Bumper Reinforcement Bar Roll Forming With Overbending Springback

The patent combines multiple bending operations and welding operations into a single integrated roll forming process. The forming rollers 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 connecting sections and position them for optimal attachment, ensuring proper alignment and reducing the need for subsequent adjustment or rework. This preliminary action simplifies the overall manufacturing process.

The roll forming process implements continuous bending action through a series of forming rollers that progressively shape the metal plate in one continuous operation. Instead of discrete bending steps with intermediate handling and positioning, the plate moves continuously through the forming rollers, maintaining constant useful action. This continuity significantly reduces production time while achieving the required curvature and shape.

The forming process is segmented into multiple rolling stages, each handled by different forming rollers that progressively create the desired shape. The first forming roller creates initial curvature, the second forming roller refines the shape, and subsequent rollers complete the final geometry. This segmentation of the bending process into specialized rolling stages allows complex shaping to be achieved efficiently in one continuous operation.