Bend-Formed Car Load-Bearing Structure With Lighter Tooling
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Solution Overview
Problem
The existing manufacturing processes for passenger cars, particularly the use of forming tools and welding technologies, result in high investment costs, complex tooling requirements, and significant capital expenditures, making it difficult for new manufacturers or those in resource-constrained regions to establish efficient and cost-effective production methods.
Innovation Solution
The method employs bend forming according to DIN 8586 as the primary forming procedure to create a folding-box-like load-bearing structure using high-strength steel, reducing the number of components and welding needs, and allowing for flexible tool usage and efficient material transport, with the option to integrate additional reinforcement elements like tubes and remnant sheets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional tensile compressive forming or tensile forming methods like deep drawing, hydroforming or embossing are used, then high quantities and fast cycle times can be achieved, but high investment costs and heavy tooling weight result
Solution Approach 1:
The forming process is segmented into bend forming operations that can be performed with lighter, more modular tooling. Instead of using heavy monolithic forming presses, the invention employs sequential bending operations that achieve complex geometries through multiple smaller-forming steps, reducing individual tool weight while maintaining productivity
Solution Approach 2:
The invention introduces dynamic adaptability in the forming process by using bend forming technology that allows for quick tool changes and reconfiguration. The tooling system can be dynamically adjusted for different component geometries, eliminating the need for heavy, dedicated forming tools for each component type
2Adaptability or versatility
If a high number of forming tools are used to build up all components for a vehicle, then complete vehicle manufacturing capability is achieved, but high fixed capital value and large storage area are required
Solution Approach 1:
The bend forming tooling is designed with universal applicability, where a single forming press can perform multiple bending operations for different components by changing tooling configurations. This multi-functional approach reduces the total number of specialized forming tools needed, thereby reducing fixed capital requirements while maintaining comprehensive vehicle manufacturing capability
Solution Approach 2:
The invention utilizes parameter changes in the bending process (bending angles, sequences, and tooling configurations) to create diverse components from the same base material and equipment. By varying process parameters rather than requiring dedicated tools for each parameter set, the system achieves high adaptability with reduced capital investment
3Manufacturing precision
If traditional forming tools are used, then precise component geometry can be achieved, but the tools become heavy requiring support by machines like cranes
Solution Approach 1:
Complex forming operations are segmented into multiple bend forming steps, each performed with lighter tooling. The segmentation of the forming process allows precision to be achieved through cumulative bending operations rather than requiring a single heavy forming tool, maintaining geometric precision while reducing tool weight below crane support thresholds
4Adaptability or versatility
If state of the art manufacturing processes with extensive machinery and paint shops are used, then complete vehicle production capability is achieved, but high investment costs and long ramp-up time result
Solution Approach 1:
The invention extracts and eliminates non-essential process steps from traditional manufacturing, such as separate paint shops and extensive machining operations. By focusing on bend forming as the primary shaping method, the process reduces the number of required production facilities, lowering investment costs and enabling faster plant ramp-up while maintaining complete vehicle production capability
Solution Approach 2:
The bend forming process performs preliminary shaping operations that eliminate the need for subsequent extensive machining and painting operations. By pre-forming components to near-final geometry through bending, the process reduces downstream processing requirements, accelerating production ramp-up and reducing overall investment in auxiliary facilities
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables a lightweight, cost-effective load-bearing structure with reduced investment costs, enabling rapid ramp-up and flexible production, suitable for various vehicle types, including electric vehicles, without the need for extensive machinery or paint shops, and allows for efficient logistics and recycling.
Implementation Method 1
bend forming according to DIN 8586... bending angle α ≥ 90°... high strength steel with a yield strength R p0.2 ≥ 400MPa
Data Source
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Figure 3
AI summary
The invention relates to a method, use or a profile for manufacturing metallic flat materials to a cost-effective load-bearing structure of a passenger car and the usage of it. As the main forming manufacturing method the bend forming according to DIN EN ISO 8580 is used.