Shared Front Floor Mold for Multi-Wheelbase Stamping
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Solution Overview
Problem
Current automotive manufacturing processes require separate molds for each wheelbase variation, leading to increased development work, investment costs, and prolonged development cycles.
Innovation Solution
A mold capable of processing front floors with different wheelbases, featuring a head convex mold, tail convex mold, wheelbase variation area, locking ribs, crimping ring, and reinforcement forming portions, allowing for the production of front floors with the same cross-sectional shape across varying wheelbases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate molds are developed for each wheelbase variation, then manufacturing precision for specific wheelbase models is improved, but device complexity and investment costs increase significantly
Solution Approach 1:
The patent applies universality by designing a single mold capable of producing front floors for multiple wheelbase variations (2700mm, 2900mm, 3100mm) through adjustable positioning mechanisms. The mold includes movable positioning plates and adjustable support blocks that can be repositioned along the molding direction to accommodate different wheelbase requirements, eliminating the need for separate dedicated molds for each model.
Solution Approach 2:
The patent implements dynamics through adjustable and movable components within the mold structure. The positioning plates can be moved to different locations, support blocks can be adjusted in position, and the mold incorporates adjustable mechanisms that allow dynamic reconfiguration between different wheelbase productions, enabling the same mold to adapt to varying manufacturing requirements.
2Manufacturing precision
If separate molds are developed for each wheelbase variation, then product quality for specific models is maintained, but loss of time in development cycle increases
Solution Approach 1:
The universal mold design allows a single mold to produce front floors for multiple wheelbase models by adjusting positioning elements. This eliminates the sequential development and validation processes required for separate molds, significantly reducing the development cycle while maintaining consistent product quality across different models through standardized molding processes.
Solution Approach 2:
The mold incorporates pre-designed adjustable positioning mechanisms and standardized support structures that can be quickly reconfigured between different wheelbase productions. These preliminary prepared adjustment mechanisms enable rapid switching between models without requiring extensive retooling or redevelopment time.
3Adaptability or versatility
If separate molds are developed for each wheelbase variation, then adaptability to different models is improved, but loss of substance through material waste increases
Solution Approach 1:
The universal mold produces front floors for multiple wheelbase models using the same basic mold structure and material blank size. By adjusting positioning plates and support blocks rather than using entirely different molds, the system reduces material waste that would otherwise occur in developing and validating separate molds for each model, while maintaining full adaptability to different wheelbase requirements.
4Adaptability or versatility
If conventional separate mold development is used for high, low, and crossover models, then specific model requirements are met, but investment costs reach ten million level
Solution Approach 1:
The patent applies universality by creating a single mold that can produce front floors for high, low, and crossover models with wheelbases of 2700mm, 2900mm, and 3100mm respectively. This eliminates the need to invest in three separate million-level mold developments, reducing total investment costs while maintaining the ability to meet specific requirements for each model type through adjustable positioning mechanisms.
Data Source
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AI summary
A mold capable of processing front floors (1) having different wheelbases, comprising a head male die (3) and a tail male die (4), the head male die and the tail male die being respectively used for manufacturing the front portion and rear portion of a front floor by means of an opening and drawing process in a step distance direction. The mold further comprises a wheelbase length change area (1a) configured to be adapted to a length change of the front floor, the wheelbase length change area being used for manufacturing the front floor having same-shaped cross portions in the step distance direction. According to the mold capable of processing front floors having different wheelbases, conformal areas of the rear portions of the front floors are manufactured by using the opening and drawing process, so that molds for the parts of the front floors having different total wheelbases but the same conformal area cross portion are shared, while product quality is ensured and raw materials are not wasted. The front floors can also be produced by means of a double-cavity process or a process for producing two pieces by using one mold, so that the mold investment, the material costs, the production costs, and the development cycle are all optimized.