Bidirectional Sweep Roll Former for High-Strength Beams
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing roll-forming technologies are limited in forming non-linear structural members with alternating sweeps in opposite directions, especially when dealing with high-strength materials and larger cross-sectional dimensions, which complicates the production of beams like bumper reinforcement and vehicle frames.
Innovation Solution
A roll-forming apparatus with a sweep station that allows for bidirectional sweeping of beams during the roll-forming process, using a subframe and adjustable support structures to move sweep bending rollers in opposite directions, enabling the formation of beams with back-and-forth sweeps from a roll-formed centerline, even with high-strength materials and larger cross-sectional sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional roll-forming processes are used to form beams with alternating sweeps in opposite directions, then the manufacturing process becomes complex and inconsistent, but the ability to produce high-strength beams with sharp sweeps and large cross-sectional dimensions is required
Solution Approach 1:
The patent employs dynamic sweep-forming devices that can move laterally in opposite directions during the roll-forming process. The sweep-forming device includes a sweep arm that can oscillate or move laterally to create alternating sweeps, transforming a static forming process into a dynamic one. This allows consistent formation of complex beam geometries with alternating sweeps while maintaining manufacturing precision.
2Strength
If high-strength materials with tensile strength greater than 60 KSI are used to achieve high strength-to-weight ratio, then the material strength is improved, but the difficulty of sweep-forming increases due to material resistance to deformation
Solution Approach 1:
The patent incorporates preliminary shaping rolls that pre-form the beam cross-section and prepare the material before it reaches the sweep-forming device. This preliminary action reduces the deformation resistance when the high-strength material enters the sweep-forming zone, making it easier to create sharp sweeps without compromising the material's final strength properties.
Solution Approach 2:
The sweep-forming device allows for adjustable sweep radius, sweep angle, and forming speed parameters. By optimizing these parameters for high-strength materials, the device can achieve the desired beam geometry while managing the material's resistance to deformation. The ability to vary forming parameters enables consistent production despite using high-strength materials.
3Manufacturing precision
If sharp sweeps with radius less than 1500 mm are formed to achieve complex geometries, then the beam geometry precision is improved, but the manufacturing difficulty increases significantly
Solution Approach 1:
The sweep-forming device is divided into multiple independent components including sweep arms, forming rolls, and support structures that can be adjusted separately. This segmentation allows each component to be optimized for creating sharp sweeps while maintaining overall system manageability. The modular design reduces the practical complexity of handling sharp curvature requirements.
4Strength
If tubular beams with cross-sectional dimensions greater than 50 mm×50 mm are produced to achieve structural requirements, then the beam structural capacity is improved, but the sweep-forming consistency becomes difficult to maintain
Solution Approach 1:
The patent uses intermediate support rolls and guide structures positioned between the sweep-forming device and the final beam product. These intermediary elements provide continuous support to large-diameter tubular beams during the sweeping process, preventing distortion and maintaining sweep consistency despite the beams' large cross-sectional dimensions and high structural capacity requirements.
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
Enables the production of beams with high strength-to-weight ratio and complex geometries, such as bumper reinforcement beams and vehicle frames, with increased dimensional accuracy and consistency, capable of forming beams with sharp sweeps and large cross-sectional dimensions.
Implementation Method 1
a sweep station in-line with the roll former, where the sweep station includes a sweep-forming device for selectively sweeping the structural beam in a first direction away from the longitudinal line and in a second direction opposite the first direction away from the longitudinal line
Data Source
AI summary
A high-strength beam includes first and second sections bent in opposite directions as part of a roll-forming process. A frame includes side frame members incorporating the double-bent beam and at least one energy management tube attached to the beam. In one form, the beam is tubular and has a cross-sectional dimension of greater than 25 mm and a material strength of at least about 60 KSI tensile strength. A roll form apparatus includes a roll former device and a sweep station in-line with the roll former device for sweeping the continuous beam in first and second opposing directions. Also, a method of roll-forming comprises steps of: roll-forming a sheet of material into a continuous beam and sweeping first and second sections of the beam in opposite directions.