Vehicle long seat rail cold stamping forming production line and processing method

Abstract

The application discloses a kind of vehicle long seat guide rail cold stamping forming production line and processing method, it is related to the production field of automobile parts, specifically includes the following steps: step S1, base surface shaping, in this step, first of all, the center area of long metal plate piece is applied pressure, and the raised base surface structure is formed in the center area of plate piece by special forming die, and the installation base surface of guide rail is formed.This raised structure provides a stable contact surface for subsequent guide rail installation, ensuring accurate positioning of the guide rail during installation, while enhancing the strength and stability of the guide rail base, avoiding deformation affecting the seat adjustment function.The method optimizes the cold stamping process, accurately controls each forming step of the metal plate, ensures that the guide rail has high dimensional accuracy, flatness and structural strength, and meets the functional requirements of the automobile seat guide rail.

Description

Technical Field

[0001] This application relates to the field of automotive parts manufacturing, and in particular to a production line and processing method for cold stamping of long seat rails for vehicles. Background Technology

[0002] Currently, long seat rails, as an important component of vehicle interior systems, are widely used in seat adjustment systems of various passenger cars and commercial vehicles, especially in multi-purpose vehicles (MPVs), large SUVs, and motorhomes, where they have significant application value. As users' demands for seat comfort, functionality, and adjustment precision continue to increase, the design requirements for long seat rails necessitate longer adjustment travel to meet the diverse needs of different body types and driving styles. Therefore, the manufacturing process of long seat rails must enable precise forming of longer rails while maintaining high strength, stability, and precision to ensure smooth seat adjustment and reliability during use.

[0003] In the existing manufacturing of long seat rails, roll forming is a widely used process. Roll forming involves feeding a metal sheet of a certain width between multiple rollers, and under continuous pressure, gradually plastically deforming the metal sheet to form the desired rail shape. This process has high production efficiency, enabling large-scale mass production, and can, to a certain extent, meet the mechanical properties, strength, and durability requirements of the rails. Roll forming is widely used in the production of long seat rails, and is particularly suitable for producing rails with complex cross-sectional shapes and long lengths.

[0004] However, while roll forming can effectively control product quality in the production of short guide rails, existing processes face significant challenges in ensuring flatness and dimensional accuracy when the guide rail length exceeds 600mm. Long guide rails, after being pressed by multiple rollers, often exhibit surface unevenness, especially with greater lengths, where the metal sheet surface may develop deformations such as waviness, wrinkles, or localized bulges. This lack of flatness not only affects the appearance of the guide rail but, more seriously, can reduce the installation accuracy of the connection between the guide rail and the seat adjustment system, thus affecting the seat's adjustment function and potentially negatively impacting the long-term performance of the seat and the overall comfort of the vehicle.

[0005] The root cause of this unevenness lies in the uneven plastic deformation of the metal material during the roll forming process. Roll forming relies on the pressure applied to the metal sheet by rollers to gradually deform it. However, due to the uneven distribution of pressure from the rollers, stress concentration may occur in the metal material during the stress process, leading to uneven metal flow and plastic deformation, which in turn causes surface unevenness. When processing long guideways, the force exerted by the rollers on the metal sheet exhibits different stress distributions at different parts of the long guideway, especially at both ends and the middle, where there is often a significant pressure difference. This makes it difficult for the plastic deformation of the material to proceed uniformly, resulting in localized deformation or wavy undulations.

[0006] Furthermore, the current technology and process control precision of most roll forming equipment have certain limitations. Existing equipment largely relies on traditional mechanical control systems, whose precision is insufficient to handle the minute changes during the forming process of long guideways. Especially during production, as the guideway length increases, the equipment's ability to control material deformation gradually weakens. In the production of long guideways, limitations in equipment precision and operational stability may make it difficult to monitor and precisely adjust the forming pressure at each stage in real time, further exacerbating the difficulty of flatness control.

[0007] These issues lead to significant deviations in flatness and precision control when using existing roll forming processes for longer guide rails, thus affecting the overall product quality. Unevenness on the surface of long guide rails not only affects the precision and smoothness of seat adjustments but can also cause jamming during adjustment, impacting driver and passenger comfort. Over prolonged use, guide rail deformation can cause malfunctions in the seat adjustment mechanism, increasing maintenance costs and potentially affecting the safety of the seat system. Furthermore, insufficient flatness of the guide rails can lead to poor fit during vehicle assembly, affecting the installation precision between the guide rail and the seat frame, further impacting overall vehicle quality control and comfort.

[0008] Developing a new production line and processing method to address these issues has significant technological value. Summary of the Invention

[0009] The purpose of this application is to overcome at least one deficiency of the prior art and provide a cold stamping forming production line and processing method for vehicle long seat guide rails. This processing method uses stamping technology and replaces roll forming with stamping forming to meet the production and use needs of high-precision long guide rails.

[0010] To achieve the above objectives, in a first aspect, this application discloses a cold stamping forming production line for vehicle long seat guide rails, which sequentially includes a material receiving device, a first stamping forming device, a second stamping forming device, a third stamping forming device, a fourth stamping forming device, a punching processing device, and a material discharge device. The material receiving device continuously feeds metal sheets into the first stamping forming device. Material transfer is achieved between the first, second, third, fourth, and punching forming devices via a material delivery device. The material discharge device continuously discharges the guide rail parts processed by the fourth stamping forming device, thus achieving continuous production. The first stamping forming device is used to complete the base surface forming of metal sheet. Structurally, it includes a first upper die and a first lower die opposite to the first upper die. The first upper die and the second lower die are driven to move relative to each other by a drive mechanism to complete the die closing and opening actions. The first lower die in the first stamping forming device is provided with a first forming module. The first forming module has a protruding first forming block. The center of the forming block is protruding to form a center surface, and the two sides are lower than the center surface to form side forming surfaces. The side forming surfaces are sloped downward from the center surface to the outside to form a bending forming compensation angle. The compensation angle is used to increase the stamping forming angle and thus compensate for the stress rebound of the material. Correspondingly, the first upper die is provided with a first central pressure block opposite to the first forming block and forming punches located on both sides of the central pressure block. The second stamping forming device is used to complete the first side bending of the metal sheet. Structurally, it includes a second upper die and a second lower die that cooperates with the second upper die. The second lower die is provided with a second forming block, the upper surface of which is adapted to the shape of the metal sheet. Correspondingly, the second upper die is provided with a second central pressure block opposite to the second forming block and first bending punches located on both sides of the second central pressure block for completing the bending process. The side of the second forming block cooperates with the first bending punches to complete the bending process. At the same time, the side of the second forming block is tilted inward to form a bending compensation angle. The third stamping forming device is used to complete the second bending of the side of the metal sheet, so that the side of the metal sheet is U-shaped after the first and second bending. In terms of structure, the third stamping forming device is the same as the second forming device. The difference is that the third forming block in the third stamping forming device is T-shaped or I-shaped, and the side is concave to avoid the bending already processed by the second stamping forming device.

[0011] The fourth stamping forming device is used to complete the overall bending of the first plate, so that the metal plate is bent into a U-shaped cross section guide rail. Structurally, the fourth stamping forming device has the same structure as the third stamping forming device.

[0012] To achieve the above objectives, in a second aspect, this application discloses a cold stamping forming method for vehicle long seat guide rails. This method optimizes the cold stamping process and precisely controls each forming step of the metal sheet to ensure that the guide rail has high dimensional accuracy, flatness, and structural strength, meeting the functional requirements of automotive seat guide rails. Specifically, it includes the following steps: Step S1, Base Surface Forming: In this step, pressure is first applied to the central area of ​​the elongated metal plate. Using a specialized forming mold, a raised base surface structure is formed in the central area of ​​the plate, creating the mounting base surface for the guide rail. This raised structure provides a stable contact surface for subsequent guide rail installation, ensuring accurate positioning of the guide rail during installation. It also enhances the strength and stability of the guide rail base surface, preventing deformation from affecting the seat adjustment function.

[0013] Step S2, Folding: After completing the base surface forming process, the folding stage begins. In this step, both sides of the sheet are folded to create a 90° edge structure. The folding operation aims to form the side structure of the guide rail, preparing it for subsequent flanging and bending processes. By precisely controlling the folding angle, the edges on both sides of the guide rail are ensured to have good shape and stability, thereby reducing deformation or unevenness caused by uneven edges.

[0014] Step S3: Flanging. After folding, the next step is flanging. In this step, the panel is folded again near the folding area to form a flanged structure. The main purpose of flanging is to enhance the edge strength and rigidity of the guide rail, ensuring sufficient support on both sides to prevent deformation or damage during use. Furthermore, the flanged structure improves the connection stability between the guide rail and other components, ensuring a high-precision fit when assembled with components such as the seat frame.

[0015] Step S4, bending and forming, is a crucial step in the cold stamping process. This step uses a precision bending die to bend the sheet metal, ultimately forming the guide groove structure of the guide rail. The guide groove structure is the core of the seat guide rail, supporting the sliding components in the seat adjustment system and ensuring smoothness and precision during seat adjustment. Through stamping and bending, ideal groove cross-sections are formed on both sides and the bottom of the guide rail, ensuring that the strength and rigidity of the guide rail meet the dynamic load requirements of the seat adjustment system. Furthermore, this bending process effectively reduces stress concentration and uneven deformation of the material, ensuring the guide rail has high dimensional accuracy and good flatness.

[0016] Step S5: Punching. Finally, after the guide groove structure is formed, the punching process begins. Punching is performed on the sheet metal using stamping or laser to meet the requirements of subsequent guide rail installation and seat adjustment.

[0017] Compared with existing technologies, the cold stamping forming method for vehicle long seat guide rails described in this application ensures that the guide rail maintains good flatness, dimensional accuracy, and structural strength during the forming process through precise control of multiple processes such as base surface forming, folding, flanging, bending, and punching. In particular, the use of precise molds and bending angle control during the bending process ensures the stability and strength of the guide rail groove structure, thereby meeting the stringent requirements of seat adjustment systems for guide rail precision and durability.

[0018] This method includes at least one of the following beneficial effects: 1. Improved precision and structural strength of the guide rail. In particular, during the formation of the guide groove structure, the precise bending process enables the sides and bottom of the guide rail to effectively bear the dynamic load of the seat adjustment system, avoiding functional failure due to excessive deformation.

[0019] 2. The production process has been optimized. Compared with the cold stamping process, it solves the problem of frequent roller replacement due to wear in roll forming. The yield rate is high, the production speed is fast, and the overall production cost of the finished product is significantly reduced.

[0020] 3. Improved production stability and reliability. By precisely controlling each process, product defects caused by material deformation and equipment errors were reduced, ensuring the high quality and high precision of the long seat guide rail.

[0021] 4. Reduced production costs: The cold stamping process reduces the need for high-temperature heating and shortens the forming time, effectively reducing energy consumption and production costs.

[0022] The beneficial effects listed above are not exhaustive of all advantages. Other potential beneficial effects and detailed technical implementation methods will be further disclosed in the embodiments or other descriptive sections of this application. Attached Figure Description

[0023] A better understanding of various aspects of this disclosure will be achieved by reading the following detailed description in conjunction with the accompanying drawings. The positions, dimensions, and extents of the structures shown in the drawings, etc., do not always represent actual positions, dimensions, and extents. In the drawings: Figure 1 This is a schematic diagram of the structure of the first stamping forming device in one embodiment of this application, and also a schematic diagram of the processing step S1.

[0024] Figure 2 This is a schematic diagram of the structure of the second stamping forming device in one embodiment of this application, and also a schematic diagram of step S2 processing.

[0025] Figure 3 This is a schematic diagram of the structure of the third stamping forming device in one embodiment of this application, and also a schematic diagram of step S3 processing.

[0026] Figure 4 This is a schematic diagram of the structure of the fourth stamping forming device in one embodiment of this application, and also a schematic diagram of the processing in step S4. Detailed Implementation

[0027] The present disclosure will now be described with reference to the accompanying drawings, which illustrate several embodiments of the present disclosure. However, it should be understood that the present disclosure can be presented in many different ways and is not limited to the embodiments described below; in fact, the embodiments described below are intended to make the disclosure more complete and to fully illustrate the scope of protection of the present disclosure to those skilled in the art. It should also be understood that the embodiments disclosed herein can be combined in various ways to provide further additional embodiments.

[0028] It should be understood that the same reference numerals denote the same elements in all the accompanying drawings. For clarity, the dimensions of certain features may be modified in the drawings.

[0029] It should be understood that the terminology used in this specification is for describing specific embodiments only and is not intended to limit this disclosure. All terms used in this specification (including technical and scientific terms) have the meanings commonly understood by those skilled in the art, unless otherwise defined. For the sake of brevity and / or clarity, techniques, methods, and apparatus known to those skilled in the art may not be discussed in detail; however, where appropriate, such techniques, methods, and apparatus should be considered part of this specification.

[0030] Unless otherwise specified, the singular forms “a,” “the,” and “the” used in this specification include the plural forms. The terms “comprising,” “including,” and “containing” used in this specification indicate the presence of the claimed feature but do not exclude the presence of one or more other features. The term “and / or” used in this specification includes any and all combinations of one or more of the relevant listed items. Example

[0031] See attached document Figures 1 to 4 This embodiment discloses a cold stamping forming method and production line for producing automotive seat guide rails. This production line, through precisely designed molds and strictly controlled processing techniques, ensures that the guide rails meet high standards in terms of dimensional accuracy, surface flatness, and mechanical strength, making it particularly suitable for producing guide rails longer than 600mm. The entire processing adopts a step-by-step precision control method. Deformation in each process is reduced and defects minimized through optimized mold design and precise equipment control, thereby avoiding the dimensional deformation and surface unevenness problems commonly found in traditional roll forming processes.

[0032] Compared to traditional roll forming processes, production lines using multi-mold processing have significant advantages in several aspects. Firstly, in terms of space utilization, since each forming process is completed independently using a dedicated mold, there is no need to occupy a large space for complex roll forming equipment. This results in a smaller production line footprint, enabling efficient production within a limited space. Secondly, production lines employing multi-mold processing, through precisely designed molds and equipment, effectively avoid the dimensional deformation and surface unevenness problems that may occur in traditional roll forming, ensuring the precision of each process.

[0033] Furthermore, production lines using multi-stage machining processes can significantly improve yield rates. Each stage is precisely designed and controlled, reducing material waste and deformation, thereby effectively lowering scrap rates. Lower scrap rates not only improve production efficiency but also reduce material costs, making the production line more economically competitive.

[0034] Furthermore, multi-die processing production lines offer longer maintenance cycles. Traditional roll forming processes, due to heavy equipment loads and prolonged high-intensity operation, often experience wear and frequent repairs. Multi-die processing, by rationally distributing the load and using high-strength tool steel with surface-treated molds, significantly extends the lifespan of both molds and equipment. Distributed load across the equipment results in smoother production line operation, reducing downtime and maintenance frequency, and further lowering subsequent maintenance costs.

[0035] These advantages enable multi-mode processing production lines to effectively reduce the production cost of a single seat rail while improving the stability and predictability of the production process, thereby enhancing overall economy and production efficiency.

[0036] Next, the specific structural composition and technological process of this production line and processing method will be described in detail. First, the metal sheet is conveyed to the first stamping and forming device 1 via the feeding device to begin the base surface forming process. The main purpose of this process is to apply pressure to the central area of ​​the metal sheet using a high-precision die to form a stable base surface. This base surface provides a stable contact surface for subsequent guide rail installation and enhances the strength and stability of the base surface.

[0037] In this process, the first stamping forming device 1 is designed with a precise fit between the first upper die and the first lower die. A first forming module 6 is installed on the first lower die 5, and this module contains a raised first forming block 7. The center of the forming block is raised, forming a stable base surface. The two sides of the forming block are sloped, forming a forming surface 7 lower than the center surface, used to compensate for stress rebound generated by the material during the forming process. The precise design of the die and the precise control of the hydraulic system ensure the pressure and deformation accuracy in each forming process.

[0038] In addition, the first upper die is provided with a first central pressure block 8 and a forming punch 8 that is adapted to the first forming block 7. These two components work together to ensure the stability and positioning accuracy of the metal sheet during the forming process, avoiding any deviation or instability.

[0039] After the base surface is formed, the metal sheet is conveyed to the second stamping forming device 2 for the first bending process. In this process, the second stamping forming device 2 consists of a second upper die and a second lower die. The second lower die is equipped with a second forming block 9 to guide the folded edges on both sides of the metal sheet. Through precisely designed dies, the bending process can be precisely controlled, and the bending angle is usually controlled between **90°±0.2°**, ensuring bending accuracy and avoiding uneven bending or deformation.

[0040] During this process, precise control of the hydraulic system ensures uniform pressure distribution during bending, preventing material deformation or waste caused by excessive local pressure. This allows the folding process to be completed accurately, ensuring dimensional stability of the folded area.

[0041] After the first bend, the metal sheet is conveyed to the third stamping forming device 3 for a second bend. The design of the third stamping forming device 3 is similar to that of the second stamping forming device 2, except that the third forming block 10 adopts a T-shaped or I-shaped design with concave sides to avoid the bending area already formed during the second bend, thus preventing interference. This design ensures that the folded edges on both sides of the metal sheet do not interfere with each other during the forming process, thereby avoiding errors in the processing.

[0042] This device further bends the metal sheet on both sides, ultimately forming the U-shaped sides of the guide rail, providing excellent support and strength. This process ensures the sides of the metal sheet possess the necessary strength and support capabilities, meeting the requirements for the guide rail to withstand external forces during use.

[0043] After the second bend, the metal sheet is conveyed to the fourth stamping forming unit 4 to complete the final bending and punching processes. It is particularly important to note that the third bend and punching processes are performed simultaneously, driven by the same power source, to improve production efficiency.

[0044] The fourth stamping forming device 4 has a similar structural design to the third stamping forming device 3, but its position and forming process differ. The purpose of this process is to finalize the shape of the guide rail channel and simultaneously complete the punching. The punching is performed using a mechanical punching process. A through channel and a punching punch are located above the punching die. A hydraulic system pushes the punching punch downwards, precisely creating holes in the metal sheet. The die design ensures that the punching and bending processes are performed simultaneously, thereby improving production efficiency.

[0045] In the punching process, laser cutting technology can also be used for precise hole cutting according to actual needs. Laser cutting technology has high precision and flexibility, and can reduce material waste while ensuring hole accuracy, making it especially suitable for situations with high requirements for hole position and size.

[0046] Through meticulous design and precise control of each of the aforementioned processes, this production line ensures the production of high-precision, high-strength, smooth-surfaced, and standard-compliant automotive seat rails. This process not only effectively improves production efficiency and reduces production costs but also ensures product quality stability and consistency, meeting the high standards required by the modern automotive manufacturing industry for seat rails.

[0047] While exemplary embodiments of this disclosure have been described, those skilled in the art will understand that various changes and modifications can be made to the exemplary embodiments of this disclosure without departing from the spirit and scope thereof. Therefore, all changes and modifications are included within the scope of protection of this disclosure as defined by the claims. This disclosure is defined by the appended claims, and equivalents of those claims are also included.

Claims

1. A vehicle long seat rail cold stamping forming production line, characterized in that, The system sequentially includes an infeed device, a first stamping forming device, a second stamping forming device, a third stamping forming device, a fourth stamping forming device, a punching device, and an outfeed device. The infeed device continuously feeds metal sheets into the first stamping forming device. Material transfer is achieved between the first stamping forming device, the second stamping forming device, the third stamping forming device, the fourth stamping forming device, and the punching device. The outfeed device continuously delivers the guide rail parts processed by the fourth stamping forming device, thus achieving continuous production. The first stamping forming device is used to complete the base surface forming of metal sheet. Structurally, it includes a first upper die and a first lower die opposite to the first upper die. The first upper die and the second lower die are driven to move relative to each other by a drive mechanism to complete the die closing and opening actions. The first lower die in the first stamping forming device is provided with a first forming module. The first forming module has a protruding first forming block. The center of the forming block is protruding to form a center surface, and the two sides are lower than the center surface to form side forming surfaces. The side forming surfaces are sloped downward from the center surface to the outside to form a bending forming compensation angle. The compensation angle is used to increase the stamping forming angle and thus compensate for the stress rebound of the material. Correspondingly, the first upper die is provided with a first central pressure block opposite to the first forming block and forming punches located on both sides of the central pressure block. The second stamping forming device is used to complete the first side bending of the metal sheet. Structurally, it includes a second upper die and a second lower die that cooperates with the second upper die. The second lower die is provided with a second forming block, the upper surface of which is adapted to the shape of the metal sheet. Correspondingly, the second upper die is provided with a second central pressure block opposite to the second forming block and first bending punches located on both sides of the second central pressure block for completing the bending process. The side of the second forming block cooperates with the first bending punches to complete the bending process. At the same time, the side of the second forming block is tilted inward to form a bending compensation angle. The third stamping forming device is used to complete the second bending of the side of the metal sheet, so that the side of the metal sheet is U-shaped after the first and second bending. In terms of structure, the third stamping forming device is the same as the second forming device. The difference is that the third forming block in the third stamping forming device is T-shaped or I-shaped, and the side is concave to avoid the bending already processed by the second stamping forming device. The fourth stamping forming device is used to complete the overall bending of the first plate, so that the metal plate is bent into a U-shaped cross section guide rail. Structurally, the fourth stamping forming device has the same structure as the third stamping forming device.

2. A method for cold stamping and forming a long seat rail for vehicles, characterized in that, Specifically, the following steps are included: Step S1, base surface forming: In this step, pressure is first applied to the central area of ​​the long metal plate, and a raised base surface structure is formed in the central area of ​​the plate using a special forming mold to form the mounting base surface of the guide rail. Step S2, Folding: In this step, the two sides of the board are folded to create a 90° edge structure. Step S3, Folding: In this step, the sheet is folded again near the folding area to form a folded structure. Step S4, bending and forming: This step involves bending the sheet metal using a precision bending die to ultimately form the guide groove structure of the guide rail. Step S5: Punching. Punching is performed on the sheet metal using stamping or laser to meet the requirements of subsequent guide rail installation and seat adjustment functions.

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