Vehicle Bumper Reinforcement Bar Roll Forming With Springback

The patent combines multiple bending operations and welding operations into a single integrated roll forming process. The forming rollers are configured to simultaneously bend the metal plate into the desired reinforcement bar shape and perform welding at the connecting sections, eliminating the need for separate bending and welding steps. This merging of operations reduces manufacturing complexity while maintaining structural integrity.

The roll forming process performs preliminary shaping and positioning of the metal plate sections before final attachment. The forming rollers pre-bend the metal plate into the reinforcement bar configuration with connecting sections positioned for attachment to the intermediate portion, preparing the structure for subsequent steps while reducing the complexity of final assembly.

The roll forming process implements continuous bending and shaping operations in a single pass through the forming rollers. The metal plate continuously moves through the rollers that progressively bend it into the reinforcement bar shape without interruption, eliminating the start-stop nature of multiple discrete bending steps. This continuous action significantly improves manufacturing efficiency while achieving the required rigidity.

The forming rollers perform preliminary shaping of the metal plate into the final reinforcement bar configuration during the primary forming process, reducing the need for subsequent corrective bending operations. This preliminary action ensures the desired shape and rigidity are achieved in the main processing step, improving overall manufacturing efficiency.

The roll forming process divides the metal plate into distinct functional sections (first portion, intermediate portion, second portion, and connecting sections) and applies different bending radii and forming actions to each section simultaneously. The forming rollers are configured to create different curvature radii in different sections in a single pass, achieving the required shape precision for each section without requiring multiple separate processing steps.

The patent uses a multi-dimensional roll forming approach where forming rollers are arranged in three-dimensional space to simultaneously apply bending forces from multiple directions. This allows complex three-dimensional shaping of the reinforcement bar with precise control over curvature and geometry in a single processing step, achieving high shape precision without increasing the number of processing steps.