Double Rail Fastening Sections Bending for Rigidity
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Solution Overview
Problem
Conventional methods for producing double rails from C-shaped mounting rails are inefficient, requiring excessive material and resulting in unstable products due to material misallocation and limited flexibility in mounting element adjustment.
Innovation Solution
Bending out fastening sections from sheet metal profiles to connect them via clinching, riveting, or welding, allowing for reduced material usage and increased rigidity by positioning fastening sections at a distance, which can be clinched, riveted, or welded for stability and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two C-shaped mounting rails are connected over the entire surface, then the connection stability is improved, but the material usage increases and rigidity decreases
Solution Approach 1:
The connection between the two mounting rails is segmented into discrete fastening sections spaced apart along the longitudinal direction, rather than continuous surface connection. This segmentation reduces material usage while maintaining connection stability through strategically positioned attachment points.
Solution Approach 2:
The fastening sections are bent out of the plane of the sheet metal into a third dimension, creating tabs or flanges that protrude from the rail profiles. This dimensional change allows connection without requiring extensive material overlap in the original plane, thus reducing material usage while maintaining connection strength.
2Strength
If material is placed in the plane of symmetry for connection, then connection strength is improved, but the rigidity of the double rail decreases
Solution Approach 1:
Connection material is positioned out of the plane of symmetry by bending fastening sections into a third dimension. This creates connection tabs that extend perpendicular to the rail profile plane, providing connection strength without adding material that would reduce rigidity in the critical bending planes of the double rail structure.
Solution Approach 2:
Material is concentrated locally at discrete fastening sections rather than distributed across the entire connection area. This local concentration provides sufficient connection strength at specific points while leaving the majority of the rail structure free of excess material, thereby maintaining overall rigidity.
3Adaptability or versatility
If continuous opening slots are provided in both rails, then mounting flexibility is improved, but material usage increases
Solution Approach 1:
The fastening sections are spaced discretely along the longitudinal direction rather than providing continuous connection. This segmentation allows mounting elements to be positioned at various intervals along the rail, maintaining mounting flexibility while using less material than continuous connection would require.
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
The method enables the production of stable and cost-effective double rails with reduced material usage, enhanced rigidity, and flexible mounting options, improving processing speed and stability.
Implementation Method 1
fastening sections spaced apart from one another in the longitudinal direction of the later double rail are bent out of the sheet metal
Implementation Method 2
the two profiles connected to one another by fastening the fastening sections of a first profile to the fastening sections of a second profile
Implementation Method 3
which can be designed as tabs, for example. Mutually facing areas of the two profiles therefore run at a distance from one another
Data Source
Figure 1~3
Figure 4~5
Figure 6~7
AI summary
The present invention relates to a method for manufacturing a double rail (1) with at least two rails, namely a first rail (2) and a second rail (3), wherein each rail (2, 3) has two flanks (4) that define an opening slot (5) between them, through which an engaging mounting element can be inserted into the rail (2, 3). The double rail (1) is composed of two profiles (6, 7) extending over the entire length of the double rail (1), each profile being manufactured from a profiled, strip-shaped metal sheet (8).According to the invention, fastening sections (9) spaced apart from one another in the longitudinal direction of the subsequent double rail (1) are bent out of the metal sheet (8) before, during, or after the profile production, whereby the two profiles (6, 7) are connected to each other by attaching the fastening sections (9) of a first profile (6) to the fastening sections (9) of a second profile (7). The invention further provides a double rail (1) produced according to the inventive method.