Hot stamping using sequential tandem presses for automotive parts

Abstract

A system and method for hot-stamping automotive products use a sequence of physically separated tandem presses (110, 120, 130, 140), where each press (110, 120, 130, 140) has its own die configured to receive material (112). The system processes material (112) that has been heated to austenitic temperature through sequential operations, with material being introduced into an initial tandem press (110) and moved through subsequent presses (120, 130, 140). Each press (110, 120, 130, 140) may include heating and / or cooling elements to maintain austenitic temperature in specific regions while quenching others. The tandem presses (110, 120, 130, 140) perform various operations including forming, piercing, trimming, and quenching to create complex automotive products such as door rings. Robotic elements transfer material between presses (110, 120, 130, 140), enabling manufacturing of products that are substantially larger and more complex than those possible with single or transfer presses (110, 120, 130, 140). The system can produce complex automotive parts in seconds while maintaining precise temperature control throughout the manufacturing process.

Description

HOT STAMPING USING SEQUENTIAL TANDEM PRESSES FOR AUTOMOTIVE PARTSCLAIM OF PRIORITY

[0001] This patent application claims the benefit of priority to Rush et al, U.S. Provisional Patent Application Serial Number 63 / 554,071, entitled “HOT STAMPING USING SEQUENTIAL TANDEM PRESSES FOR AUTOMOTIVE PARTS,” filed on February 15, 2024, which is hereby incorporated by reference herein in its entirety.BACKGROUND

[0002] Hot stamping is a technique that may be used to manufacture elements, such as automotive products, which are used during automotive manufacturing.BRIEF DESCRIPTION OF THE DRAWINGS

[0003] The present disclosure is described with reference to the accompanying drawings, in which like reference characters reference like elements, and wherein:

[0004] Figure 1 illustrates example tandem presses which may be used to manufacture a product according to the techniques described herein.

[0005] Figure 2 illustrates a flowchart of an example process for manufacturing an automotive part using tandem presses.DETAILED DESCRIPTION

[0006] This application describes techniques to output large products at high speed via hot stamping. Specifically, the application describes producing products greater than a threshold size metric (e.g., width, height, area, volume), such as those using greater than a threshold area or volume of a blank. In some examples, the threshold area may be similar to a size metric associated with a side of a vehicle (e.g., a single or double door ring). Example products may include a single door ring, a double door ring, a panel of a vehicle, and so on.

[0007] As described herein, a series or sequence of tandem presses may be used to form a product. For example, a first tandem press may receive a blank which has been raised to greater than a threshold temperature (e.g., raised to austenitic levels). In this example, the first tandem press may output a main form associated with a final product. A second tandem press may then receive the output material from the first tandem press, for example via a robot moving the output material (e.g., a robotic arm). The second tandem press may adjust the material, such as piercing and / or trimming portions of the material. A third tandem press may then receive output material from the second tandem press, for example via a robot moving the output material. The third tandem press may optionally represent a final press which performs a final quench. The third tandem press may optionally perform additional adjustments of the material. For example, a portion of the material may be quenched while another portion may be pierced and / or trimmed.

[0008] While this application describes examples of use of tandem presses, as may be appreciated there may be any number of tandem presses and fall within the scope of the disclosure herein. Additionally, each die used for a tandem press may have heating and / or cooling circuits to enable portions of material to remain hot (e.g., above austenitic levels) while other portions may be cooled (e.g., to achieve martensitic strength).

[0009] In some examples, the techniques described herein may be used to form complex products in seconds (e.g., 3 seconds, 5 seconds, 10 seconds). These products may then be used downstream as part of a process of manufacturing a vehicle. As described above, an example product may include a double door ring or a portion thereof (e.g., the double door ring may be formed from two hot stamped products which are connected). For this example product, the series of tandem presses may be used to form a double door ring which has a complex shape formed via, at least in part, piercing. The series of tandem presses may also be used to pierce portions and form holes, vias, and so on.

[0010] An example double door ring which may be used using the techniques described herein is described in more detail with respect to PCT / US2024 / 057563 filed November 26, 2024, titled “HOT STAMPED CLASS-A DOUBLE DOOR RING FOR VEHICLE”, and claiming priority fromU.S. Prov. Patent App. No. 63 / 604,049 titled “HOT STAMPED CLASS-A DOUBLE DOOR RING FOR VEHICLE” and filed on November 29, 2023, which are both hereby incorporated by reference herein in their entirety. For example, each of the two portions of the double door ring may be manufactured using a sequence or series of tandem presses.

[0011] Use of tandem presses allows for manufacturing of products which are substantially more complex than other techniques. For example, a single press is commonly used in automotive manufacturing to form products. However, these products lack the complexity required for certain automotive products. As an example, a door ring may have a substantial number of complex holes, datums, and portions which need to be trimmed. A single press will not allow for the multi-stage requirement to manufacture such a door ring. Indeed, a complex product may require distinct dies which are used to trim and / or pierce specific portions.

[0012] Additionally, the use of a series of tandem presses allows for manufacturing of products which are larger than those that may use other techniques. For example, another example technique may include use of a transfer press. In this example, the transfer press may include a multitude of portions which form part of a larger transfer press. Each portion may be connected via a transfer element, such as a transfer bar. Similarly, each portion may adjust received material before the material is transferred to a subsequent portion. The portions may, as an example, include respective dies which are connected to the same press. Thus, the transfer press may perform multiple operations a single press. A transfer press is generally limited to manufacturing smaller products than larger tandem presses. Due to their ability to handle substantially larger products as compared to a transfer press, the series of tandem presses allows for a better process when manufacturing door ring or double door ring sized parts.

[0013] Figure 1 illustrates example tandem presses 110, 120, 130, 140 which may be used to manufacture a product according to the techniques described herein. The tandem presses may represent discrete presses with their own dies included therein. For example, each tandem press may form and / or quench a defined section of the product. Additionally, each tandem press mayinclude cooling and / or heating elements or circuits. For example, the elements or circuits may be associated with the die. Thus, when material is pressed against the die the elements or circuits may maintain a temperature (e.g., an austenitic temperature) or may reduce the temperature (e.g., quench, such as to achieve martensitic strength). In this way, portions of a material may be adjusted to appropriate temperature levels to either quench (and achieve martensitic strength) and / or maintain temperature levels to achieve downstream processes (e.g., piercing / cutting) prior to the portions developing martensitic strength which would optimize die life and reduce hot stamping post-processing.

[0014] While not illustrated, robotic elements, such as robotic arms with end- effectors, may be used to move material between the tandem presses 110, 120, 130, 140. For example, a robotic element may pick up, move, and deposit, material from a tandem press upstream (e.g., on its left) to a different tandem press downstream (e.g., on its right).

[0015] Tandem press 110 may receive a blank 112 which has been heated up to at least its austenitic temperature. In some examples the blank 112 may be steel, such as Al Si coated boron steel. In other examples, other material may be used and fall within the scope of the disclosure herein. The blank may be pressed by the tandem press 110 using a first die 114. As illustrated, the first die 114 may be used to form material (e.g., the blank) into a main form, or substantially closer to a main form, which is associated with an end-product.

[0016] The material may then be provided to the second tandem press 120. As illustrated, the second tandem press 120 may perform specific operations on the material. For example, the press 120 may pierce specific portions of the material (e.g., to create holes or vias) using portions 122 of the die. As another example, the press 120 may trim portions of the material. The second tandem press 120 may also quench specific portions of the material.

[0017] The material may then be provided to the third tandem press 130. In the illustrated example, the third tandem press 130 has quenched 132 a leftmost and right-most portion of the material. The press 130 has also pierced 134 portions of the material. As described above, in some examples cooling and / or heating circuits or elements may be used.

[0018] The material may then be provided to the fourth tandem press 140. In the illustrated example, press 140 is used to perform a final quench and output a manufactured product 142. For example, the press 140 may output a door ring (e.g., a single or double door ring as described in PCT / US2024 / 057563 mentioned above, and incorporated by reference herein in its entirety).

[0019] While Figure 1 illustrates use of four tandem presses, as may be appreciated there may be less than four or greater than four presses.

[0020] Figure 2 illustrates a flowchart of an example process 200 for manufacturing an automotive product using tandem presses. The process 200 may be performed by one or more processors (e.g., controllers, programmable logic controllers, or other processing elements) which are associated with control of at least a portion of a manufacturing line. For example, the processors may control a multitude of tandem presses. The processors may also control robotic elements which are positioned between the tandem presses, and which move material between the tandem presses. The processors may represent processors which communicate with, or are included in, the tandem presses, robotic elements, and so on. In some examples, the processors may be in communication with sensors, such as vision sensors, tactile sensors, and so on.

[0021] At block 202, material in austenitic state is obtained. As described above, material may be blanked and introduced into a furnace or other heating technique. The material may be raised to austenitic levels such that it can be used in a hot stamping process.

[0022] At block 204, a first tandem press is applied to the obtained material. The austenitic material may be moved to the first tandem press, for example via a robotic element (e.g., a robotic arm). The first tandem press has a die between which the material is positioned. The first tandem press then presses the material to obtain an initial adjustment of the material towards the automotive product. As described above, heating and / or cooling circuits or elements may be used to maintain the austenitic temperature and / or to quench portions of the material.

[0023] At block 206, the material is moved to another tandem press. The material may be moved via a robotic element, such as a robotic arm. In some examples, the processors may utilize sensor information, such as vision sensorsor other sensors, to position the material. In some examples, the robotic elements use feedback from sensors on end- effectors to position the material.

[0024] At block 208, other tandem presses are sequentially applied to the obtained material. As illustrated in Figure 1, the tandem presses may adjust the material towards a substantially final form of the automotive product. For example, a subset of the tandem presses may pierce and / or trim portions of the material. As another example, a subset of the tandem presses may cause quenching of specific portions of the material.

[0025] An example product includes a single or double door ring. An example of a double door ring is described in the PCT / US2024 / 057563 mentioned above, and incorporated by reference herein in its entirety.

[0026] Each tandem press in a series or sequence can have, or not have, material during the process, and the strokes of the tandem presses are not necessarily linked together. Additionally, the tandem presses described herein may be flexibly incorporated into existing tandem line processes or equipment. For example, after quenching (e.g., as illustrated in Figure 1 with respect to press 140), one or more additional presses (e.g., presses with dampening mechanisms) may be used to operate on the quenched material (e.g., trim and / or pierce the quenched material, such as to perform finishing operations).

[0027] It is to be understood that not necessarily all objects or advantages may be achieved in accordance with any particular example described herein. Thus, for example, those skilled in the art will recognize that certain examples may be configured to operate in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other objects or advantages as may be taught or suggested herein.EXAMPLES

[0028] Some examples of this disclosure include the following:

[0029] Example 1 includes a system for hot-stamping an automotive product, the system comprising: a plurality of tandem presses, wherein the tandem presses are physically separated from each other, wherein each tandem press has its own die configured to receive material, wherein the tandem presses form a sequence, and wherein material is introduced into an initial tandem presswhich forms the sequence and sequentially moved to subsequent tandem presses which form the sequence.

[0030] Example 2 includes the system of example 1, wherein a subset of the tandem presses has respective heating and / or cooling elements.

[0031] Example 3 includes the system of example 2, wherein the heating and / or cooling elements for a tandem press included in the subset are positioned on or proximate to the die.

[0032] Example 4 includes the system of any one of examples 1-3, wherein the material moved into the initial tandem press is a blank which has been raised to at least austenitic temperature.

[0033] Example 5 includes the system of any one of examples 1-4, wherein the subsequent tandem presses pierce and / or trim the material.

[0034] Example 6 includes the system of any one of examples 1-5, wherein at least one subsequent tandem press quenches portions of the material while maintain austenitic temperature of remaining portions.

[0035] Example 7 includes the system of any one of examples 1-6, further comprising at least one robotic element between the initial tandem press and at least one subsequent tandem press.

[0036] Example 8 includes the system of example 7, wherein the at least one robotic element is a robotic arm.

[0037] Example 9 includes the system of any one of examples 1-8, wherein output of the system is the automotive product, and wherein the automotive product is a double door ring.

[0038] Example 10 includes a method implemented by the system of any one of examples 1-9, the method comprising: obtaining, via the initial tandem press, material in austenitic state; applying the initial tandem press to the obtained material; causing movement of the material from the initial tandem press to at least one of the subsequent tandem presses; and apply the at least one of the subsequent tandem presses to the material, wherein remaining of the subsequent tandem presses are sequentially applied.

[0039] All of the processes described herein may be fully automated via software code modules, including one or more specific computer-executable instructions executed by a computing system. The computing system mayinclude one or more computers or processors. The code modules may be stored in any type of non-transitory computer-readable medium or other computer storage device. Some or all the methods may be embodied in specialized computer hardware.

[0040] Many other variations than those described herein will be apparent from this disclosure. For example, depending on the example, certain acts, events, or functions of any of the processes described herein can be performed in a different sequence, can be added, merged, or left out altogether (e.g., not all described acts or events are necessary for the practice of the processes). Moreover, in certain examples, acts or events can be performed concurrently, e.g., through multi -threaded processing, interrupt processing, or multiple processors or processor cores or on other parallel architectures, rather than sequentially. In addition, different tasks or processes can be performed by different machines and / or computing systems that can function together.

[0041] The various illustrative logical blocks and modules described in connection with the examples disclosed herein can be implemented or performed by a machine, such as a processing unit or processor, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA) or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof designed to perform the functions described herein. A processor can be a microprocessor, but in the alternative, the processor can be a controller, microcontroller, or state machine, combinations of the same, or the like. A processor can include electrical circuitry configured to process computerexecutable instructions. In another example, a processor includes an FPGA or other programmable device that performs logic operations without processing computer-executable instructions. A processor can also be implemented as a combination of external computing devices, e.g., a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a DSP core, or any other such configuration. Although described herein primarily with respect to digital technology, a processor may also include primarily analog components. A computing environment can include any type of computer system, including, but not limited to, a computersystem based on a microprocessor, a mainframe computer, a digital signal processor, a portable external computing device, a device controller, or a computational engine within an appliance, to be name a few.

[0042] Conditional language such as, among others, “can,” “could,” “might,” or “may,” unless specifically stated otherwise, are otherwise understood within the context as used in general to convey that certain examples include, while other examples do not include, certain features, elements and / or steps. Thus, such conditional language is not generally intended to imply that features, elements and / or steps are in any way required for one or more examples or that one or more examples necessarily include logic for deciding, with or without user input or prompting, whether these features, elements and / or steps are included or are to be performed in any particular example.

[0043] Disjunctive language such as the phrase “at least one of X, Y, or Z,” unless specifically stated otherwise, is otherwise understood with the context as used in general to present that an item, term, etc., may be either X, Y, or Z, or any combination thereof (e.g., X, Y, and / or Z). Thus, such disjunctive language is not generally intended to, and should not, imply that certain examples require at least one of X, at least one of Y, or at least one of Z to each be present.

[0044] Any process descriptions, elements or blocks in the flow diagrams described herein and / or depicted in the attached figures should be understood as potentially representing modules, segments, or portions of code that include one or more executable instructions for implementing specific logical functions or elements in the process. Alternate implementations are included within the scope of the examples described herein in which elements or functions may be deleted, executed out of order from that shown, or discussed, including substantially concurrently or in reverse order, depending on the functionality involved as would be understood by those skilled in the art.

[0045] Unless otherwise explicitly stated, articles such as “a” or “an” should generally be interpreted to include one or more described items. Accordingly, phrases such as “a device configured to” are intended to include one or more recited devices. Such one or more recited devices can also be collectively configured to carry out the stated recitations. For example, “a processor configured to carry out recitations A, B, and C” can include a firstprocessor configured to carry out recitation A working in conjunction with a second processor configured to carry out recitations B and C.

Claims

CLAIMS1. A system for hot-stamping an automotive product, the system comprising: a plurality of tandem presses, wherein the tandem presses are physically separated from each other, wherein each tandem press has its own die configured to receive material, wherein the tandem presses form a sequence, and wherein material is introduced into an initial tandem press which forms the sequence and sequentially moved to subsequent tandem presses which form the sequence.

2. The system of claim 1, wherein a subset of the tandem presses has respective heating and / or cooling elements.

3. The system of claim 2, wherein the heating and / or cooling elements for a tandem press included in the subset are positioned on or proximate to the die.

4. The system of claim 1, wherein the material moved into the initial tandem press is a blank which has been raised to at least austenitic temperature.

5. The system of claim 4, wherein the subsequent tandem presses pierce and / or trim the material.

6. The system of claim 4, wherein at least one subsequent tandem press quenches portions of the material while maintain austenitic temperature of remaining portions.

7. The system of claim 1, further comprising at least one robotic element between the initial tandem press and at least one subsequent tandem press.

8. The system of claim 7, wherein the at least one robotic element is a robotic arm.

9. The system of claim 1, wherein output of the system is the automotive product, and wherein the automotive product is a double door ring.

10. A method implemented by the system of claim 1, the method comprising: obtaining, via the initial tandem press, material in austenitic state; applying the initial tandem press to the obtained material; causing movement of the material from the initial tandem press to at least one of the subsequent tandem presses; and apply the at least one of the subsequent tandem presses to the material, wherein remaining of the subsequent tandem presses are sequentially applied.

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