System and method for radially orienting extruded tubes for vehicle body components

Abstract

The present disclosure provides "Systems and methods for radially orienting extruded tubes for vehicle body components". A method of orienting a weld in an aluminum vehicle body tube is provided. The method can include measuring a circumference of a first end of the tube to locate a position of a prong disposed on a wall of the first end of the tube, and rotating the tube such that the weld is in a predetermined position suitable for tube forming.

Description

Technical Field

[0001] This disclosure relates to extruded tubes for automotive applications. Background Technology

[0002] Automakers are implementing lighter, stronger materials, such as aluminum alloys, to meet emissions reduction targets, fuel economy goals, lower manufacturing costs, and reduce vehicle weight. Increasingly stringent safety requirements must be met while simultaneously reducing vehicle weight. One way to meet these competing goals is to hydroform high-strength aluminum alloy tubular blanks into robust, lightweight hydroformed parts.

[0003] Structural (portal) tubes are formed by extruding aluminum billets under high temperature and pressure using an extrusion die. As the flowing aluminum separates in the mandrel plate and reconverges in the cap-shaped section, discontinuous material flow occurs across the cross-section of this shape. Weld lines or buttress lines are created where the flowing aluminum reconverges to form the extruded shape. Structural tubes can have two or more weld lines and are an artifact of the porthole extrusion process.

[0004] Extruded structural tubes can be bent or pre-formed before the hydroforming process. The radial position of the weld line must be controlled and verified throughout the process. Summary of the Invention

[0005] According to one embodiment of this disclosure, a method for welding a weld in a oriented aluminum body tube is provided. The method may include measuring the profile of an inner periphery at a first end of the tube to locate a first position of a tip disposed on the wall of the tube. The method may further include rotating the tube such that the weld is positioned in a predetermined position suitable for tube forming.

[0006] According to another embodiment of this disclosure, a method for hydroforming an extruded circular tube is provided. The method may include measuring the inner peripheries of a first end and a second end of the tube to identify a first circumferential position and a second circumferential position of a point disposed on a wall at each end of the tube. The method may further include comparing the positional difference between the first circumferential position and the second circumferential position with a predetermined threshold.

[0007] According to another embodiment of this disclosure, a method for forming a circular tube is provided. The method may include measuring the profile of a peripheral surface at each end of the tube using a laser displacement sensor to identify a first circumferential position and a second circumferential position of a tip at each end of the tube. The method may further include rotating the tube such that a weld, positioned relative to the first and second circumferential positions, is located in a predetermined position suitable for tube forming. Attached Figure Description

[0008] Figure 1 is a partial perspective view of the extruded alloy tube for a circular porthole.

[0009] Figure 1A is a front view of the extruded alloy tube for a circular porthole.

[0010] Figure 1B is a detailed view of the pointed feature on a tube according to a first embodiment of the present disclosure.

[0011] Figure 1C is a detailed view of a pointed feature on a tube according to another embodiment of the present disclosure.

[0012] Figure 2 This is a partial perspective view of the extruded alloy tube of the rectangular porthole.

[0013] Figure 3 This is a flowchart illustrating an example of a method for forming a porthole extruded alloy tube.

[0014] Figure 4 This is a perspective view of a laser displacement sensor guided on the inner periphery of one end of the tube.

[0015] Figure 5 This is a top view of the point position set on the forming tube for verification.

[0016] Figure 5A It is a detailed perspective view of the laser displacement sensor being clamped and guided toward the inner periphery of the forming tube. Detailed Implementation

[0017] Detailed embodiments of the invention are disclosed herein as needed; however, it should be understood that the disclosed embodiments are merely examples of the invention that can be embodied in various and alternative forms. The drawings are not necessarily drawn to scale; some features may be enlarged or minimized to show details of specific components. Therefore, the specific structural and functional details disclosed herein should not be construed as limiting, but merely as a representative basis for teaching those skilled in the art to use the invention in different ways.

[0018] Referring to Figure 1, an extruded tube, such as an aluminum alloy porthole extruded structural tube 44, is shown. Tube 44 can be a circular tube with a hollow circular center or another shape. The tube includes a wall 46 having an inner surface 54 and an outer surface 56. Tube 44 may include welds 48 formed in the wall 46. Welds 48 extend longitudinally along the length of tube 44 and pass entirely through the wall 46. During extrusion, a tip 52 is formed on the inner surface 54. The tip 52 travels longitudinally along the length of tube 44. Opposite ends of tube 44 are the same as the end shown in the figure. The tip 52 can be located between welds 48 or on one of the welds. The tip 52 and welds 48 are substantially parallel to each other in a fixed spatial relationship. As shown, the tip 52 is positioned on the inner surface 54, but the tip 52 can also be positioned on the outer surface 56. As shown, the tip 52 is enlarged for better visibility in the figure.

[0019] The pointed tip 52 can be a protrusion of the wall 46, as shown in Figure 1B. The protruding pointed tip 52 can be a ridge formed in the wall 46. The ridge can be formed by a recessed marking element or other suitable tooling operation. For example, the marking element can be a groove machined into the inner diameter of the extrusion die, such that during extrusion, aluminum is pushed into the groove to form the ridge.

[0020] Alternatively, the tip 53 may be a recess or groove in the wall 46, as shown in FIG1C. The groove is formed by a raised marking element. For example, the raised marking element may be a tooth that cuts the groove into the aluminum wall. The tip 53 defines a pair of opposing sidewalls 55 that extend from the inner surface 54 toward the outer surface 56. A base plate 57 of the tip 53 is connected between the sidewalls 55.

[0021] The structural tube 44 is formed into a finished part by hydroforming the tube into the desired shape. Prior to hydroforming, the tube may undergo a series of processes such as bending and pre-forming. The weld has slightly different material properties than the other parts of the tube. Consistent placement of the weld is necessary to ensure consistent finished parts in mass production. Damage can occur if the weld is not placed in the proper position during processing. For example, if misaligned in the hydroforming die, the tube may crack, split, or burst. In addition to the potential for physical damage to the part, it is highly desirable to provide an extruded tube with consistent properties. Final parts with different weld positions can lead to inconsistent part properties. For example, weld position affects the strength of the part. To mitigate this problem, the weld must be placed in the proper position within the manufacturing die. Unlike steel tubes with visible welds, welds on extruded aluminum tubes are almost invisible to the naked eye and difficult to locate.

[0022] Tip 52 is a positioning feature that allows a person or machine to determine the location of the weld seam even when it is not visible. The tip and the weld seam are formed during extrusion and have a fixed spatial position relative to each other. The location of the weld seam can be determined by knowing the position of the tip. The position, size, type, and shape of the tip can vary. Tip 52 can also be used to measure the amount of torsion that occurs during the extrusion process. Different extrusion operations require different amounts of torsion. The tip provides a convenient visual indicator that can be monitored during the extrusion process to ensure that the required torsion occurs. The tip can be used to verify the location of the weld seam after forming.

[0023] refer to Figure 3 A flowchart illustrating a tube forming method 300 is provided. Method 300 includes detecting the tip 52 and orienting and verifying the location of the weld 48 before and after forming. It should be noted that... Figure 3 The flowcharts in this document are for illustrative purposes only and method 300 should not be construed as limiting. Figure 3The steps in the flowchart are as follows. Some of the steps in method 300 can be rearranged, while others can be omitted entirely.

[0024] The method may include a weld rotary station for receiving unformed (e.g., straight) structural tubes 44, as indicated by operation 302. The weld rotary station may receive tubes 44 from a conveyor belt that transfers tubes between assembly stations or from another suitable device. Once received, tubes 44 may be nested within a clamping device or jig and clamped by a pneumatic clamp or other suitable clamping device 402. Figure 4 Clamping, as indicated in operation 304. Once clamped, the tube 44 is rotated, as indicated in operation 306. The tube 44 can be fixed to the clamp 402 ( Figure 4 The rotating device 402 is driven by a gear motor to rotate.

[0025] When the tube 44 rotates, the first laser displacement sensor 404 ( Figure 4 One or more measurements may be performed, as indicated by operation 308. In one embodiment, the measurement may be a measurement of the profile or surface profile of the inner periphery or inner surface 54 of the tube 44. The term profile or surface profile is used to refer to a generally uniform boundary around the surface where the surface element is located. A tip 52 extending outward from the inner surface 54 by a height H1 extends beyond the generally uniform boundary. Similarly, a tip 53 extending relative to the recess depth H2 of the inner surface 54 extends beyond the generally uniform boundary (in the opposite direction). In another embodiment, the surface profile of the outer surface 56 is measured when either tip 52 or 53 is positioned on the outer surface 56.

[0026] Operation 310 also includes writing or recording the positioning position of the tips 52 at each end for association. If there is no association between the tips 52 at each end of the tube 44, the tube can be rejected, as indicated by operation 316. If there is an association between the tips 52 at each end of the tube 44, the tube is passed to a bending station to bend the tube 44, as indicated by operation 312.

[0027] In another embodiment, the inner diameter D1 can be measured to determine the position of the tip 52. The inner diameter D1 is the straight-line distance between the tip 52 and the wall 54. The inner diameter D1 is measured for each end of the tube 44. The position of the tip 52 can be determined based on the difference between the inner diameter between the tip 52 and the wall 54 and the inner diameter between two opposite points on the wall 54.

[0028] Then, tube 44 can be formed by a hydroforming process, as indicated in operation 314. Once tube 44 is formed, it is transferred to secondary tip position verification station 500. In the secondary tip position verification station, at least one end of tube 44 is clamped by a pneumatic clamp or other suitable clamping device 402. Figure 5AThe tube is clamped or secured, and the second laser displacement sensor 404 measures the profile of the inner periphery or inner surface 54 at one end of the formed tube. The term "profile" or "surface profile" is used to refer to a generally uniform boundary representing the area around the surface where the face element is located. The tip 52, extending outward from the inner surface 54 by a height H2, extends beyond the generally uniform boundary. Similarly, the tip 53, relative to the recess depth H2 of the inner surface 54, extends beyond the generally uniform boundary (in the opposite direction). In another embodiment, the surface profile of the outer surface 56 is measured when either tip 52 or 53 is positioned on the outer surface 56. In another embodiment, the position of the tip 52 can be derived based on a measurement of the inner diameter. The position of the tip 52 can then be compared with the positioning position of the tip with the intended design and the associated tolerance zone, as indicated by operation 318. If the position of the tip 52 does not meet the intended design position, the tube 44 is rejected, as indicated by operation 316. If the position of the tip 52 meets the intended design position, it is released and installed on the vehicle as indicated by operation 320.

[0029] refer to Figure 4 This illustrates a measurement of one end of the tube 44 as outlined in the description of operation 308 above. A portion of the assembly apparatus 400 includes a clamp 402 that nests in and clamps the tube 44. As the tube 44 is rotated, a laser displacement sensor 404 projects a laser 406 onto the inner surface 54 of the tube 44. The laser displacement sensor may be made of… Or another suitable laser displacement sensor is manufactured and sold as an "ultra-high speed / high precision laser displacement sensor".

[0030] refer to Figure 5 and Figure 5A This provides an example of performing operation 318. The formed tubes 44 are transported along conveyor 410 in an alternating manner: every other tube 44 is positioned on the side closest to the conveyor, and other tubes 44 are positioned on the opposite side. Each side of the conveyor includes a verification station 500, which measures the inner periphery or inner diameter of one end of the formed tube 44. Verification station 500 includes clamping device 502 and fixture 402. The formed tube 44 is clamped between fixture 402 and clamping device 502. Laser displacement sensor 404 projects a laser onto the inner surface 54 of tube 44 to determine the position of tip 52. The measured position of tip 52 can then be compared with a known or designed intended position using a computing device (e.g., a programmable logic device).

[0031] While exemplary embodiments have been described above, these embodiments are not intended to describe all possible forms of the invention. Rather, the terminology used in this specification is descriptive rather than restrictive, and it should be understood that various changes may be made without departing from the spirit and scope of the invention. Furthermore, features of various implementation embodiments may be combined to form other embodiments of the invention.

[0032] According to the present invention, a method for welding a weld in a directional aluminum body tube includes: measuring the profile of the inner periphery at a first end of the tube to locate a first position of a tip disposed on the wall of the tube; and rotating the tube such that the weld is located in a predetermined position suitable for tube forming.

[0033] According to one embodiment, the invention is further characterized by measuring the contour of the inner periphery at the second end of the tube to locate a second position of the tip at the second end of the tube; and comparing the difference between the first position and the second position of the tip with a predetermined misalignment threshold.

[0034] According to one embodiment, measuring the profile of the inner periphery at the first and second ends of the tube includes guiding a laser displacement sensor to the inner periphery of the first and second ends of the tube.

[0035] According to one embodiment, measuring the contour of the inner periphery includes measuring the distance between a portion of the tip and the wall.

[0036] According to one embodiment, the tip is a protrusion disposed along the length of the wall, the protrusion including a base and a peak extending therefrom toward the central axis of the tube.

[0037] According to one embodiment, the invention is further characterized by deforming the tube to produce a shaped tube; measuring the profile of the inner periphery at one end of the shaped tube to locate a first position of the tip at the one end of the shaped tube; and comparing the first position of the tip with a predetermined positional tolerance zone associated with the shaped tube.

[0038] According to one embodiment, measuring the profile of the inner periphery at one end of the forming tube includes guiding a laser displacement sensor to the inner periphery of the forming tube to measure the inner diameter of each end of the forming tube.

[0039] According to the present invention, a method for hydroforming an extruded circular tube includes: measuring the inner periphery of a first end and a second end of the tube to identify a first circumferential position and a second circumferential position of a tip disposed on a wall at each end of the tube; and comparing the position difference between the first circumferential position and the second circumferential position with a predetermined threshold.

[0040] According to one embodiment, the invention is further characterized in that the tube is aligned in a bending tool to place the weld at a predetermined position relative to the bending tool in a manner circumferentially spaced from the tip.

[0041] According to one embodiment, measuring the inner periphery of the first end and the second end of the tube includes guiding a laser displacement sensor to the inner periphery of the first end and the second end of the tube.

[0042] According to one embodiment, measuring the inner periphery of the first end and the second end of the tube includes rotating the tube while applying the laser displacement sensor to the inner periphery of the first end and the second end of the tube.

[0043] According to one embodiment, measuring the inner periphery of the first end and the second end of the tube includes measuring the surface profile of the inner periphery.

[0044] According to one embodiment, the pointed end is a recessed channel defined by the length of the wall and extending along the length of the wall.

[0045] According to one embodiment, the invention is further characterized by deforming the tube to produce a shaped tube; re-measuring the surface profile of the inner periphery at at least one end of the shaped tube to locate the circumferential position of the tip at the at least one end of the tube; and comparing the positional difference between the circumferential position of the tip at the at least one end of the shaped tube and a predetermined circumferential position with a predetermined upper threshold and a predetermined lower threshold.

[0046] According to the present invention, a method for forming a circular tube includes: measuring the profile of a peripheral surface at each end of the tube using a laser displacement sensor to identify a first circumferential position and a second circumferential position of a tip at each end of the tube; and rotating the tube such that a weld positioned relative to the first circumferential position and the second circumferential position is located in a predetermined position suitable for tube forming.

[0047] According to one embodiment, the invention is further characterized in that the positional difference between the first circumferential position and the second circumferential position of the tip at each end of the tube is compared with a predetermined upper threshold and a predetermined lower threshold.

[0048] According to one embodiment, the invention is further characterized in that the tube is rotated while measuring the profile of the peripheral surface at each end of the tube.

[0049] According to one embodiment, the invention is further characterized by deforming the tube to produce a shaped tube; and measuring the profile of at least one peripheral surface at one end of the tube by means of a laser displacement sensor to identify the circumferential position of the tip at one end of the shaped tube.

[0050] According to one embodiment, the pointed end is a protrusion that is disposed along the length of the wall of the circular tube and extends from the wall of the circular tube.

[0051] According to one embodiment, the pointed end is a recessed channel defined by the length of the wall of the circular tube and extending along the length of the wall of the circular tube.

Claims

1. A method for welding a seam in a directional aluminum body tube, comprising: Measure the contour of the inner periphery at the first end of the tube to locate the first position of the tip set on the wall of the tube; The tube is rotated so that the weld is positioned in a predetermined position suitable for tube forming. The tube is deformed to produce a shaped tube; The contour of the inner periphery at one end of the forming tube is measured to locate the tip at a first position at one end of the forming tube. as well as The first position of the tip at one end of the forming tube is compared with a predetermined position tolerance zone associated with the forming tube.

2. The method of claim 1, further comprising, before deforming the tube: Measure the contour of the inner periphery at the second end of the tube to locate the tip at a second position at the second end of the tube; as well as The difference between the first position and the second position of the tip is compared with a predetermined misalignment threshold.

3. The method of claim 2, wherein measuring the profile of the inner periphery at the first and second ends of the tube comprises guiding a laser displacement sensor to the inner periphery of the first and second ends of the tube.

4. The method of claim 1, wherein measuring the contour of the inner periphery includes measuring the distance between a portion of the tip and the wall.

5. The method of claim 4, wherein the tip is a protrusion disposed along the length of the wall, the protrusion comprising a base and a peak extending therefrom toward the central axis of the tube.

6. The method of claim 1, wherein measuring the profile of the inner periphery at one end of the forming tube comprises guiding a laser displacement sensor to the inner periphery of the forming tube to measure the inner diameter of each end of the forming tube.

7. A method for hydroforming extruded circular tubes, comprising: Measure the inner periphery of the first and second ends of the tube to identify the first and second circumferential positions of the tips disposed on the wall at each end of the tube; The position difference between the first circumferential position and the second circumferential position is compared with a predetermined threshold. The tube is deformed to produce a shaped tube; The surface profile of the inner periphery at at least one end of the formed tube is remeasured to locate the circumferential position of the tip at at least one end of the tube. as well as The positional difference between the circumferential position of the tip at at least one end of the forming tube and a predetermined circumferential position is compared with a predetermined upper threshold and a predetermined lower threshold.

8. The method of claim 7, further comprising, before deforming the tube: Align the tube in the bending tool to place the weld in a predetermined position relative to the bending tool, spaced circumferentially from the tip.

9. The method of claim 7, wherein measuring the inner periphery of the first end and the second end of the tube comprises guiding a laser displacement sensor to the inner periphery of the first end and the second end of the tube.

10. The method of claim 9, wherein measuring the inner periphery of the first end and the second end of the tube comprises rotating the tube while applying the laser displacement sensor to the inner periphery of the first end and the second end of the tube.

11. The method of claim 10, wherein measuring the inner periphery of the first end and the second end of the tube includes measuring the surface profile of the inner periphery.

12. The method of claim 9, wherein the pointed end is a recessed channel defined by and extending along the length of the wall.

13. A method for forming a circular tube, comprising: The profile of the peripheral surface at each end of the tube is measured by a laser displacement sensor to identify the first and second circumferential positions of the tip at each end of the tube. The tube is rotated such that the weld, positioned relative to the first circumferential position and the second circumferential position, is located in a predetermined position suitable for tube forming. as well as The tube is deformed to produce a shaped tube; The profile of the peripheral surface at at least one end of the formed tube is remeasured to locate the circumferential position of the tip at the at least one end of the tube. as well as The positional difference between the circumferential position of the tip at at least one end of the forming tube and a predetermined circumferential position is compared with a predetermined upper threshold and a predetermined lower threshold.

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