Elongated Profile Forming with Pre-Trimming for Offset Sections
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Solution Overview
Problem
The existing method for producing elongate profile parts with height offsets and different cross-sections requires high accuracy in trimming, leading to increased manufacturing tolerances, energy inefficiency, and tool wear, while also compromising the stability of the profile part due to material removal and complex embossing processes.
Innovation Solution
Trimming the flat strip before profiling and embossing simplifies the process, reduces the need for high embossing forces, and allows for symmetrical trimming to enhance reproducibility and energy efficiency, with the embossing step being divided into multiple stages and using hold-down devices to prevent waviness, and a control system to adjust for dimensional accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If trimming is carried out after embossing to create different cross-sections for offset longitudinal sections, then the desired profile shape is achieved, but manufacturing precision deteriorates due to increased sensitivity to positioning accuracy and manufacturing tolerances
Solution Approach 1:
The patent applies preliminary action by trimming the flat strip before profiling and embossing operations. The trimming device removes material from the flat strip to create different cross-sections in advance, so that subsequent embossing operates on pre-prepared material with reduced force requirements and improved dimensional accuracy.
2Shape
If high embossing forces are used to offset longitudinal sections, then the desired profile configuration is achieved, but energy efficiency deteriorates and tool wear increases
Solution Approach 1:
The trimming device performs preliminary material removal to create different cross-sections before embossing. This preliminary action reduces the amount of material that needs to be displaced during embossing, thereby reducing the embossing forces required and improving energy efficiency while decreasing tool wear.
3Shape
If material is removed from the profiled strip during trimming after embossing, then different cross-sections are achieved, but stability deteriorates due to weakening of the profile part
Solution Approach 1:
The trimming operation is performed on the flat strip before profiling and embossing. By removing material in advance from the flat strip rather than from the already-formed profiled strip, the structural integrity and stability of the final profile part are preserved while still achieving the required different cross-sections.
4Ease of manufacture
If trimming is performed after profiling and embossing, then the process sequence is simple, but reproducibility deteriorates due to increased influence of manufacturing tolerances
Solution Approach 1:
The trimming device operates on the flat strip before profiling and embossing operations. This preliminary trimming establishes precise dimensional relationships early in the process, making the subsequent forming operations more reproducible and less sensitive to accumulated tolerances, thereby improving overall process reliability.
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 approach results in a more reproducible, energy-efficient, and cost-effective method for producing highly resilient elongate profile parts with improved dimensional accuracy and reduced tool wear, enabling stable and precise production of profile parts.
Implementation Method 1
a profiled strip is produced from a flat strip, in particular metal strip, by rolling
Implementation Method 2
the profiled strip is embossed in sections, as a result of which at least one longitudinal section of the profiled strip is opposite to at least one other longitudinal section is offset
Implementation Method 3
the strip is trimmed in such a way that after embossing the offset longitudinal sections have different cross-sections
Data Source
Figure 1~3
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AI summary
A device (12) and a method for producing an elongated profile section (1) are shown, in which a profiled strip (14) is produced from a flat strip (14), in particular a metal strip, by rolling, and the profiled strip (14) is embossed section by section, whereby at least one longitudinal section (3) of the profiled strip (14) is offset relative to at least one other longitudinal section (2) in a direction perpendicular to the longitudinal extent of the profiled strip (14), and in which method the strip (14) is trimmed such that, after embossing, the offset longitudinal sections (2, 3) have different cross-sections (8, 9). To increase the reproducibility of the method, it is proposed that the flat strip (14) be trimmed before profiling such that, by embossing the trimmed and profiled strip (14), the offset longitudinal sections (2, 3) have different cross-sections (8, 9).