Vehicle Door Die Assembly With Segmented Binder Travel
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Solution Overview
Problem
Traditional vehicle door manufacturing methods generate material waste and excessive forming strain due to a single binder system, which requires the same depth draw for both the header and main body portions, leading to inefficiencies.
Innovation Solution
The die assembly is split into separate components, including an upper header binder, lower main body binder, and lower header binder, allowing for different forming distances and reduced overall travel, specifically a shorter stroke for the header portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single unitary binder is used for both header and main body portions, then the binder wrap remains clean and simple, but material waste increases and forming strain becomes excessive
Solution Approach 1:
The single unitary binder is divided into multiple separate binder components, each responsible for forming specific portions of the vehicle door. This segmentation allows each binder to travel only the necessary distance for its designated area, reducing overall material consumption while maintaining clean binder wraps.
2Ease of manufacture
If the same draw depth is applied to both header and main body portions, then the binder wrap remains clean, but forming strain on the vehicle door increases excessively
Solution Approach 1:
By segmenting the binder system into multiple components with different travel distances, the forming process can apply appropriate draw depths to different portions of the vehicle door. The header portion binder travels a shorter distance while the main body binder travels longer, reducing excessive forming strain while maintaining clean binder wraps.
Solution Approach 2:
Different portions of the vehicle door receive different forming treatments through the segmented binder system. The header portion undergoes shorter draw depth forming while the main body receives longer draw depth, allowing each area to be formed with the appropriate level of strain rather than forcing uniform treatment throughout.
3Productivity
If a single binder travels the full forming distance for the main body, then complete forming is achieved, but the header portion experiences excessive draw depth and material waste
Solution Approach 1:
The forming process is divided into multiple binder components with differentiated travel distances. The main body binder travels the full forming distance to ensure complete forming, while the header binder travels a shorter distance to prevent excessive draw depth and material waste in the header portion.
Data Source
AI summary
A die assembly for manufacturing a vehicle door includes an upper die assembly having an upper die, and a lower die assembly including a lower die. The lower die assembly includes a lower header binder configured to travel downwardly relative to the lower die an initial forming distance D1 during a downward forming movement of the upper die assembly. The lower die assembly includes a lower main body binder configured to travel downwardly relative to the lower header binder and the upper die a longer forming distance D1+D2 during the downward forming movement of the upper die assembly. The upper die assembly includes an upper header binder separate from and compressible upwardly relative to the upper die by the lower header binder a compressing distance Dc during the downward forming movement of the upper die assembly.