Notch Pressing Device for Vehicle Crash Box
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Solution Overview
Problem
The existing methods for forming notches in crash boxes, particularly those made of steel or aluminum, are inefficient and costly, requiring additional processes like pressing, welding, or hydroforming, which complicate the manufacturing process.
Innovation Solution
A notch pressing device comprising a lower and upper fixing plate, a core rotating unit, a supporting unit, and a forming unit with a punch, allowing for the formation of notches in closed sectional tube-type crash boxes by selectively rotating the core and using a punch to push the crash box, enabling easy replacement of cores and punches for various notch configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If hydroforming is applied to form notches in aluminum crash boxes, then notch formation becomes possible, but manufacturing cost increases and additional post-processing steps are required
Solution Approach 1:
The patent replaces the complex hydroforming system with a simple mechanical pressing system. A press applies direct mechanical force through a die to form notches in the crash box, eliminating the need for hydroforming equipment, metallic patterns, and associated post-processing steps while achieving the same notch formation capability
Solution Approach 2:
The patent extracts and eliminates the unnecessary intermediate steps of hydroforming, metallic pattern manufacturing, washing, and cutting processes. By using direct mechanical pressing, only the essential notch formation operation remains, significantly simplifying the manufacturing process
2Ease of manufacture
If pressing is used to form notches in steel crash boxes made of 2 panel sheets, then notch formation is achievable, but additional welding processes are required
Solution Approach 1:
The patent merges the notch formation operation with the existing press line workflow. By integrating notch pressing into the standard pressing process without requiring separate welding operations or additional assembly steps, the manufacturing efficiency is maintained while achieving notch formation capability
3Device complexity
If conventional pressing methods are used for closed sectional tube-type crash boxes, then the process remains simple, but notch formation is difficult or impossible
Solution Approach 1:
The patent introduces a movable die that can dynamically adjust its position and apply force to the crash box during the pressing operation. This dynamic capability allows the simple pressing process to effectively form notches in closed sectional tube-type crash boxes by adapting to the workpiece geometry and deformation 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
This solution allows for the economical and efficient formation of notches in crash boxes, reducing manufacturing complexity and costs by enabling the formation of multiple notch configurations without the need for costly hydroforming or extensive post-processing.
Implementation Method 1
a core rotating unit that selectively rotates a core where the crash box is put
Implementation Method 2
a forming unit that is connected to a punch, which selectively pushes the crash box put to the core for forming the notch
Implementation Method 3
pushes the crash box put to the core for forming the notch
Data Source
AI summary
The present invention relates to a notch pressing device for a crash box of a vehicle.The notch pressing device for a crash box of a vehicle includes a lower fixing plate, an upper fixing plate mounted to the lower fixing plate by a plurality of posts, a core rotating unit that selectively rotates a core where the crash box is put and is disposed to one end of the lower fixing plate, a supporting unit that is connected to a moving die for selectively supporting a lower portion of an end of the core and that is disposed to a side of the lower fixing plate, and a forming unit which is connected to a punch, which selectively pushes the crash box put to the core for forming the notch, and that is disposed to the upper fixing plate.