Integrated inner and outer plate doorsill beam and processing production line thereof

Abstract

The utility model provides an integrated inner and outer plate doorsill beam. The doorsill beam is a closed cavity formed by bending a plate for multiple times. The doorsill beam is composed of an inner beam and an outer beam which are oppositely arranged in a buckled mode, a first bent flange edge and a second bent flange edge which are stacked in a double-layer mode are arranged at the connecting position of the inner beam and the outer beam respectively, and the first bent flange edge is formed by symmetrically bending a plate by 180 degrees. The product provided by the utility model has the advantages of high strength and good energy absorption effect, and meets the requirement of light weight, so that the profile has sufficient rigidity and bending strength; the weight of the profile is guaranteed, and the requirements for high strength, high energy absorption and light weight are met. The utility model further provides a processing production line of the integrated inner and outer plate doorsill beam. The local softening mechanism is reasonably arranged to ensure that the plates are not cracked when being bent by 180 degrees; conventional equipment is selected for the production line, the power requirement is low, and the installation cost, the maintenance cost and the threshold beam machining cost of the production line are effectively reduced.

Description

Technical Field

[0001] This utility model relates to the field of automotive profile technology, and in particular to an integrated inner and outer panel door sill beam and its processing production line. Background Technology

[0002] With the increasing prevalence of the automotive industry, people are paying more and more attention to vehicle safety performance. The safety performance of automotive safety protection systems is particularly important, especially various safety structural components that significantly impact vehicle safety, such as crash beams, battery side beams, and inner and outer door sill beams. The main functions of these safety structural components are to enhance vehicle strength, absorb impact forces, and reduce personal injury to drivers and passengers during collisions. Therefore, to improve vehicle body safety performance while ensuring product quality, it is necessary to continuously improve and develop high-energy-absorbing, high-strength, and lightweight safety structural components.

[0003] As crucial automotive safety components, the inner and outer door sill beams prevent deformation and intrusion into the passenger compartment, playing a vital role in protecting personal safety and property during side collisions. In new energy vehicles, these beams also protect the battery pack, preventing deformation and fire. However, the inner and outer side beams of the battery casing are often made of extruded aluminum alloy profiles, resulting in high material processing costs and low product strength, leading to insufficient side-impact performance. In gasoline vehicles, the inner and outer door sill beams are typically made using high-strength steel sheet metal stamping and roll forming. Due to technological limitations, regardless of the method used, the inner and outer door sill plates are processed separately and then assembled and welded together. This process involves high mold development costs and complex processing steps; especially with sheet metal stamping, the product is heavy, the process is complex, and material utilization is low. Given the cost-control needs of enterprises in pursuit of efficiency, improving the processing technology of the inner and outer door sill beams to achieve cost reduction and efficiency improvement while ensuring safety performance has become a critical issue that urgently needs to be addressed. Utility Model Content

[0004] To address the aforementioned problems in the existing technology, the purpose of this utility model is to provide an integrated inner and outer panel door sill beam and its processing production line.

[0005] To solve the above-mentioned technical problems, the technical solution adopted by this utility model is as follows:

[0006] An integrated inner and outer panel door sill beam is a closed cavity formed by bending a single sheet of material multiple times. The door sill beam consists of an inner beam and an outer beam that interlock with each other. A first bent flange and a second bent flange are respectively provided at the connection between the inner beam and the outer beam. Both the first and second bent flanges are double-layered. The first bent flange is formed by symmetrically bending the sheet material by 180°, and the second bent flange is formed by welding the two ends of the sheet material together in parallel.

[0007] A further improvement of this utility model is that: the outer beam includes a second bent outer edge, an upper wall of the outer beam, a side wall of the outer beam, a lower wall of the outer beam, and a first bent outer edge; the inner beam includes a second bent inner edge, an upper wall of the inner beam, a side wall of the inner beam, a lower wall of the inner beam, and a first bent inner edge; the first bent inner edge and the first bent outer edge are stacked to form a first bent flange edge; the second bent inner edge and the second bent outer edge are bonded together and then welded to form a second bent flange edge.

[0008] A further improvement of this utility model is that the first inner bend, the first outer bend, the second inner bend, and the second outer bend are arranged in parallel.

[0009] A further improvement of this utility model is that the included angle between the upper wall of the outer beam and the upper wall of the inner beam, and the included angle between the lower wall of the outer beam and the lower wall of the inner beam are both not less than 120°.

[0010] A further improvement of this utility model is that the inner beam sidewall and the outer beam sidewall are planar or irregularly shaped to adapt to the boundary conditions of automobile manufacturers.

[0011] A further improvement of this utility model is that the length of the first bent flange edge is not less than 4 times the material thickness.

[0012] The integrated inner and outer panel door sill beam processing production line includes an uncoiler, a first leveler, a local softening mechanism, a servo feeding mechanism, a cold bending forming unit, a welding mechanism, and a cutting mechanism arranged in sequence. The cold bending forming unit is equipped with multiple pressure rollers for forming the door sill beam.

[0013] A further improvement of this utility model is that the local softening mechanism includes a heating probe located at the front end, a cooling nozzle located at the rear end, and a feed guide wheel and a feed clamping wheel located upstream of the heating probe, and a discharge clamping wheel and a discharge guide wheel located downstream of the cooling nozzle.

[0014] A further improvement of this utility model is that: the heating probe is a laser heating probe, the cooling nozzle is a spray cooling nozzle; and the welding machine in the welding mechanism is an arc welding machine or a fusion welding machine.

[0015] A further improvement of this utility model is that: a second leveling machine is provided downstream of the local softening mechanism; a punching mechanism is provided upstream of the servo feeding mechanism; and a pit bridge is provided upstream of the cold bending forming unit.

[0016] The technological advancements achieved by this utility model due to the adoption of the above technical solution are as follows:

[0017] This utility model discloses an integrated inner and outer plate sill beam structure, which has high strength, good energy absorption effect, meets the requirements of lightweighting, and the profile structure has sufficient rigidity and bending strength, which can meet the anti-collision performance requirements of the sill beam.

[0018] This utility model's threshold beam is composed of an inner beam and an outer beam interlocked together. The inner and outer beams are connected via a first bent flange and a second bent flange. The first bent flange is formed by bending a sheet metal at 180°. Generally, conventional split-type welding processes require the welded edge to be no less than 14mm in length; however, using roll bending only requires no less than 4 times the material thickness, for example, a conventional material thickness of 1-2mm. Therefore, the flange length is no less than 4-8mm, significantly reducing the amount of sheet metal used and greatly saving raw materials.

[0019] The threshold beam of this utility model is formed by rolling a single steel plate, resulting in higher cross-sectional strength; the split-type welded inner and outer plate threshold beam adopts a discontinuous spot welding process, which significantly reduces the strength of the unwelded positions; while the one-piece forming process significantly improves the shear strength of the threshold beam cross section.

[0020] This utility model also provides a processing production line for the integrated inner and outer panel sill beam. A local softening mechanism is installed upstream of the cold bending forming unit to locally soften the sheet metal at the rounded corner of the first bending flange, giving it good ductility and ensuring that the strength of the sill beam is not affected during bending. This utility model production line can be used to process sill beams of different structures, offering high flexibility and practicality. Furthermore, this utility model processing production line uses conventional equipment, has low power requirements, and can effectively reduce the installation cost, maintenance cost, and sill beam processing cost of the production line. Attached Figure Description

[0021] Figure 1 This is a schematic cross-sectional view of the inner and outer sill beams of this utility model;

[0022] Figure 2 This is a schematic diagram of the cross-section of a threshold beam with irregularly shaped inner and outer plates on the outer beam sidewalls;

[0023] Figure 3 A schematic diagram of the cross-section of the inner and outer plate threshold beams with energy-absorbing zones on the outer beam sidewalls;

[0024] Figure 4 A connection diagram for an integrated inner and outer panel door sill beam processing production line;

[0025] Figure 5 A schematic diagram of an integrated inner and outer panel door sill beam processing production line;

[0026] Figure 6 This is a top view schematic diagram of the local softening mechanism;

[0027] Figure 7 This is a front view schematic diagram of the local softening mechanism;

[0028] In the diagram, 1-1 is the outer edge of the second bend, 1-2 is the upper wall of the outer plate, 1-3 is the side wall of the outer beam, 1-4 is the lower wall of the outer plate, 1-5 is the outer edge of the first bend, 1-6 is the inner edge of the first bend, 1-7 is the lower wall of the inner plate, 1-8 is the side wall of the inner plate, 1-9 is the upper wall of the inner plate, 1-10 is the inner edge of the second bend, 1-11 is the energy-absorbing zone, and 9-3 is the weld point.

[0029] 2. Steel belt; 3. Feed guide roller; 4. Feed clamping roller; 5. Heating probe; 6. Cooling nozzle; 7. Discharge clamping roller; 8. Discharge guide roller.

[0030] 10. Uncoiling machine; 20. First leveling machine; 30. Local softening mechanism; 40. Second leveling machine; 50. Punching mechanism; 60. Servo feeding mechanism; 70. Missing punch detection mechanism; 80. Pit bridge; 90. Cold bending forming unit; 100. Welding mechanism; 110. Cutting mechanism; 120. Receiving mechanism. Detailed Implementation

[0031] The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0032] An integrated inner and outer panel door sill beam, such as Figure 1 As shown, the sill beam is a closed cavity formed by bending a single sheet of material multiple times. The sill beam comprises an inner beam and an outer beam, both U-shaped structures that interlock to form the internal cavity. The two connections between the inner and outer beams are respectively formed by a first bent flange and a second bent flange. Both the first and second bent flanges are double-layered, with the first flange formed by symmetrically bending the sheet material 180°, and the second flange formed by welding the two ends of the sheet material together in parallel.

[0033] Specifically, the outer beam includes a second bent outer edge 1-1, an upper outer wall 1-2, a side wall 1-3, a lower outer wall 1-4, and a first bent outer edge 1-5. The inner beam includes a second bent inner edge 1-10, an upper inner wall 1-9, a side wall 1-8, a lower inner wall 1-7, and a first bent inner edge 1-6. The first bent inner edge 1-6 and the first bent outer edge 1-5 are stacked to form a first bent flange edge; the second bent inner edge 1-10 and the second bent outer edge 1-1 are bonded together and welded to form a second bent flange edge.

[0034] The first bend inner edge 1-6, the first bend outer edge 1-5, the second bend inner edge 1-10, and the second bend outer edge 1-1 are arranged in parallel, as shown in... Figure 1 In the embodiment shown, the inner edge 1-6 of the first bend, the outer edge 1-5 of the first bend, the inner edge 1-10 of the second bend, and the outer edge 1-1 of the second bend are all vertically arranged.

[0035] The inner beam sidewalls 1-8 and outer beam sidewalls 1-3 are either planar or irregularly shaped to meet the boundary conditions of the automobile manufacturer. For example... Figure 1 As shown, both the inner beam sidewall 1-8 and the outer beam sidewall 1-3 are vertical planes. In practical applications, however, the inner beam sidewall 1-8 and the outer beam sidewall 1-3 are often not planar, but rather irregular shapes formed by multiple reinforcing bars, such as... Figure 2 As shown. The specific shapes of the inner beam sidewall 1-8 and the outer beam sidewall 1-3 are adjusted according to the boundary conditions of the automobile manufacturer to fully fit the external structure. It should also be noted that the inner beam sidewall 1-8 and the outer beam sidewall 1-3 are independent of each other, and their shapes can be the same or different.

[0036] Depending on the actual anti-collision performance requirements, energy-absorbing zones 1-11 can also be provided inside the outer beam sidewalls 1-3, such as... Figure 3 As shown. The shape and structure of energy absorption zones 1-11 can be adjusted according to the boundary conditions of the automobile manufacturer, and are not subject to mandatory restrictions here.

[0037] Reinforcing ribs, such as U-shaped ribs, can also be provided on the inner beam sidewall 1-8 and the outer beam sidewall 1-3 to improve the sill strength.

[0038] Similarly, the outer beam upper wall 1-2, outer beam lower wall 1-4, inner beam upper wall 1-9, and inner beam lower wall 1-7 can be horizontal or inclined. When the outer beam upper wall 1-2, outer beam lower wall 1-4, inner beam upper wall 1-9, and inner beam lower wall 1-7 are horizontal, the inner and outer panel sill beams are rectangular. However, generally speaking, the outer beam upper wall 1-2, outer beam lower wall 1-4, inner beam upper wall 1-9, and inner beam lower wall 1-7 are preferably inclined, which can better fit the external structure, reduce stress dead angles, and enhance support performance.

[0039] All corners of the inner and outer panel threshold beams are rounded. In particular, the connection between the outer edge 1-5 of the first bend and the inner edge 1-6 of the first bend is a 180° rounded corner, which reduces stress points and increases anti-collision performance.

[0040] More preferably, the included angle between the upper wall 1-2 of the outer beam and the upper wall 1-9 of the inner beam, and the included angle between the lower wall 1-4 of the outer beam and the lower wall 1-7 of the inner beam, are both not less than 120°.

[0041] The inner beam and the outer beam can have the same or different shapes, and their shapes can be adjusted according to the arrangement of the vehicle body components.

[0042] The length of the first bent flange edge is not less than 4 times the material thickness, and the length is preferably 4~8mm; the length of the second bent flange edge is usually not less than 14mm, and the length of the second bent flange edge can be shortened when the vehicle body boundary conditions do not allow it.

[0043] Production lines used for processing integrated inner and outer panel door sill beams, such as Figure 4 , Figure 5 As shown, the assembly includes, in sequence, an uncoiler 10, a first leveler 20, a local softening mechanism 30, a second leveler 40, a punching mechanism 50, a servo feeding mechanism 60, a missing punch detection mechanism 70, a pit bridge 80, a cold bending forming unit 90, a welding mechanism 100, a cutting mechanism 110, and a receiving mechanism 120.

[0044] The uncoiler 10 and the first leveler 20 are used to uncoil the sheet metal and perform the first leveling.

[0045] In actual processing, due to the need to change the sheet metal coil, the outlet end of the first leveling machine 20 is also equipped with a shearing and welding mechanism (not shown in the figure) to cut the head and tail of the metal sheet metal when changing the sheet metal coil, and weld the front and rear steel together to achieve continuous feeding, reduce material waste, and improve production efficiency.

[0046] The local softening mechanism 30 is used to locally heat and cool the sheet material corresponding to the rounded corner of the first bending flange in advance, improving the ductility of this part of the sheet material and ensuring that no cracks occur on the surface of the sheet material when forming a 180° rounded corner. Specifically, the local softening mechanism 30 includes a heating probe 5 and a cooling nozzle 6, wherein the heating probe 5 is located at the front end and the cooling nozzle 6 is located at the rear end; the sheet material is transformed into austenite by heating with the heating probe 5, and then the sheet material temperature is kept within the austenite range by appropriate cooling before bending and forming.

[0047] This invention features a local softening mechanism 30 positioned upstream of the cold bending forming unit 90. Multiple operating mechanisms are also arranged between the local softening mechanism 30 and the cold bending forming unit 90: a second leveling machine 40, a punching mechanism 50, a servo feeding mechanism 60, a missed punching detection mechanism 70, and a pit bridge 80. When the locally heated steel strip passes through these mechanisms, the temperature of the locally heated portion of the steel strip is conducted evenly, further ensuring that no cracks occur on either the inner or outer sides of the rounded corner when the steel strip is bent 180°. Simultaneously, using a local softening mechanism to heat the steel strip, rather than the formed profile, not only makes it easier to control the heating range and precision, but also allows for unrestricted spatial arrangement of the local softening mechanism, convenient operation, and facilitates the arrangement of heating and cooling components.

[0048] During the localized softening process of the sheet metal, to ensure high-precision positioning of the heating and cooling positions, prevent the steel strip from deviating, and ensure effective clamping of the steel strip 2, an infeed guide wheel 3 and an infeed clamping wheel 4 are provided upstream of the heating probe 5, and an outfeed clamping wheel 7 and an outfeed guide wheel 8 are provided downstream of the cooling nozzle 6. A certain amount of sealing gap is maintained between the guide wheel, clamping wheel, and the steel strip to ensure that the steel strip does not deviate laterally.

[0049] When the steel strip 2 enters the local softening mechanism 30, it passes sequentially through the feed guide roller 3, the feed clamping roller 4, the discharge clamping roller 7, and the discharge guide roller 8. The feed guide roller initially aligns the steel strip, while the feed clamping roller keeps it straight and stable, facilitating precise positioning of the heating and cooling equipment. Once the guide rollers and clamping rollers are in the appropriate positions and the strip passes through normally, the heating probe and cooling nozzle are activated. The heating probe 5 and cooling nozzle 6 are aimed at the area of ​​the steel strip to be treated to perform the softening operation. After local softening, the steel strip 2 is horizontally output under the guidance of the discharge clamping roller 7 and the discharge guide roller 8.

[0050] Preferably, the heating probe 5 is a laser heating probe, and the cooling nozzle 6 is a spray cooling nozzle, which has high precision and high efficiency.

[0051] Since the steel strip will inevitably deform after local softening, in order to ensure high precision of cooling and forming and to ensure that the locally softened part is bent 180°, a second leveling machine 40 is also set downstream of the local softening mechanism 30. After the steel strip is leveled twice, it is sent to the cold bending forming unit 90 for roll forming.

[0052] According to the installation and connection requirements of the roll-formed profile and other components, a punching mechanism 50 is set after the second leveling machine 40 and before the cold bending forming unit 90 to pre-punch the product mounting holes. Among them, the servo feeding unit serves as an electronic auxiliary device before pre-punching, used to assist in pre-punching fixed-length feeding; the stamping unit is used to pre-punch the holes on the product; and the missing punch detection unit is used to check whether the stamping unit has missed punching.

[0053] Since the punching speed and the metal sheet feeding speed are not necessarily the same, a pit bridge 80 is set downstream of the punching mechanism 50 to store metal sheet material. This ensures that the front and rear processing are not affected when the production speeds are different. It is mainly used for the correction of the material strips required by the punching mechanism 50 and the front and rear.

[0054] Each bending forming unit 90 is equipped with multiple pressure rollers to meet the forming requirements of the sill beam. The shape and arrangement of the pressure rollers are determined according to the specific structure of the sill beam. When the structure or shape of the inner or outer beam is modified, adjustments can be made by increasing or decreasing the number of pressure roller passes and changing their shape within the corresponding cold bending forming unit. Processing of products with different structures can be achieved with minor equipment modifications.

[0055] The welding machine in the welding mechanism 100 can be an arc welding machine or a fusion welding machine, which has a fast welding speed and high precision. Downstream of the welding mechanism 100, there is a cutting mechanism 110 for cutting the sill beam profile according to the length to be used.

[0056] In addition, the production line also includes some processing auxiliary mechanisms, such as a receiving machine 120, an electrical control mechanism, and a safety protection mechanism. The receiving machine 120 is located downstream of the cutting mechanism 110 and assists in manual material feeding; the electrical control mechanism is used for the overall control of the roller pressing line; and the safety protection mechanism is used for human-machine isolation along the entire line, mainly including isolation nets, safety doors, and safety light curtains. Since these auxiliary mechanisms are not the inventive point of this utility model and are all prior art, they will not be described in detail here.

[0057] The above description is only a preferred embodiment of the present utility model. All equivalent changes and modifications made within the scope of the patent application of the present utility model shall be covered by the present utility model.

Claims

1. An integrated inner and outer rockers, characterized by: The threshold beam is a closed cavity formed by multiple bending of a plate; the threshold beam is composed of an inner beam and an outer beam which are relatively buckled, and the connecting parts of the inner beam and the outer beam are respectively provided with a first bending flange and a second bending flange, and the first bending flange and the second bending flange are both double-layered material stacking edges; the first bending flange is formed by 180° self-symmetrical bending of the plate, and the second bending flange is formed by welding after parallel lamination of two end portions of the plate.

2. The one-piece inner and outer rock panel door sill beam of claim 1, wherein: The outer beam comprises a second bending outer edge (1-1), an outer beam upper wall (1-2), an outer beam side wall (1-3), an outer beam lower wall (1-4) and a first bending outer edge (1-5), and the inner beam comprises a second bending inner edge (1-10), an inner beam upper wall (1-9), an inner beam side wall (1-8), an inner beam lower wall (1-7) and a first bending inner edge (1-6); the first bending inner edge (1-6) and the first bending outer edge (1-5) are formed by material stacking to form a first bending flange; the second bending inner edge (1-10) and the second bending outer edge (1-1) are welded after lamination to form a second bending flange.

3. The one-piece inner and outer rock panel door sill beam of claim 2, wherein: The first bending inner edge (1-6), the first bending outer edge (1-5), the second bending inner edge (1-10) and the second bending outer edge (1-1) are arranged in parallel.

4. The one-piece inner and outer rock panel door sill beam of claim 3, wherein: The included angle between the outer beam upper wall (1-2) and the inner beam upper wall (1-9) and the included angle between the outer beam lower wall (1-4) and the inner beam lower wall (1-7) are both not less than 120°.

5. The one-piece inner and outer rock panel rocker rail of claim 2, wherein: The inner beam side wall (1-8) and the outer beam side wall (1-3) are planar or are of a special shape suitable for the boundary conditions of the automobile manufacturer.

6. The one-piece inner and outer rock panel door sill beam of claim 2, wherein: The length of the first bending flange is not less than 4 times the thickness of the plate material.

7. The integrated inner and outer panel rocker production line of any one of claims 1-6, wherein: The device comprises a decoiler (10), a first leveling machine (20), a local softening mechanism (30), a servo feeding mechanism (60), a cold bending forming unit (90), a welding mechanism (100) and a cutting mechanism (110) arranged in sequence, and a plurality of pressing rollers for forming the threshold beam are arranged in the cold bending forming unit (90).

8. The manufacturing line for the integrated inner and outer panel rocker according to claim 7, characterized in that: The local softening mechanism (30) comprises a heating probe (5) at the front end, a cooling nozzle (6) at the rear end, an inlet guide wheel (3) and an inlet clamping wheel (4) arranged upstream of the heating probe (5), and an outlet clamping wheel (7) and an outlet guide wheel (8) arranged downstream of the cooling nozzle (6).

9. The manufacturing line for the integrated inner and outer panel rocker according to claim 8, characterized in that: The heating probe (5) is a laser heating probe, and the cooling nozzle (6) is a spray cooling nozzle; the welding machine in the welding mechanism (100) is an electric arc welding machine or a fusion welding machine.

10. The manufacturing line for the integrated inner and outer panel rocker according to claim 7, characterized in that: A second leveling machine (40) is further arranged downstream of the local softening mechanism (30); a punching mechanism (50) is further arranged upstream of the servo feeding mechanism (60), and a pit bridge (80) is further arranged upstream of the cold bending forming unit (90).

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