Multi-process integrated rolling forming process and device for battery edge beam

Abstract

The invention discloses a battery edge beam multi-process integrated rolling forming device which comprises an uncoiling and leveling module, a rolling forming module, an online cutting module, a fixed-length accurate cutting module, an accurate machining module and a detection module. The uncoiling and leveling module, the rolling forming module, the online cutting module, the fixed-length accurate cutting module, the accurate machining module and the detection module are sequentially connected from left to right, and the detection module is arranged between the online cutting module and the fixed-length accurate cutting module and between the fixed-length accurate cutting module and the accurate machining module. A conveying roller set used for conveying the boundary beams is arranged between the precise machining module and the detection module. The processes of uncoiling and leveling, rolling forming, online cutting, fixed-length accurate cutting, accurate machining, detecting and the like are integrated, workpieces do not need to be transferred for multiple times, the transferring time and the repeated positioning frequency are reduced, and the production efficiency is improved by 30% or above.

Description

Technical Field

[0001] This invention relates to the field of automotive batteries, and specifically to a multi-process integrated roll forming process and apparatus for battery side beams. Background Technology

[0002] As a core load-bearing component of the battery pack, the side beam of an automotive battery directly affects the structural stability and safety of the battery pack, and must possess high strength and high precision structural characteristics. Currently, automotive battery side beams are mostly made of HC420 / 780DPD+Z high-strength galvanized steel, with thicknesses ranging from 1.2mm to 1.5mm. Their processing precision requirements are stringent, needing to meet a cross-sectional tolerance of ±0.25mm and straightness and torsion requirements of ≤0.5mm / m. Simultaneously, the vertical matching gap with the other side beam must be ≤0.6mm to ensure assembly compatibility.

[0003] The existing processing technology for automotive battery side beams has many defects and cannot meet the above technical requirements, as follows: 1. Dispersed processes, low production efficiency and difficulty in ensuring accuracy: In the existing process, roll forming, cutting, punching and cutting are all carried out independently. The workpiece needs to be transferred between different equipment multiple times, which not only leads to low production efficiency, but also the repeated positioning during multiple transfers can easily cause cumulative errors, making it difficult for the cross-sectional tolerance, straightness and torsion of the side beam to meet the design standards, affecting subsequent assembly.

[0004] 2. Poor tooling versatility and high production costs: The side beam structure of different battery models varies. The existing process requires the separate design of forming rollers, fixtures and other tooling for each model, which leads to a significant increase in equipment investment costs. At the same time, the tooling needs to be changed, which requires complex debugging and has a long changeover cycle, further affecting production efficiency.

[0005] 3. Unstable machining accuracy and poor assembly matching in key processes: In the machining of the side beams, key processes such as milling notches at the overlapping ends of the oblique frame and cutting the end angles suffer from unstable precision control using existing methods. This results in excessive vertical matching gaps (greater than 0.6mm) between the side beam and the matching side beam, affecting the overall assembly quality of the battery pack and even posing safety hazards. Therefore, those skilled in the art have provided a multi-process integrated roll forming process and apparatus for battery side beams to solve the problems mentioned in the background art. Summary of the Invention

[0006] To address the aforementioned technical problems, this invention provides a multi-process integrated roll forming process for battery side beams, including uncoiling and leveling, roll forming, online cutting, fixed-length precision cutting, precision machining, and inspection. The battery side beam processing is completed through the six processes of uncoiling and leveling, roll forming, online cutting, fixed-length precision cutting, precision machining, and inspection. The specific steps are as follows: S1: Uncoiling and leveling: Place the coil on the coil roller frame, fix the coil with the adjusting rod, start the extrusion roller to ensure stable output of the coil, and convey the coil to the leveling machine through the extrusion roller. The leveling machine detects the thickness of the coil in real time through the thickness detection sensor and automatically adjusts the leveling force to perform leveling treatment on the coil. S2: Roll forming. The leveled roll material is fed into the roll forming module. The servo pressure rollers, controlled by multi-axis coordination, drive the forming rollers to gradually extrude and form the roll material. The height of the servo pressure rollers is adjusted by the lifting mechanism to match the thickness of the roll material. During the forming process, the parameters are fed back in real time by the closed-loop control system and the rolling speed and force are adjusted. S3: Online cutting. The formed side beam is conveyed to the set position by the conveyor roller. The side beam is clamped by the clamping mechanism. The sawing mechanism is started to roughly cut the side beam and then convey it to the next module. S4: Fixed-length precision cutting. The rough-cut edge beam is conveyed to the wire cutting mechanism via conveyor rollers. The edge beam is precisely positioned by clamping plates. The slow wire cutting mechanism is used to precisely cut the end of the edge beam at an angle to control the length tolerance. After the precision cutting is completed, it is conveyed to the next module. S5: Precision machining. The precision-cut edge beam is sent into the precision machining module. The CAD drawings are imported using a five-axis laser cutting machine. The feature holes are cut with the end face of the edge beam as the positioning reference. For edge beams that need to have milled notches at the overlapping ends, the milling mechanism is started and the milling speed and depth are adjusted according to the notch size to complete the milling notch machining. S6: Inspection. The edge beam is sent into the inspection module. The fully automatic coordinate measuring machine performs comprehensive inspection on various parameters of the edge beam and records the data. A special inspection tool is used to inspect the assembly gap of the edge beam. After passing the inspection, the processing is completed.

[0007] Preferably, the roll material is made of HC420 / 780DPD+Z material, the roll thickness is 1.2mm-1.5mm, during the roll forming process, the cross-sectional tolerance of the side beam is controlled within ±0.25mm, the straightness and twist are ≤0.5mm / M, during the fixed-length precision cutting process, the length tolerance is controlled within 0-0.3mm; during the precision processing process, the position accuracy of the feature hole is ≤0.1mm.

[0008] Preferably, in the online cutting step, the cutting speed can be adjusted to 30mm / s-50mm / s according to the thickness of the roll material, and in the fixed-length precision cutting step, the cutting angle at the end of the side beam can be adjusted to 45°-53.5° as required.

[0009] A multi-process integrated roll forming device for battery side beams includes an uncoiling and leveling module, a roll forming module, an online cutting module, a fixed-length precision cutting module, a precision processing module, and a detection module. The uncoiling and leveling module, roll forming module, online cutting module, fixed-length precision cutting module, precision processing module, and detection module are sequentially connected from left to right. Transfer roller groups for conveying the side beams are provided between the online cutting module and the fixed-length precision cutting module, between the fixed-length precision cutting module and the precision processing module, and between the precision processing module and the detection module.

[0010] Preferably, the unwinding and leveling module includes a roll frame and a leveling machine. The roll frame has symmetrically arranged adjusting rods for fixing rolls of different diameters outside the winding roll. The roll frame is equipped with a squeezing roll for stable output of the roll. The leveling machine is located on the right side of the roll frame. The leveling machine is a multi-roller leveling machine and is equipped with a thickness detection sensor that can detect the thickness of the roll in real time and automatically adjust the leveling force.

[0011] Preferably, the roll forming module includes several servo pressure rollers and forming rollers. The servo pressure rollers are controlled by multiple axes. Several forming rollers are installed on the outer surface of the servo pressure rollers. The forming rollers are made of Cr12MoV material and have been quenched. Lifting mechanisms for adjusting the height of the servo pressure rollers are provided at both ends of the upper servo pressure rollers.

[0012] Preferably, the online cutting module includes a conveying roller and a sawing mechanism. Several conveying rollers are symmetrically arranged, and a sawing mechanism is set between the two conveying rollers. The sawing mechanism uses a high-precision saw blade, and the cutting speed can be adjusted within the range of 0-500mm / min according to the material and thickness of the side beam. Clamping mechanisms that can be adapted to the positioning requirements of different types of side beams are set on both sides of the sawing mechanism.

[0013] Preferably, the fixed-length precision cutting module includes a conveyor roller, a wire cutting mechanism, and a clamping plate. Several conveyor rollers are symmetrically arranged, and a wire cutting mechanism is set between the two conveyor rollers. The wire cutting mechanism adopts slow wire cutting technology with a cutting accuracy of ≤0.01mm. The clamping plate adopts a pneumatic clamping method with a changeover time of ≤10min.

[0014] Preferably, the precision machining module includes a five-axis laser cutting machine mechanism. The five-axis laser cutting machine adopts a fiber laser cutting machine with a cutting accuracy of ≤0.05mm and a positioning accuracy of ≤0.1mm. The precision machining module can also be optionally equipped with a milling mechanism for milling notches at the overlapping ends. The milling speed and depth of the milling mechanism can be adjusted according to the notch size.

[0015] Preferably, the detection module includes a coordinate measuring machine and a storage box. The coordinate measuring machine is a fully automatic coordinate measuring machine, which can automatically detect and record data on the side beam cross-sectional tolerance, straightness, torsion, length tolerance, and feature hole position parameters. The storage box is installed on the side of the coordinate measuring machine, and a special gauge made of cast iron and subjected to aging treatment is placed inside the storage box. The detection module can also be equipped with a data recording and analysis system for real-time recording and analysis of detection data.

[0016] The technical effects and advantages of this invention are as follows: 1. This invention integrates uncoiling and leveling, roll forming, online cutting, fixed-length precision cutting, precision processing, and inspection into one process. The workpiece does not need to be transferred multiple times, reducing transfer time and the number of repeated positioning, thus increasing production efficiency by more than 30%. At the same time, it avoids the cumulative errors caused by multiple positioning. Combined with high-precision processing technologies such as servo roll forming, laser positioning, and wire cutting, the cross-sectional tolerance, straightness, torsion, and length tolerance of the side beam all meet the design requirements, and the assembly gap is controlled within ≤0.6mm, significantly improving the matching accuracy.

[0017] 2. By adopting common B70D series forming rollers and other tooling, as well as special fixtures that can be quickly changed, this invention achieves universal processing of multiple types of side beams, eliminating the need to design tooling separately for each type, and reducing tooling investment costs by 40%. At the same time, the quick change-of-type structure shortens the change-of-type cycle, improves production flexibility, and adapts to the production needs of multiple varieties and small batches.

[0018] 3. This invention addresses key processes such as milling notches at the overlapping ends of the oblique frame and cutting the end angles by employing high-precision equipment such as five-axis laser cutting machines and wire cutting machines. This enables precise processing of key processes with stable processing accuracy, effectively solving the problem of excessive assembly gaps, improving the assembly matching between the side beam and the opposite side frame beam, and ensuring the structural stability and safety of the battery pack. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the structure of this application; Figure 2 This is a structural schematic diagram of the unwinding and leveling module of this application; Figure 3 This is a schematic diagram of the roll forming module of this application; Figure 4 This is a schematic diagram of the online cutting module of this application; Figure 5 This is a schematic diagram of the fixed-length precision cutting module of this application; Figure 6 This is a schematic diagram of the detection module of this application; In the diagram: 1. Uncoiling and leveling module; 11. Coil roller frame; 12. Adjusting rod; 13. Extrusion roller; 14. Leveling machine; 2. Roll forming module; 21. Servo pressure roller; 22. Forming roller; 23. Lifting mechanism; 3. Online cutting module; 31. Conveying roller; 32. Sawing mechanism; 33. Clamping mechanism; 4. Fixed-length precision cutting module; 41. Conveying roller; 42. Wire cutting mechanism; 43. Clamping plate; 5. Precision machining module; 6. Detection module; 61. Coordinate measuring machine; 62. Storage box. Detailed Implementation

[0020] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments. The embodiments of the present invention are given for illustrative and descriptive purposes only, and are not intended to be exhaustive or to limit the invention to the forms disclosed. Many modifications and variations will be apparent to those skilled in the art. The embodiments were chosen and described to better illustrate the principles and practical application of the invention, and to enable those skilled in the art to understand the invention and design various embodiments with various modifications suitable for a particular purpose.

[0021] Example 1: like Figures 1-6 As shown; a multi-process integrated roll forming device for battery side beams includes an uncoiling and leveling module 1, a roll forming module 2, an online cutting module 3, a fixed-length precision cutting module 4, a precision processing module 5, and a detection module 6. The uncoiling and leveling module 1, the roll forming module 2, the online cutting module 3, the fixed-length precision cutting module 4, the precision processing module 5, and the detection module 6 are connected sequentially from left to right. Transmission roller groups are provided between the online cutting module 3 and the fixed-length precision cutting module 4, between the fixed-length precision cutting module 4 and the precision processing module 5, and between the precision processing module 5 and the detection module 6. The uncoiling and leveling module 1 includes a roll frame 11 and a leveler 14. Adjusting rods 12 are symmetrically arranged on the outside of the take-up roller of the roll frame 11 to fix rolls of different diameters. Extrusion rollers 13 are arranged on the roll frame 11 for stable output of the roll. The leveler 14 is arranged on the right side of the roll frame 11. The leveler 14 is a multi-roller leveler. The leveler 14 is equipped with a thickness detection sensor, which can detect the thickness of the roll in real time and automatically adjust the leveling force. The roll forming module 2 includes several servo pressure rollers 21 and forming rollers 22. The servo pressure rollers 21 adopt multi-axis collaborative control, which can realize the step-by-step forming of the side beam cross section with high forming accuracy. Several forming rollers 22 are installed on the outer surface of the servo pressure rollers 21. The forming rollers 22 are B70D series forming rollers. The B70D series forming rollers are made of Cr12MoV material and are hardened, resulting in high hardness and strong wear resistance. Lifting mechanisms 23 are set at both ends of the upper servo pressure rollers 21 to adjust the height of the servo pressure rollers 21. The online cutting module 3 includes a conveying roller 31 and a sawing mechanism 32. Several conveying rollers 31 are symmetrically arranged, and the sawing mechanism 32 is set between the two conveying rollers 31. The sawing mechanism 32 adopts a high-precision saw blade, and the cutting speed is 0-500mm / min, which can realize the rapid rough cutting of the side beam. The cutting speed can be adjusted according to the material and thickness of the side beam. Clamping mechanisms 33 are set on both sides of the sawing mechanism 32. The clamps can be adapted to the positioning requirements of different types of side beams, reducing the number of tooling changes. The fixed-length precision cutting module 4 includes a conveyor roller 41, a wire cutting mechanism 42, and a clamping plate 43. Several conveyor rollers 41 are symmetrically arranged, and the wire cutting mechanism 42 is set between the two conveyor rollers 41. The wire cutting mechanism 42 adopts slow wire cutting technology, with a cutting accuracy of ≤0.01mm. It has high cutting accuracy and a flat cut, and can achieve precise cutting of the end angle of the side beam. The clamping plate 43 adopts a pneumatic clamping method, with high positioning accuracy and a changeover time of ≤10min. The precision machining module 5 includes a five-axis laser cutting machine mechanism: the five-axis laser cutting machine adopts a fiber laser cutting machine with a cutting accuracy of ≤0.05mm and a positioning accuracy of ≤0.1mm. The five-axis laser cutting machine can realize multi-angle and multi-position cutting, adapt to the processing needs of feature holes in different positions, and has high cutting accuracy and high efficiency. For special model side beams, this module can also be equipped with a milling mechanism for milling notches at the overlapping ends. The milling speed and depth of the milling mechanism can be adjusted according to the notch size to ensure the notch processing accuracy. The inspection module 6 includes a coordinate measuring machine (CMM) 61 and a storage box 62. The CMM 61 is a fully automatic CMM, which can automatically detect and record the dimensions of the edge beam. The CMM 61 is used for precise detection of the edge beam dimensions and can comprehensively detect parameters such as cross-sectional tolerance, straightness, torsion, length tolerance, and feature hole position. The detection data is accurate and reliable. The storage box 62 is installed on the side of the CMM 61, and a special inspection tool is placed inside the storage box 62. The special inspection tool is made of cast iron and has undergone aging treatment, so its accuracy is stable. It can quickly detect the assembly gap and key dimensions of the edge beam. The inspection module 6 can also be equipped with a data recording and analysis system to record and analyze the detection data in real time, so as to facilitate the timely detection of problems in the processing process, adjust the processing parameters, and improve the product qualification rate.

[0022] Example 2 A multi-process integrated roll forming process for battery side beams This embodiment focuses on processing a short frame edge beam (cutting length 2300mm, end angle 45°) of HC420 / 780DPD+Z material with a thickness of 1.2mm. The process is accomplished through the coordinated operation of a sequentially connected uncoiling and leveling module 1, roll forming module 2, online cutting module 3, fixed-length precision cutting module 4, precision processing module 5, and detection module 6. The specific steps are as follows: S1: Uncoiling and Leveling: Place the 1.2mm thick HC420 / 780DPD+Z material roll on the roll roller frame 11 of the uncoiling and leveling module 1. Fix the roll (adapt to the roll diameter) with the adjusting rods 12 symmetrically arranged outside the take-up roller of the roll roller frame 11. Start the extrusion roller 13 on the roll roller frame 11 to ensure stable output of the roll. The roll is conveyed to the leveling machine 14 on the right side of the roll roller frame 11 through the extrusion roller 13. The leveling machine 14 adopts a multi-roller structure. Its thickness detection sensor detects the thickness of the roll in real time and automatically adjusts the leveling force to level the roll, remove the bending deformation of the roll, and ensure that the flatness of the roll meets the requirements of subsequent processing. S2: Roll forming: The leveled roll material is fed into the roll forming module 2, where it is gradually extruded and formed by several servo pressure rollers 21 (using multi-axis collaborative control). The B70D series forming rollers 22 (Cr12MoV material, quenched) installed on the outer surface of the servo pressure rollers 21 adhere to the roll material, realizing the gradual forming of the side beam cross-section. According to the thickness of the roll material, the lifting mechanisms 23 at both ends of the upper servo pressure rollers 21 are adjusted to adjust the height of the servo pressure rollers 21 to ensure the rolling fit. During the forming process, the parameters are fed back in real time through the closed-loop control system to adjust the rolling speed and force, ensuring that the tolerance of the side beam cross-section is controlled within ±0.25mm, and the straightness and twist are ≤0.5mm / M. S3: Online Cutting: The formed side beam is fed into the online cutting module 3 and smoothly transported by several symmetrically arranged conveyor rollers 31 within the module. When the side beam is transported to the set position, the clamping mechanisms 33 on both sides of the sawing mechanism 32 are activated to clamp the side beam (the fixture is adapted to the positioning requirements of short frame, and there is no need to change the tooling). Then the sawing mechanism 32 is activated, using a high-precision saw blade, and the cutting speed is adjusted to 50mm / s to perform rough cutting of the side beam, ensuring that the rough cutting length is 2300mm. During the cutting process, the clamping mechanism 33 always maintains a clamped state to prevent the side beam from shaking and causing cutting deviation. After cutting, the conveyor rollers 31 continue to transport the side beam to the next module. S4: Fixed-length precision cutting: The rough-cut edge beam is fed into the fixed-length precision cutting module 4, and smoothly conveyed to the wire cutting mechanism 42 by the symmetrically arranged conveyor rollers 41 within the module. The clamping plate 43 is activated, and the edge beam is precisely positioned using a pneumatic clamping method, with the positioning accuracy meeting the requirements. The wire cutting mechanism 42 is adjusted (using slow wire cutting technology, with a cutting accuracy ≤0.01mm) to perform a 45° angle precision cut on the end of the edge beam, with the length tolerance controlled in real time to be 0-0.3mm to ensure the accuracy of the end dimensions and angle. After the precision cutting is completed, the clamping plate 43 is released, and the conveyor rollers 41 transport the edge beam to the precision processing module 5. S5: Precision Machining: The precision-cut edge beam is fed into the precision machining module 5, where a five-axis laser cutting machine is used to cut the feature holes. This five-axis laser cutting machine uses a fiber laser cutting machine with a cutting accuracy of ≤0.05mm and a positioning accuracy of ≤0.1mm. Relying on the five-axis linkage structure, it can achieve multi-angle and multi-position cutting, adapting to the processing requirements of feature holes at different positions on short-frame edge beams. It has high cutting accuracy and high efficiency. Using the end face of the edge beam as the positioning reference, the CAD drawing of the feature hole is imported, the laser cutting is started, and the feature hole cutting is completed, ensuring that the positional accuracy of the feature hole is ≤0.1mm. In this embodiment, the edge beam is a short-frame edge beam, so there is no need to perform the overlapping end milling notch process. After the cutting is completed, the edge beam is transported to the detection module 6. S6: Inspection: The side beam is sent into the inspection module 6. First, the coordinate measuring machine 61 (fully automatic structure) in the module is used to comprehensively inspect the parameters of the side beam, such as cross-sectional tolerance, straightness, torsion, length tolerance, and feature hole position. It can realize automatic inspection and data recording, and the inspection data is accurate and reliable. Then, a special inspection tool (made of cast iron, aged and stable) is taken out from the storage box 62 on the side of the coordinate measuring machine 61 to quickly inspect the assembly gap of the side beam. The inspection results show that the cross-sectional tolerance is ±0.22mm, the straightness and torsion are 0.45mm / M, the length tolerance is 0.2mm, the assembly gap is 0.5mm, and the metallographic inspection meets the material performance requirements. After the inspection is qualified, the processing is completed.

[0023] Example 3 A multi-process integrated roll forming process for battery side beams This embodiment focuses on the processing of a long frame edge beam (3900mm blank length, 53.5° end angle, requiring overlapping end milling notch) made of HC420 / 780DPD+Z material with a thickness of 1.5mm. The process utilizes a series of interconnected modules: uncoiling and leveling module 1, roll forming module 2, online cutting module 3, fixed-length precision cutting module 4, precision processing module 5, and detection module 6. The specific steps are as follows: S1: Uncoiling and Leveling: Place the 1.5mm thick HC420 / 780DPD+Z material roll on the roll roller frame 11 of the uncoiling and leveling module 1. Adjust the fixed width using the adjusting rod 12 of the roll roller frame 11 to match the diameter of the roll of this specification. Start the extrusion roller 13 to ensure uniform and stable output of the roll and avoid roll deviation. The roll is conveyed to the leveling machine 14 via the extrusion roller 13. The thickness detection sensor of the leveling machine 14 detects the thickness of the roll in real time and automatically adjusts the multi-roll leveling force to remove the bending deformation of the roll, ensure the flatness of the raw material, and meet the requirements of subsequent roll forming. S2: Roll forming: The leveled roll material is fed into the roll forming module 2, and several servo pressure rollers 21 are activated. Relying on the multi-axis collaborative control function, the B70D series forming rollers 22 on the outer surface of the rollers rotate synchronously to gradually extrude and form the roll material. The height of the servo pressure rollers 21 is adjusted by the lifting mechanism 23 at both ends of the upper servo pressure rollers 21 to adapt to the rolling requirements of 1.5mm thick roll material, ensuring that the forming rollers 22 are in close contact with the roll material. During the forming process, the closed-loop control system provides real-time feedback on the rolling parameters and adjusts the rolling speed and force in a timely manner to control the side beam cross-sectional tolerance to ±0.25mm, and the straightness and twist to ≤0.5mm / M. After the side beam cross-section is formed, it is conveyed to the online cutting module 3. S3: Online Cutting: The formed long frame beam is fed into the online cutting module 3 and smoothly conveyed by the conveying roller 31 in the module. The positioning parameters are set according to the blanking length of the long frame 3900mm. When the beam reaches the set position, the clamping mechanisms 33 on both sides of the sawing mechanism 32 are activated to accurately clamp the beam (the fixture is adapted to the long frame positioning and no tooling change is required); the sawing mechanism 32 is activated and the cutting speed is adjusted to 30mm / s (adapted to 1.5mm thick material). A high-precision saw blade is used to roughly cut the beam to ensure that the blanking length is 3900mm and the cut is flat and burr-free; after sawing, the chip collection mechanism collects the metal chips, the clamping mechanism 33 is released, and the conveying roller 31 conveys the rough-cut beam to the fixed-length precision cutting module 4. S4: Fixed-length precision cutting: The rough-cut edge beam is fed into the fixed-length precision cutting module 4 and smoothly conveyed to the designated position by the conveyor roller 41. The clamping plate 43 is activated, and the edge beam is precisely positioned by pneumatic clamping, which has high positioning accuracy and meets the subsequent precision cutting requirements. The wire cutting mechanism 42 (slow wire cutting technology, cutting accuracy ≤0.01mm) is adjusted and the end cutting angle of 53.5° is set to perform precision cutting on the end of the edge beam. The length tolerance is controlled in real time within the range of 0-0.3mm to ensure that the end angle and length accuracy meet the design standards. After the precision cutting is completed, the clamping plate 43 is released, and the conveyor roller 41 transports the edge beam to the precision processing module 5. The entire process changeover time is ≤10min, which improves processing efficiency. S5: Precision Machining: The precision-cut edge beam is fed into the precision machining module 5. First, the feature holes are cut using the five-axis laser cutting machine mechanism within the module. This five-axis laser cutting machine is a fiber laser cutting machine with a cutting accuracy of ≤0.05mm and a positioning accuracy of ≤0.1mm. With the help of the five-axis linkage structure, it can achieve precise cutting of feature holes at different positions and angles on the edge beam, adapting to the processing requirements of feature holes on long-frame edge beams. It has high cutting efficiency and no deformation of the cut. Using the end face of the edge beam as the positioning reference, the CAD drawing of the feature hole is imported to complete the feature hole cutting. Subsequently, the milling mechanism equipped in the module is started to mill notches at the overlapping end of the long-frame edge beam. The milling speed and depth are adjusted according to the notch size to ensure that the notch size and angle meet the design requirements and the processing accuracy is stable. After processing, the edge beam is transported to the inspection module 6. S6: Inspection: The side beam is fed into the inspection module 6. First, the fully automatic coordinate measuring machine 61 is started to automatically inspect parameters such as cross-sectional tolerance, straightness, torsion, length tolerance, feature hole position, and lap end notch size of the side beam, and records the inspection data in real time. Then, a special gauge is taken out from the storage box 62 to quickly inspect the assembly gap of the side beam. The special gauge has stable accuracy and can efficiently complete the inspection of key dimensions and assembly gaps. The inspection results show that the cross-sectional tolerance is ±0.24mm, the straightness and torsion are 0.48mm / M, the length tolerance is 0.25mm, the assembly gap is 0.55mm, and the metallographic inspection meets the material performance requirements of HC420 / 780DPD+Z. After passing the inspection, the entire processing process is completed.

[0024] Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. All other embodiments obtained by those skilled in the art and related fields based on the embodiments of the present invention without inventive effort should fall within the scope of protection of the present invention. Structures, devices, and operating methods not specifically described and explained in the present invention, unless otherwise specified or limited, shall be implemented according to conventional means in the art.

Claims

1. A multi-process integrated roll forming process for battery side beams, characterized in that, The battery side beam processing includes six steps: uncoiling and leveling, roll forming, online cutting, fixed-length precision cutting, precision processing, and inspection. The specific steps are as follows: S1: Unwinding and leveling: Place the roll on the roll roller frame (11), fix the roll by adjusting rod (12), start the extrusion roller (13) to ensure stable output of the roll, and convey the roll to the leveling machine (14) through the extrusion roller (13). The leveling machine (14) detects the thickness of the roll in real time through the thickness detection sensor and automatically adjusts the leveling force to level the roll. S2: Roll forming, the flattened roll material is fed into the roll forming module (2), and the forming roller (22) is driven by the servo pressure roller (21) controlled by multi-axis coordination to gradually extrude and form the roll material. The height of the servo pressure roller (21) is adjusted to match the thickness of the roll material by the lifting mechanism (23). During the forming process, the parameters are fed back in real time by the closed-loop control system and the rolling speed and force are adjusted. S3: Online cutting. The formed side beam is conveyed to the set position by the conveying roller (31), the side beam is clamped by the clamping mechanism (33), the sawing mechanism (32) is started to roughly cut the side beam, and then it is conveyed to the next module after cutting. S4: Fixed-length precision cutting. The rough-cut side beam is conveyed to the wire cutting mechanism (42) via the conveyor roller (41). The side beam is precisely positioned by the clamping plate (43). The end of the side beam is precisely angled by the slow wire cutting mechanism (42) to control the length tolerance. After the precision cutting is completed, it is conveyed to the next module. S5: Precision machining. The precision-cut edge beam is sent into the precision machining module (5). The CAD drawing is imported using a five-axis laser cutting machine. The feature hole is cut with the end face of the edge beam as the positioning reference. For the edge beam that needs to be milled at the overlapping end, the milling mechanism is started and the milling speed and depth are adjusted according to the size of the notch to complete the milling notch machining. S6: Inspection. The side beam is sent into the inspection module (6). The parameters of the side beam are fully inspected and the data is recorded by the fully automatic three-coordinate measuring machine (61). The assembly gap of the side beam is inspected by a special inspection tool. After the inspection is qualified, the processing is completed.

2. The multi-process integrated roll forming process for battery side beams according to claim 1, characterized in that, The roll material is made of HC420 / 780DPD+Z material with a thickness of 1.2mm-1.5mm. During the roll forming process, the cross-sectional tolerance of the side beam is controlled within ±0.25mm, and the straightness and twist are ≤0.5mm / M. During the fixed-length precision cutting process, the length tolerance is controlled within 0-0.3mm. During the precision machining process, the position accuracy of the feature hole is ≤0.1mm.

3. The multi-process integrated roll forming process for battery side beams according to claim 1, characterized in that, In the online cutting step, the cutting speed can be adjusted to 30mm / s-50mm / s according to the thickness of the roll material. In the fixed-length precision cutting step, the cutting angle at the end of the side beam can be adjusted to 45°-53.5° as required.

4. A multi-process integrated roll forming apparatus for battery side beams, used in any one of the multi-process integrated roll forming processes for battery side beams according to claims 1-3, characterized in that, The system includes an uncoiling and leveling module (1), a roll forming module (2), an online cutting module (3), a fixed-length precision cutting module (4), a precision processing module (5), and a detection module (6). The uncoiling and leveling module (1), the roll forming module (2), the online cutting module (3), the fixed-length precision cutting module (4), the precision processing module (5), and the detection module (6) are connected sequentially from left to right. Transmission roller groups for conveying the side beams are provided between the online cutting module (3) and the fixed-length precision cutting module (4), between the fixed-length precision cutting module (4) and the precision processing module (5), and between the precision processing module (5) and the detection module (6).

5. The multi-process integrated roll forming device for battery side beams according to claim 4, characterized in that, The unwinding and leveling module (1) includes a roll frame (11) and a leveling machine (14). The roll frame (11) has symmetrically arranged adjustment rods (12) for fixing rolls of different diameters outside the winding rollers. The roll frame (11) is equipped with a squeezing roller (13) for stable output of the roll. The leveling machine (14) is arranged on the right side of the roll frame (11). The leveling machine (14) is a multi-roller leveling machine and is equipped with a thickness detection sensor that can detect the thickness of the roll in real time and automatically adjust the leveling force.

6. A multi-process integrated roll forming device for battery side beams according to claim 4, characterized in that, The roll forming module (2) includes several servo pressure rollers (21) and forming rollers (22). The servo pressure rollers (21) are controlled by multi-axis coordination. Several forming rollers (22) are installed on the outer surface of the servo pressure rollers (21). The forming rollers (22) are made of Cr12MoV material and have been quenched. Lifting mechanisms (23) for adjusting the height of the servo pressure rollers (21) are provided at both ends of the upper servo pressure rollers (21).

7. A multi-process integrated roll forming device for battery side beams according to claim 4, characterized in that, The online cutting module (3) includes a conveying roller (31) and a sawing mechanism (32). Several conveying rollers (31) are symmetrically arranged, and a sawing mechanism (32) is set between the two conveying rollers (31). The sawing mechanism (32) uses a high-precision saw blade, and the cutting speed can be adjusted according to the material and thickness of the side beam within the range of 0-500mm / min. Clamping mechanisms (33) are set on both sides of the sawing mechanism (32) to adapt to the positioning requirements of different types of side beams.

8. A multi-process integrated roll forming device for battery side beams according to claim 4, characterized in that, The fixed-length precision cutting module (4) includes a conveyor roller (41), a wire cutting mechanism (42), and a clamping plate (43). Several conveyor rollers (41) are symmetrically arranged, and a wire cutting mechanism (42) is set between the two conveyor rollers (41). The wire cutting mechanism (42) adopts slow wire cutting technology with a cutting accuracy of ≤0.01mm. The clamping plate (43) adopts a pneumatic clamping method with a changeover time of ≤10min.

9. A multi-process integrated roll forming device for battery side beams according to claim 4, characterized in that, The precision processing module (5) includes a five-axis laser cutting machine mechanism. The five-axis laser cutting machine adopts a fiber laser cutting machine with a cutting accuracy of ≤0.05mm and a positioning accuracy of ≤0.1mm. The precision processing module (5) can also be optionally equipped with a milling mechanism for milling notches at the overlapping ends. The milling speed and depth of the milling mechanism can be adjusted according to the notch size.

10. A multi-process integrated roll forming device for battery side beams according to claim 4, characterized in that, The detection module (6) includes a coordinate measuring machine (61) and a storage box (62). The coordinate measuring machine (61) is a fully automatic coordinate measuring machine (61), which can realize automatic detection and data recording of side beam cross-sectional tolerance, straightness, torsion, length tolerance, and feature hole position parameters. The storage box (62) is installed on the side of the coordinate measuring machine (61). The storage box (62) contains a special inspection tool made of cast iron and subjected to aging treatment. The detection module (6) can also be equipped with a data recording and analysis system for real-time recording and analysis of detection data.

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