Closed-Section Beam Stamping Without Separate Assembly
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Solution Overview
Problem
Conventional methods for manufacturing beams with closed cross sections require separate components, assembly operations, and additional fixing elements, leading to increased weight, complexity, and inefficiency, particularly in applications like airplane door structures.
Innovation Solution
A method involving a system with a first punch, a second punch, and a core for direct stamping of two sections without separate assembly, where the core modifies impressions to form a closed cross-section beam, potentially incorporating an intermediate punch and local heating to ensure cohesion between sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional separate component manufacturing and assembly is used, then manufacturing flexibility is maintained, but device complexity and weight increase due to multiple components and fixing elements
Solution Approach 1:
The patent merges two separate stamping operations into a single integrated operation. The first and second sections are formed and joined simultaneously in one stamping process, eliminating the need for separate component manufacturing and assembly operations. This reduces device complexity while maintaining manufacturing capability through the combined punch system.
Solution Approach 2:
The stamping system performs multiple functions in a single operation: it forms the first section, forms the second section, and joins them together. The punch assembly acts as a universal tool that accomplishes what previously required separate specialized operations, thereby simplifying the manufacturing process.
2Strength
If fixing elements are used to join sections, then structural strength is ensured, but weight and bulk increase
Solution Approach 1:
The invention extracts and eliminates the need for separate fixing elements such as screws, nuts, or rivets. Instead, the joining function is integrated directly into the stamping process itself, where the deformation and forming operations create the joint without requiring additional fastening components, thereby reducing weight.
Solution Approach 2:
The patent replaces the mechanical fixing system (screws, nuts, rivets) with a direct forming and joining mechanism. The stamping process itself creates the structural connection through controlled deformation and material flow, substituting complex mechanical fastening systems with a more efficient integrated forming process.
3Productivity
If separate components are manufactured independently, then manufacturing flexibility is maintained, but productivity decreases due to assembly operations
Solution Approach 1:
The patent combines multiple sequential operations (forming first section, forming second section, joining sections) into a single simultaneous stamping operation. This eliminates idle time between operations and removes assembly steps, directly improving productivity while the integrated tooling design manages the complexity of the combined process.
Solution Approach 2:
The stamping process maintains continuous useful action by forming and joining both sections in one uninterrupted operation. There is no idle time or separate assembly phase where the process stops, as the forming and joining actions occur simultaneously and continuously throughout the stamping cycle.
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 method simplifies the manufacturing process by eliminating the need for separate components and assembly operations, reduces material usage, and eliminates the need for additional fixing elements, resulting in a lighter and more efficient beam production.
Implementation Method 1
stamping a first plate between a first punch having a first impression and a second punch having a second impression
Implementation Method 2
incorporating a core that modifies its second impression
Implementation Method 3
The method has a prior step of heating the first plate and the second plate
Implementation Method 4
The method has a step of locally heating at least one region of the first section obtained after the first stamping operation
Data Source
AI summary
A method for manufacturing a beam (P1, P2) with closed section, the beam being produced by combining a first profile (P10, P20) and a second profile (P11, P21), including the following steps: producing the first profile by a first stamping of a first plate (5, 50) between a first punch (1, 10) having a first imprint and a second punch (2, 20) having a second imprint and incorporating a core (3, 30) modifying its second imprint; holding the first profile (P10, P20) on the first punch and positioning the core (3, 30) above the first profile (P10, P20); producing the second profile (P11, P21) by a second stamping of a second plate (6, 60) against the core (3, 30) between the first punch (2, 20) and the assembly formed by the superposition of the first punch (1, 10), the first profile (P10, P20) and the core.