Anti-deformation bending device for electric vehicle U-shaped beam
By combining a multi-point support structure with a polyurethane buffer layer, the stress concentration problem of traditional electric vehicle U-beam bending devices is solved, enabling high-precision and lightweight production, improving the dimensional accuracy and structural strength of the U-beam, and reducing manufacturing costs.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- TIANJIN JUPENG BICYCLE FITTINGS
- Filing Date
- 2025-07-10
- Publication Date
- 2026-06-26
AI Technical Summary
Traditional electric vehicle U-beam bending devices are prone to stress concentration when dealing with high-strength, lightweight materials, resulting in wrinkles and excessive ellipticity, which affects production efficiency and material utilization.
The design employs a combination of multi-point support structure and polyurethane buffer layer. Through the synergistic effect of mechanical limiting and elastic buffering, stress is dispersed to form a dynamic support network, eliminating wrinkles and out-of-tolerance ellipticity.
It significantly improves the dimensional accuracy and structural strength of U-shaped beams, increases material utilization, and reduces manufacturing costs.
Smart Images
Figure CN224406134U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the technical field of U-beam bending devices, and in particular to an anti-deformation bending device for U-beams of electric vehicles. Background Technology
[0002] With the rapid development of the new energy vehicle industry, lightweighting and structural safety of electric vehicles have become core research and development directions. As a key component of the electric vehicle body frame, U-beams are widely used in core load-bearing structures such as vehicle frames and battery pack frames due to their excellent torsional stiffness and space utilization.
[0003] When using the U-beam bending device for electric vehicles, traditional bending processes generally employ rigid molds to linearly extrude and form steel pipes. However, due to limitations in mold contact methods and stress distribution characteristics, this process has significant technical defects when dealing with high-strength, lightweight materials such as aluminum alloys and high-strength steel. Specifically, traditional bending devices achieve plastic deformation through the rigid clamping of upper and lower molds, but the contact surface is linearly supported, leading to stress concentration in the bending area. When the material's yield strength exceeds a specified value, local compressive stress easily exceeds the material's plastic deformation threshold, causing defects such as pipe wall wrinkles and excessive ellipticity of the cross-section. These problems are particularly prominent in electric vehicle frame production, as the U-beam needs to simultaneously meet the requirements of precise positioning of multiple holes and lightweight design. The stress concentration characteristics of traditional processes cause material accumulation in the bending area, forming wrinkles and damaging surface quality. Uneven radial pressure distribution leads to cross-sectional distortion, resulting in excessive ellipticity. Repeated mold adjustments are time-consuming and significantly reduce production efficiency.
[0004] Therefore, to address the issue of wrinkling and deformation easily caused by traditional bending processes in the production of high-precision lightweight components such as electric vehicle frames, a deformation-resistant bending device for electric vehicle U-beams can be designed. When the electric vehicle U-beam bending device is in use, the first clamping mechanism, together with multiple sets of arc-shaped side plates, forms a multi-point support structure. The polyurethane buffer layer on the surface of the arc-shaped side plates absorbs radial pressure through elastic deformation. Combined with the segmented support structure of the arc-shaped side plates, the concentrated stress is dispersed into linear stress. Through the synergistic effect of mechanical limiting and elastic buffering, this device significantly improves the dimensional accuracy and structural strength of the U-beam. In summary, the multi-level support system, through the combined design of arc-shaped side plates and guide wheels, forms a dynamic support network during the bending process. Combined with the stress dispersion characteristics of the polyurethane buffer layer, it effectively eliminates defects such as wrinkles and ellipticity deviations easily caused by traditional bending processes. This device is particularly suitable for the production of high-precision lightweight components such as electric vehicle frames, improving material utilization and significantly reducing manufacturing costs while ensuring structural strength. Utility Model Content
[0005] To overcome the problem that traditional bending devices achieve plastic deformation through rigid clamping of upper and lower dies when using electric vehicle U-beam bending devices, but the contact surface is linearly supported, resulting in stress concentration in the bending area, this process is not ideal for producing high-precision lightweight components such as electric vehicle frames. In such cases, the local compressive stress is prone to exceed the material's plastic deformation threshold, making it difficult to eliminate the problem of wrinkling deformation that is easily generated by traditional bending processes.
[0006] The technical solution of this utility model is as follows: an anti-deformation and bending device for a U-shaped beam of an electric vehicle, comprising a frame, a side support, an arc-shaped hole, guide wheels, an arc-shaped side support plate, a cavity, a mounting groove, a support rod, a connecting block, a polyurethane buffer layer, a first clamping mechanism, and a limiting rod. A side support is fixedly installed on the top of one side of the frame. An arc-shaped hole is opened on one side of the side support. Two sets of guide wheels are installed inside the side support. Multiple sets of arc-shaped side support plates are installed inside the side support. A cavity is opened inside the side support. Multiple sets of mounting grooves are opened on the inner wall of the cavity. A support rod is fixedly installed inside the mounting groove. A connecting block is fixedly installed on the side wall of the support rod. A polyurethane buffer layer is installed on the inner wall of the arc-shaped side support plate. A first clamping mechanism is installed on the top of one side of the frame. A limiting rod is fixedly installed above the frame.
[0007] Preferably, when the electric vehicle U-beam bending device is in use, the limiting end of the steel pipe to be processed is first horizontally inserted into the limiting rod at the top of the frame to achieve axial positioning. At the same time, the side wall of the steel pipe forms a surface contact support with the arc-shaped side support plate on the inner wall of the side support. Simultaneously, the first clamping mechanism is activated, and the clamping arm is driven by hydraulic pressure to perform radial clamping from the outside of the steel pipe. The first clamping mechanism, together with multiple sets of arc-shaped side support plates, forms a multi-point support structure. During the bending process of the steel pipe, the bending end of the steel pipe bends along a preset arc trajectory under traction. The two sets of guide wheels in the side support automatically adjust the contact angle as the steel pipe slides. The polyurethane buffer layer on the surface of the arc-shaped side support plate undergoes elastic deformation. By absorbing radial pressure and dispersing concentrated stress into linear stress through a segmented support structure with arc-shaped side plates, this device significantly improves the dimensional accuracy and structural strength of the U-shaped beam through the synergistic effect of mechanical limiting and elastic buffering. In summary, the multi-level support system, through the combined design of arc-shaped side plates and guide wheels, forms a dynamic support network during bending. Combined with the stress dispersion characteristics of the polyurethane buffer layer, it effectively eliminates defects such as wrinkles and out-of-tolerance ellipticity that are easily generated by traditional bending processes. This device is particularly suitable for the production of high-precision lightweight components such as electric vehicle frames, improving material utilization and significantly reducing manufacturing costs while ensuring structural strength.
[0008] Preferably, the outer wall of the arc-shaped side support plate is fixedly connected to the inner wall of the connecting block, and the first clamping mechanism is disposed on one side of the side support.
[0009] Preferably, a rotating shaft is fixedly installed inside the guide wheel, and both the upper and lower ends of the rotating shaft are rotatably connected to the inner wall of the side support.
[0010] Preferably, a drive motor is fixedly installed at the bottom of one side of the frame, a drive shaft is installed at the output end of the drive motor, a fixed module is fixedly installed at the upper end of the drive shaft, and an arc-shaped groove is opened on the side wall of the fixed module.
[0011] Preferably, a connecting seat is fixedly provided on the side wall of the drive shaft, and a second clamping mechanism is fixedly provided on the top of the connecting seat. The second clamping mechanism is located on one side of the fixed module.
[0012] Preferably, a connecting plate is fixedly installed on one side of the connecting seat, a support frame is fixedly installed above the connecting plate, and a locking frame is fixedly installed above the connecting plate.
[0013] Preferably, a controller is installed on the top of the rack, a display screen is installed on the side wall of the controller, and multiple sets of buttons are installed inside the controller.
[0014] The beneficial effects of this utility model are:
[0015] When the electric vehicle U-beam bending device is in use, the limiting end of the steel pipe to be processed is first horizontally inserted into the limiting rod at the top of the frame to achieve axial positioning. At the same time, the side wall of the steel pipe forms a surface contact support with the arc-shaped side support plate on the inner wall of the side support. Simultaneously, the first clamping mechanism is activated, and the clamping arm is driven by hydraulics to perform radial clamping from the outside of the steel pipe. The first clamping mechanism, together with multiple sets of arc-shaped side support plates, forms a multi-point support structure. During the bending process of the steel pipe, the bending end of the steel pipe bends along a preset arc trajectory under traction. The two sets of guide wheels in the side support automatically adjust the contact angle as the steel pipe slides. The polyurethane buffer layer on the surface of the arc-shaped side support plate absorbs elastic deformation. Radial pressure, combined with the segmented support structure of the arc-shaped side support plate, disperses concentrated stress into linear stress. Through the synergistic effect of mechanical limiting and elastic buffering, this device significantly improves the dimensional accuracy and structural strength of the U-shaped beam. In summary, the multi-level support system, through the combined design of the arc-shaped side support plate and guide wheel, forms a dynamic support network during bending. Combined with the stress dispersion characteristics of the polyurethane buffer layer, it effectively eliminates defects such as wrinkles and out-of-tolerance ellipticity that are easily generated by traditional bending processes. This device is particularly suitable for the production of high-precision lightweight components such as electric vehicle frames, improving material utilization and significantly reducing manufacturing costs while ensuring structural strength. Attached Figure Description
[0016] Figure 1 The diagram shown is a first three-dimensional structural schematic of the electric vehicle U-shaped beam anti-deformation and bending device of this utility model.
[0017] Figure 2 The diagram shown is a partial three-dimensional structural schematic of the electric vehicle U-shaped beam anti-deformation and bending device of this utility model.
[0018] Figure 3The diagram shown is a three-dimensional structural diagram of the first outer periphery of the side support of the electric vehicle U-shaped beam anti-deformation and bending device of this utility model.
[0019] Figure 4 The diagram shown is a three-dimensional sectional view of the first half of the side support of the electric vehicle U-shaped beam anti-deformation and bending device of this utility model.
[0020] Figure 5 The diagram shown is a three-dimensional structural diagram of the first outer periphery of the arc-shaped side support plate of the electric vehicle U-shaped beam anti-deformation and bending device of this utility model.
[0021] Explanation of reference numerals in the attached drawings: 1. Frame; 2. Side support; 3. Arc-shaped hole; 4. Guide wheel; 5. Arc-shaped side support plate; 6. Cavity; 7. Mounting groove; 8. Support rod; 9. Connecting block; 10. Polyurethane buffer layer; 11. First clamping mechanism; 12. Limiting rod; 13. Rotating shaft; 14. Drive motor; 15. Drive shaft; 16. Fixed module; 17. Arc-shaped groove; 18. Connecting seat; 19. Second clamping mechanism; 20. Connecting plate; 21. Support frame; 22. Clamping frame; 23. Controller; 24. Display screen; 25. Button. Detailed Implementation
[0022] The present invention will be further described below with reference to the accompanying drawings and embodiments.
[0023] Please see Figure 3 and Figure 5 This utility model provides an embodiment of an anti-deformation and bending device for a U-shaped beam of an electric vehicle, comprising a frame 1, a side support 2, an arc-shaped hole 3, a guide wheel 4, an arc-shaped side support plate 5, a cavity 6, a mounting groove 7, a support rod 8, a connecting block 9, a polyurethane buffer layer 10, a first clamping mechanism 11, and a limiting rod 12. A side support 2 is fixedly installed on the top of one side of the frame 1. An arc-shaped hole 3 is opened on one side of the side support 2. Two sets of guide wheels 4 are installed inside the side support 2. Multiple sets of arc-shaped side support plates 5 are installed inside the side support 2. A cavity 6 is opened inside the side support 2. Multiple sets of mounting grooves 7 are opened on the inner wall of the cavity 6. A support rod 8 is fixedly installed inside the mounting groove 7. A connecting block 9 is fixedly installed on the side wall of the support rod 8. A polyurethane buffer layer 10 is installed on the inner wall of the arc-shaped side support plate 5. A first clamping mechanism 11 is installed on the top of one side of the frame 1. A limiting rod 12 is fixedly installed above the frame 1.
[0024] Please see Figure 2 and Figure 4The outer wall of the arc-shaped side support plate 5 is fixedly connected to the inner wall of the connecting block 9. The first clamping mechanism 11 is set on one side of the side support 2. The first clamping mechanism 11 cooperates with multiple sets of arc-shaped side support plates 5 to form a multi-point support structure. The guide wheel 4 is fixedly provided with a rotating shaft 13. Both the upper and lower ends of the rotating shaft 13 are rotatably connected to the inner wall of the side support 2. The guide wheel 4 rotates inside the side support 2 through the rotating shaft 13. A drive motor 14 is fixedly provided at the bottom of one side of the frame 1. A drive shaft 15 is provided at the output end of the drive motor 14. A fixed module 16 is fixedly provided at the upper end of the drive shaft 15. An arc-shaped groove 17 is opened on the side wall of the fixed module 16. The drive motor 14 is started to drive the drive shaft 15 and the fixed module 16 to rotate.
[0025] Please see Figure 1 and Figure 2 A connecting seat 18 is fixedly installed on the side wall of the drive shaft 15, and a second clamping mechanism 19 is fixedly installed on the top of the connecting seat 18. The second clamping mechanism 19 is located on one side of the fixed module 16. The second clamping mechanism 19 cooperates with the arc groove 17 of the fixed module 16 to form a bending end fixing structure. At this time, the bending area of the steel pipe is completely constrained. The drive motor 14 is started to drive the drive shaft 15 to rotate. The drive shaft 15 drives the fixed module 16 and the second clamping mechanism 19 to make a 90-degree circular motion through the connecting seat 18. During this process, the bending end of the steel pipe moves along the preset arc under the traction of the fixed module 16. The trajectory is curved. A connecting plate 20 is fixedly installed on one side of the connecting seat 18. A support frame 21 is fixedly installed above the connecting plate 20. A clamping frame 22 is fixedly installed above the connecting plate 20. The dual positioning system composed of the limiting rod 12 and the support frame 21 can prevent the steel pipe from springing back and deforming. The rigid connection structure between the clamping frame 22 and the connecting plate 20 ensures that the bending die always maintains verticality. A controller 23 is installed on the top of the frame 1. A display screen 24 is installed on the side wall of the controller 23. Multiple buttons 25 are installed inside the controller 23. The controller 23 automatically stops the machine through the angle sensor.
[0026] When the electric vehicle U-beam bending device is in use, the limiting end of the steel pipe to be processed is first horizontally inserted into the limiting rod 12 at the top of the frame 1 to achieve axial positioning, and at the same time, the side wall of the steel pipe and the arc-shaped side support plate 5 of the inner wall of the side support 2 form a surface contact support.
[0027] The first clamping mechanism 11 and the second clamping mechanism 19 are started simultaneously. The two clamping arms are driven by hydraulic pressure to perform radial clamping from both sides of the steel pipe. The first clamping mechanism 11, together with multiple sets of arc-shaped side support plates 5, forms a multi-point support structure. The second clamping mechanism 19, together with the arc-shaped groove 17 of the fixed module 16, forms a bending end fixing structure. At this time, the bending area of the steel pipe is completely constrained.
[0028] Subsequently, the drive motor 14 is started to drive the drive shaft 15 to rotate. The drive shaft 15 drives the fixed module 16 and the second clamping mechanism 19 to make a 90-degree circular motion through the connecting seat 18. During this process, the bending end of the steel pipe bends along the preset arc trajectory under the traction of the fixed module 16. The two sets of guide wheels 4 in the side support 2 automatically adjust the contact angle as the steel pipe slides. The polyurethane buffer layer 10 on the surface of the arc-shaped side support plate 5 absorbs the radial pressure through elastic deformation. With the segmented support structure of the arc-shaped side support plate 5, the concentrated stress is dispersed into linear stress. When the bending angle reaches the preset value, the controller 23 automatically stops the machine through the angle sensor.
[0029] This device significantly improves the dimensional accuracy and structural strength of the U-shaped beam through the synergistic effect of mechanical limiting and elastic buffering. In summary, the multi-level support system forms a dynamic support network during bending through the combination design of the arc-shaped side support plate 5 and the guide wheel 4. Combined with the stress dispersion characteristics of the polyurethane buffer layer 10, it effectively eliminates defects such as wrinkles and out-of-tolerance ovality that are easily generated by traditional bending processes. This device is particularly suitable for the production of high-precision lightweight components such as electric vehicle frames. While ensuring structural strength, it improves material utilization and significantly reduces manufacturing costs.
[0030] Through the above steps, when the electric vehicle U-beam bending device is in use, the limiting end of the steel pipe to be processed is first horizontally inserted into the limiting rod 12 at the top of the frame 1 to achieve axial positioning. At the same time, the side wall of the steel pipe forms a surface contact support with the arc-shaped side support plate 5 on the inner wall of the side support 2. Simultaneously, the first clamping mechanism 11 is activated, and the clamping arm is driven by hydraulics to perform radial clamping from the outside of the steel pipe. The first clamping mechanism 11, together with multiple sets of arc-shaped side support plates 5, forms a multi-point support structure. During the bending process of the steel pipe, the bending end of the steel pipe bends along the preset arc trajectory under traction. The two sets of guide wheels 4 inside the side support 2 automatically adjust the contact angle as the steel pipe slides. The polyurethane buffer layer 1 on the surface of the arc-shaped side support plate 5... The device absorbs radial pressure through elastic deformation, and the segmented support structure of the arc-shaped side support plate 5 disperses concentrated stress into linear stress. Through the synergistic effect of mechanical limiting and elastic buffering, the device significantly improves the dimensional accuracy and structural strength of the U-shaped beam. In summary, the multi-level support system, through the combined design of the arc-shaped side support plate 5 and the guide wheel 4, forms a dynamic support network during the bending process. Combined with the stress dispersion characteristics of the polyurethane buffer layer 10, it effectively eliminates defects such as wrinkles and out-of-tolerance ellipticity that are easily generated by traditional bending processes. This device is particularly suitable for the production of high-precision lightweight components such as electric vehicle frames. While ensuring structural strength, it improves material utilization and significantly reduces manufacturing costs.
[0031] The embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the present invention is not limited to the above embodiments. Within the scope of knowledge possessed by those skilled in the art, various changes can be made without departing from the spirit of the present invention.
Claims
1. An anti-deformation and bending device for U-shaped beams of electric vehicles, comprising a frame (1), characterized in that: It also includes a side support (2), an arc-shaped hole (3), guide wheels (4), an arc-shaped side support plate (5), a cavity (6), a mounting groove (7), a support rod (8), a connecting block (9), a polyurethane buffer layer (10), a first clamping mechanism (11), and a limiting rod (12). A side support (2) is fixedly installed on the top of one side of the frame (1). An arc-shaped hole (3) is opened on one side of the side support (2). Two sets of guide wheels (4) are installed inside the side support (2). Multiple sets of arc-shaped side support plates (5) are provided. A cavity (6) is opened inside the side support (2). Multiple sets of mounting grooves (7) are opened on the inner wall of the cavity (6). A support rod (8) is fixedly installed inside the mounting groove (7). A connecting block (9) is fixedly installed on the side wall of the support rod (8). A polyurethane buffer layer (10) is provided on the inner wall of the arc-shaped side support plate (5). A first clamping mechanism (11) is provided on the top of one side of the frame (1). A limit rod (12) is fixedly installed above the frame (1).
2. The electric vehicle U-shaped beam anti-deformation and bending device according to claim 1, characterized in that: The outer wall of the arc-shaped side support plate (5) is fixedly connected to the inner wall of the connecting block (9), and the first clamping mechanism (11) is located on one side of the side support (2).
3. The electric vehicle U-shaped beam anti-deformation and bending device according to claim 1, characterized in that: The guide wheel (4) has a fixed rotating shaft (13) inside, and both the upper and lower ends of the rotating shaft (13) are rotatably connected to the inner wall of the side support (2).
4. The electric vehicle U-shaped beam anti-deformation and bending device according to claim 1, characterized in that: A drive motor (14) is fixedly installed on the bottom side of the frame (1). A drive shaft (15) is installed at the output end of the drive motor (14). A fixed module (16) is fixedly installed at the upper end of the drive shaft (15). An arc groove (17) is opened on the side wall of the fixed module (16).
5. The electric vehicle U-shaped beam anti-deformation and bending device according to claim 4, characterized in that: A connecting seat (18) is fixedly provided on the side wall of the drive shaft (15), and a second clamping mechanism (19) is fixedly provided on the top of the connecting seat (18). The second clamping mechanism (19) is located on one side of the fixed module (16).
6. The electric vehicle U-shaped beam anti-deformation and bending device according to claim 5, characterized in that: A connecting plate (20) is fixedly installed on one side of the connecting seat (18), a support frame (21) is fixedly installed above the connecting plate (20), and a locking frame (22) is fixedly installed above the connecting plate (20).
7. The electric vehicle U-shaped beam anti-deformation and bending device according to claim 1, characterized in that: A controller (23) is installed on the top of the rack (1), a display screen (24) is installed on the side wall of the controller (23), and multiple buttons (25) are installed inside the controller (23).