhang,
  • Junying Min

摘要

English wheel (EW) forming is a process that allows to form compound curves from sheet metal. The shapes can be generated without part specific tools, like dies, and hence allows the flexible and economic manufacture of prototypical and low volume metal parts with short lead times. Conventional EW forming solely relies on a human worker whose movements of the metal sheet between two wheels, which are mounted on a frame that is fixed to the ground, determines the shape of the formed sheets. The need for repeatability, reduction in human labor costs and the scarcity of skilled workers have led to the research of robotic EW forming. These initial endeavors have kept the design and use of the EW the same as with the conventional process and only replaced the worker with a robot or multiple robots, i.e., the frame holding the two wheels was still fixed to the ground with only the sheet metal being handled robotically. This paper explores the other options that exist in moving a metal sheet relative to the wheels, without the constraint of the conventional approach. Those are enabled by using the EW as an end-effector for the robot flange and using its degrees of freedom for the forming process, either solely or assisted by optional degrees of freedom from the system holding the sheet metal.