New energy vehicle charging port forming process and mold

Abstract

The present application relates to a kind of new energy automobile charging port forming process, comprising the following steps: S1, drawing, the side wall outer plate to be shaped is drawn according to surface trend to cancel surface step;S2, punching, the outer side part of the charging port area of the side wall outer plate to be shaped is pressed, and charging port is punched out at charging port area, wherein the straight line section of charging port edge is roughed, the corner section of charging port edge is finished, then the outer side of charging port edge is pre-shaped by flanging;S3, flange forming, the area of side wall outer plate located at the outer side of flange is pressed, and flange is formed by flanging shaping along the circumference of charging port;S4, finishing, the straight line section of charging port edge is finished, the present application effectively eliminates the recess of side wall outer plate, and the delicate quality of side wall outer plate is improved, and the present application also provides a kind of new energy automobile charging port forming die.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of appearance structure design of new energy vehicles, and particularly relates to a new energy vehicle charging port forming process and a die. BACKGROUND

[0002] When the side outer plate of an electric vehicle is developed, the refueling port becomes a charging port, and the sealing requirement of the product for the charging port is more stringent than that for the previous refueling port. Therefore, the product structure of the charging port of the current electric vehicle is changed from a straight edge or a part of a straight edge with a flange structure to a flange structure with a flange along the circumferential direction. This change causes the A surface near the charging port to be deformed during the stamping forming process, thereby affecting the surface quality of the side outer plate.

[0003] In view of the defects of the side outer plate near the charging port, the process scheme adopted in the prior art is to use a pre-forming scheme in the drawing process, that is, a first process: drawing forming a part of a step, a second process: punching a charging port, a third process: oil port flanging and shaping, and a fourth process: flange finishing edge. Meanwhile, in the first process and the third process, the flange is pressed along the circumferential direction of the oil port to ensure the material pressing. However, it is found in the implementation of the prior art scheme that the A surface depression problem can only be alleviated, but cannot be completely eliminated. The parts need to be completely repaired before being put into storage. In addition, after the step forming in the drawing, a depression is generated at the corner of the drawn part. SUMMARY

[0004] Based on the above description, the present application provides a new energy vehicle charging port forming process to solve the above technical problems existing in the prior art.

[0005] The technical scheme for solving the above technical problems of the present application is as follows:

[0006] A new energy vehicle charging port forming process, comprising the following steps:

[0007] S1, drawing, drawing the side outer plate to be formed according to the surface trend to cancel the surface step;

[0008] S2, punching, pressing the outer side of the charging port area of the side outer plate to be formed, punching out the charging port at the charging port area, wherein the straight line segment of the charging port edge is subjected to rough trimming edge processing, the corner segment of the charging port edge is subjected to fine trimming edge processing, and the outer side of the charging port edge is subjected to flanging and pre-shaping;

[0009] S3, flange forming, pressing the area of the side outer plate located outside the flange, flanging and shaping along the circumferential direction of the charging port to form the flange;

[0010] S4, fine trimming, the straight line segment of the charging port edge is subjected to fine trimming edge processing.

[0011] Compared with the prior art, the technical scheme of the application has the following beneficial technical effects:

[0012] The forming process of the charging port provided by the application first draws the side outer plate to be formed according to the surface trend, cancels the step structure on the surface of the side outer plate, forms a smooth curved surface, and then punches a hole. The linear segment of the edge of the charging port is subjected to rough trimming, and the corner segment of the edge of the charging port is subjected to fine trimming. The flow of material in the shaping process is improved, the excess material of the linear segment of the edge of the charging port is transferred to the corner position, and the generation of a large internal stress of the surface material flow during shaping is effectively avoided, thereby effectively eliminating the depression of the side outer plate and improving the delicate quality of the side outer plate. At the same time, the workload of on-site debugging and rectification is reduced, and the project development cycle is optimized.

[0013] On the basis of the above technical scheme, the application can also be improved as follows.

[0014] Further, the flanging blade penetration amount of the corner segment of the edge of the charging port in step S2 is lower than the flanging blade penetration amount of the linear segment.

[0015] Further, the flanging blade penetration amount of the corner segment of the edge of the charging port in step S2 is one-third of the product flange height, and the flanging blade penetration amount of the linear segment is two-thirds of the product flange height.

[0016] Further, the rough trimming adopts cutting edge extending outward by 3-5 mm at the product boundary, and the fine trimming adopts cutting edge at the product boundary.

[0017] Further, the pre-shaping surface formed by pre-shaping in step S2 is uniformly transitioned with the drawing process surface formed by drawing in step S1.

[0018] The application also provides a new energy automobile charging port forming die, which comprises an upper die assembly, a pressing plate and a lower punch;

[0019] The upper die assembly comprises an upper bottom plate, a pre-shaping insert, a trimming insert and a pressing piece. The pre-shaping insert is connected to the lower end of the upper bottom plate. The lower end edge of the pre-shaping insert has a pre-shaping protrusion in the circumferential direction. The trimming insert is connected to the middle position of the lower end of the pre-shaping insert. The lower end of the trimming insert has a trimming blade edge. The lower end of the trimming blade edge is located on the lower side of the lowermost end of the shaping protrusion. The pressing piece is installed on the upper bottom plate.

[0020] The upper end of the lower punch has a conformal surface consistent with the lower surface of the side outer plate of the automobile. The lower punch has a trimming groove corresponding to the trimming insert. The lower punch has a pre-shaping groove corresponding to the pre-shaping protrusion.

[0021] The pressing plate is arranged between the upper die assembly and the lower punch, and a conformal surface of the lower end of the pressing plate is consistent with the upper surface of the side outer plate of the automobile.

[0022] The charging port forming die provided by the application punches out a charging port at the charging port area of the side outer plate through the trimming blade edge of the trimming insert, wherein the pre-shaping protrusion shapes a groove on the outside of the charging port to realize pre-flanging, the height difference between the trimming blade edge and the pre-shaping protrusion realizes punching and flanging at one time, time is saved, and the surface material flow during shaping is effectively avoided to generate a large internal stress, thereby effectively eliminating the depression of the side outer plate and improving the delicate quality of the side outer plate.

[0023] Further, the lower end of the pre-shaping insert has a mounting groove, and the trimming insert is detachably mounted in the mounting groove.

[0024] Further, the height difference between the lower end of the trimming blade edge and the lowermost end of the shaping protrusion is not less than 1 mm.

[0025] Further, the pressing part includes a plurality of pressing nitrogen gas springs which are uniformly distributed along the circumference of the pre-shaping insert.

[0026] Further, the number of the pressing nitrogen gas springs satisfies the following relationship: the number of the pressing nitrogen gas springs ≥ the blanking force ÷ the force of a single nitrogen gas spring, and the distance between the center of each nitrogen gas spring and the trimming blade edge is less than or equal to 80 mm. BRIEF DESCRIPTION OF DRAWINGS

[0027] Figure 1 It is a structural schematic diagram of the refueling port of the side outer plate of the automobile in the prior art;

[0028] Figure 2 It is a structural schematic diagram of the charging port of the side outer plate of the automobile in the application;

[0029] Figure 3 It is a step schematic diagram of the new energy automobile charging port forming process provided by the first embodiment of the application;

[0030] Figure 4 It is a structural variation schematic diagram of the charging port of the forming process of the first embodiment of the application;

[0031] Figure 5 It is a schematic diagram of the linear segment and the corner segment of the edge area of the charging port;

[0032] Figure 6 It is a structural schematic diagram of the new energy automobile charging port forming die provided by the second embodiment of the application;

[0033] Figure 7 It is Figure 6 It is an enlarged schematic diagram of the X area. DETAILED DESCRIPTION

[0034] For the purposes of this application, reference will be made to the accompanying drawings in which embodiments of the application are illustrated. The application may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and fully convey the scope of the application to those skilled in the art.

[0035] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used in the description of the application herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the application.

[0036] It is to be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientations depicted in the figures. For example, if a device described is turned over, elements described as "below" or "beneath" other elements or features would then be oriented "above" the other elements or features. The terms "below" and "above" can encompass the relative orientations of up and down when the device is turned over. Thus, the exemplary term "below" can encompass both an orientation of above and below. The application can also be implemented in other orientations than those depicted in the figures.

[0037] It is to be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientations depicted in the figures. For example, if a device described is turned over, elements described as "below" or "beneath" other elements or features would then be oriented "above" the other elements or features. The terms "below" and "above" can encompass the relative orientations of up and down when the device is turned over. Thus, the exemplary term "below" can encompass both an orientation of above and below. The application can also be implemented in other orientations than those depicted in the figures.

[0038] As used herein, the singular forms "a", "an" and "the" include plural referents unless the context clearly dictates otherwise. It is to be understood that the terms "comprise / comprises" or "include / includes" or "have / have" when used in this specification, specify the presence of stated features, integers, steps, operations, components, parts, or combinations thereof, but do not preclude the presence or addition of one or more other features, integers, steps, operations, components, parts, or combinations thereof.

[0039] Embodiment One

[0040] The conventional oil vehicle oil filler port is as follows Figure 1As shown, on a type of car, its overall parallelogram structure, smooth transition at the corner, can be seen, at the corner position and a straight side without flange structure.

[0041] When the oil car changes to the electric car, the oil port becomes the charging port, and the charging port structure is as Figure 2 As shown, it has a flange fold along its axial direction in the oil port edge area, and this changed structure causes the A surface (A-level surface, usually refers to the visible outer surface of the vehicle body) in the area A of the side wall outer plate near the charging port to be deformed during the stamping forming process, thereby affecting the surface quality of the side wall outer plate and causing a greater impact on the overall styling of the vehicle.

[0042] The prior art adopts the scheme of pre-forming and punching in the drawing process and then performing flanging and shaping, which can alleviate the problem of A surface depression, but cannot completely eliminate this defect, so the present application optimizes and improves the forming process in the prior art, thereby realizing the technical effect of defect.

[0043] The embodiment of the present application provides a new energy vehicle charging port forming process, Figure 3 As shown, it is a step sequence diagram of the process, Figure 4 As shown, it is a schematic diagram of the structure change of the charging port area of the side wall outer plate during the process, wherein the process comprises the following steps:

[0044] S1, drawing, drawing the side wall outer plate to be formed according to the surface trend to cancel the surface step;

[0045] That is, drawing the side wall outer plate according to the trend of the A surface and performing certain process supplement to make the A surface smoother and cancel the surface step structure.

[0046] S2, punching, pressing the outer side part of the charging port area of the side wall outer plate to be formed, punching out the charging port at the charging port area, wherein the straight line segment of the charging port edge is coarsely trimmed, the corner segment of the charging port edge is finely trimmed, and the outer side of the charging port edge is flanged and pre-shaped;

[0047] Step S2 is the biggest improvement point of the forming process of the present application compared with the traditional process, wherein in this step, the charging port of the charging port area of the side wall outer plate is punched out, and then the straight line segment of the charging port edge is coarsely trimmed and the corner segment of the charging port edge is finely trimmed during the punching process.

[0048] In this embodiment, the coarse trimming adopts the trimming operation of extending a certain distance outward from the product boundary, and in the present application, the distance range is 3-5mm, and the fine trimming adopts the trimming according to the product boundary.

[0049] For ease of understanding, as Figure 5As shown, the charging port structure is completed, the edge thereof comprises an edge structure from a-b-c-d-e-f-g-h-i-j-a, wherein a~b, c~d, e~f, g~h, i~j are straight line segments, and b~c, d~e, f~g, h~i, j~a are corner segments.

[0050] Therefore, in the implementation of step S2, the edge cutting is performed in the areas of a~b, c~d, e~f, g~h, i~j along the charging port boundary by 3~5 mm, and the edge cutting is performed along the charging port boundary in b~c, d~e, f~g, h~i, j~a, so that the excessive internal stress at the corners caused by the A surface material flow during the shaping when the edge cutting is performed along the boundary in the corner segments and the straight line segments can be effectively prevented, and further, the surface type defects can be caused.

[0051] Under the premise of the edge cutting into holes, step S2 also performs the flanging pre-shaping on the outer side of the charging port edge.

[0052] Preferably, the flanging blade entry amount of the corner segment of the charging port edge is lower than the flanging blade entry amount of the straight line segment, specifically, the flanging blade entry amount of the corner segment of the charging port edge is one-third of the product flange height, and the flanging blade entry amount of the straight line segment is two-thirds of the product flange height, the product flange height refers to the height difference of the product flange formed at this position after the shaping and the A surface, and the lower flanging blade entry amount adopted for the corner segment can effectively improve the material flow in the pre-shaping process in the corner segment area, and ensure the delicate A surface.

[0053] S3, flange shaping, the side outer plate located at the outer side of the flange is pressed and flanged and shaped along the charging port periphery to form a flange;

[0054] Step S3 can be regarded as a supplementary process of the pre-flanging process in step S2, which is mainly used for completely flanging and shaping the charging port edge area pre-flanged in step S2, so that whether the corner segment area or the straight line segment area reaches the complete product flange height, and a complete flange structure is formed along the charging port periphery.

[0055] S4, finishing, the straight line segment of the charging port edge is subjected to a finishing edge treatment.

[0056] Step S4 can also be regarded as a supplementary process of the rough finishing edge of the straight line segment in step S2, in which the edge cutting is performed in the straight line segment area along the charging port boundary, and thus the charging port shaping of the side outer plate is realized.

[0057] In summary, the charging port forming process provided by the embodiment of the application first draws the side outer plate to be formed according to the surface trend, cancels the step structure on the surface of the side outer plate, forms a smooth curved surface, and then punches a hole. The linear section of the charging port edge is subjected to rough trimming, and the corner section of the charging port edge is subjected to fine trimming. The flow of material in the shaping process is improved, the excess material of the linear section of the charging port edge is transferred to the corner section, and the generation of a large internal stress of the surface material flow in the shaping is effectively avoided, thereby effectively eliminating the depression of the side outer plate, improving the delicate quality of the side outer plate, reducing the workload of on-site debugging and rectification, and optimizing the project development cycle.

[0058] Embodiment Two

[0059] In order to implement the above forming process, since steps S1, S3 and S4 only need to change the parameters or the shape of the mold of the traditional process, but for the process corresponding to step 2, since the hole forming and pre-shaping are completed at the same time in this step, it is necessary to provide a brand new forming mold to simplify the operation process.

[0060] As shown in Figure 6 , the embodiment provides a new energy automobile charging port forming mold, which comprises an upper mold assembly 10, a pressing plate 20 and a lower punch 30.

[0061] The upper mold assembly 10 comprises an upper bottom plate 11, a pre-shaping insert 12, a trimming insert 13 and a pressing piece 14.

[0062] The pre-shaping insert 12 is connected to the lower end of the upper bottom plate 11. Specifically, the pre-shaping insert 12 is fixed on the upper bottom plate 11 by screws.

[0063] As shown in Figure 7 , the lower end of the pre-shaping insert 12 has a pre-shaping protrusion 121 in the circumferential direction, and the trimming insert 13 is connected to the middle position of the lower end of the pre-shaping insert 12.

[0064] In the embodiment, in order to ensure the installation stability of the trimming insert 13, the middle part of the lower end of the pre-shaping insert 12 has a mounting groove, and the trimming insert 13 is detachably mounted in the mounting groove by screws.

[0065] As shown in Figure 6 and Figure 7 , the lower end of the trimming insert 13 has a trimming edge 131, the lower end of the trimming edge 131 is located below the lowermost end of the shaping protrusion 121, and the pressing piece 14 is mounted on the upper bottom plate 11.

[0066] The lower end of the trimming blade 131 is preferably not less than 1 mm higher than the lowermost end of the shaping protrusion 121, so that the trimming blade 131 first trims the oil filler opening during the downward movement of the upper die, and then the shaping protrusion 121 acts on the outer part of the oil filler opening to shape it downward.

[0067] The upper end of the lower die 30 has a conformal surface consistent with the lower surface of the side outer plate of the automobile, the lower die 30 has a trimming groove corresponding to the trimming insert 13, and the lower die 30 has a pre-flanging groove corresponding to the pre-shaping protrusion 131.

[0068] When the side outer plate is placed on the lower die 30, the charging port area thereof corresponds to the trimming groove, and the lower surface thereof conformally fits the surface of the lower die 30. During the downward movement of the upper die, the trimming blade 131 trims and shapes the charging port area, the waste falls from the lower end of the trimming groove, and the shaping protrusion 121 acts on the outer part of the oil filler opening to realize pre-flanging in the pre-flanging groove.

[0069] The pressure plate 20 is arranged between the upper die assembly 10 and the lower die 30, and the lower end of the pressure plate 20 has a conformal surface consistent with the upper surface of the side outer plate of the automobile. The pressure plate 20 is pressed against the side outer plate under the action of the pressure element of the upper die assembly 10.

[0070] In order to have a specific understanding of the working process of the present application, as shown in Figure 7 , wherein A is the A surface of the side outer plate, B is the pre-flanging surface after pre-flanging is completed, C is the drawing process surface, and D is the flanging height surface required by the product after forming is completed.

[0071] During the downward movement of the upper die of the forming die, the trimming blade 131 trims and shapes the charging port area corresponding to the trimming groove, wherein the trimming blade 131 is inwardly retracted by 3-5 mm at a position corresponding to the linear segment of the edge of the charging port, and corresponds to the boundary of the charging port at a position corresponding to the corner segment of the edge of the charging port, thereby realizing rough trimming of the linear segment of the edge of the charging port and fine trimming of the corner segment of the edge of the charging port.

[0072] The lower end of the shaping protrusion 121 has a height corresponding to one-third of the flange height of the product at the corner segment of the edge of the charging port and two-thirds of the flange height of the product at the linear segment. When the shaping protrusion 121 presses the corresponding position of the side outer plate into the pre-flanging groove, the height thereof is the flanging blade penetration amount. Therefore, the pre-flanging pre-flanging surface is not a complete curved surface of the same height, but is related to the height of the lower end of the shaping protrusion 121.

[0073] The pre-flanging surface B formed by the flanging pre-flanging and the drawing process surface C formed by drawing are uniformly transitioned. Figure 7 As can be seen in the figure, the two sides of the pre-flanging surface B are uniformly transitioned to the drawing process surface C.

[0074] Specifically, in the embodiment of the present application, the pressure material 14 includes a plurality of pressure material nitrogen gas springs which are evenly distributed circumferentially along the pre-shaping insert 12.

[0075] In order to ensure the effect of edge pressing and prevent the deformation of the A surface, the number of the pressure material nitrogen gas springs is greater than or equal to the edge pressing force divided by the force of a single nitrogen gas spring, and the distance from the center of each nitrogen gas spring to the trimming edge 131 is less than or equal to 80 mm.

[0076] According to field verification and mechanical principles, the size of the edge pressing force satisfies the following equation: F = KσtL, wherein K is an empirical constant, σ represents the tensile strength of the material, t is the thickness of the material in mm, and L is the length of the edge of the oil filler port in mm.

[0077] In a specific oil filler port forming process, the number of pressure material nitrogen gas springs is calculated to be greater than or equal to 8, and 9 pressure material nitrogen gas springs are evenly distributed circumferentially along the pre-shaping insert 12, and are mainly arranged in the corner section area, so as to ensure the effect of edge pressing and prevent the deformation of the A surface at the corner.

[0078] The oil filler port forming die provided in the present application corresponds to step S2 in the above forming process, and the trimming edge 131 of the trimming insert 13 punches out an oil filler port at the oil filler port area of the side wall outer panel, wherein the pre-shaping protrusion 121 shapes a groove on the outside of the oil filler port to achieve pre-flanging, and the height difference between the trimming edge 131 and the pre-shaping protrusion 121 achieves punching and flanging at the same time in one stroke, thereby saving time and effectively avoiding the generation of large internal stress due to the flow of surface material during shaping, and thus effectively eliminating the concave of the side wall outer panel and improving the delicate quality of the side wall outer panel.

[0079] After the side wall outer panel is formed by the forming die, the flange is then formed, the pre-shaping surface B is pressed downward to the flanging height surface required by the product forming, and then the straight section of the edge of the oil filler port is subjected to fine trimming processing, thereby completing the processing of the oil filler port.

[0080] The above description is only the preferred embodiment of the present application and is not intended to limit the present application. Any modification, equivalent replacement, improvement, etc. made within the spirit and principles of the present application shall be included in the protection scope of the present application.

Claims

1. A molding process for a charging port of a new energy vehicle, comprising the following steps: S1. Drawing: The side panel to be formed is drawn according to the surface trend to eliminate surface steps; S2. Punching: Press the outer side of the charging port area of ​​the side panel to be formed, and punch out the charging port in the charging port area. The straight section of the charging port edge is rough trimmed, and the corner section of the charging port edge is fine trimmed. Then, the outer side of the charging port edge is pre-shaped by flanging. The flanging cutting depth of the corner section of the charging port edge is lower than that of the straight section. The flanging cutting depth of the corner section of the charging port edge is one-third of the product flange height, and the flanging cutting depth of the straight section is two-thirds of the product flange height. The rough trimming is done by cutting the edge 3-5mm outward from the product boundary, and the fine trimming is done by cutting the edge according to the product boundary. Step S2 is completed using a new energy vehicle charging port forming mold, which includes an upper mold assembly, a pressure plate, and a lower punch. The upper mold assembly includes an upper base plate, a pre-shaping insert, a trimming insert, and a pressure member. The pre-shaping insert is connected to the lower end of the upper base plate, and the lower edge of the pre-shaping insert has a pre-shaping protrusion along the circumferential direction. The trimming insert is connected to the middle of the lower end of the pre-shaping insert, and the lower end of the trimming insert has a trimming edge. The lower end of the trimming edge is located below the lowermost end of the shaping protrusion. The pressure member is mounted on the upper base plate. The upper end of the lower punch has a conforming surface that is consistent with the lower surface of the side panel of the car. The lower punch has a trimming groove corresponding to the trimming insert and a pre-forming groove corresponding to the pre-forming protrusion. The pressure plate is disposed between the upper mold assembly and the lower punch, and the lower end of the pressure plate has a conformal surface that is consistent with the upper surface of the side panel of the automobile. S3. Flange forming: Press down the area of ​​the side panel located outside the flange, and shape it by flanging along the circumference of the charging port to form a flange. S4. Fine finishing: The straight sections of the charging port edge are finished with fine finishing.

2. The new energy vehicle charging port forming process according to claim 1, characterized in that, The pre-forming surface formed by the flanging pre-forming in step S2 is uniformly transitioned to the drawing process surface formed by the drawing in step S1.

3. The forming process for a new energy vehicle charging port according to claim 1, characterized in that, The pre-shaped insert has a mounting groove at the lower center, and the trimmed insert is detachably mounted in the mounting groove.

4. The forming process for a new energy vehicle charging port according to claim 1, characterized in that, The height difference between the lower end of the trimming blade and the lowermost end of the shaping protrusion is not less than 1 mm.

5. The forming process for a new energy vehicle charging port according to claim 1, characterized in that, The pressing component includes several nitrogen springs that are evenly distributed around the pre-shaped insert.

6. The new energy vehicle charging port forming process according to claim 5, characterized in that, The number of nitrogen springs for pressing the material satisfies the following relationship: the number of nitrogen springs for pressing the material ≥ the pressing force ÷ the force of a single nitrogen spring, and the distance from the center of each nitrogen spring to the trimming edge is less than or equal to 80mm.

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