Heated Roller Hemming Apparatus for High-Strength Vehicle Panels
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Solution Overview
Problem
Conventional roller hemming processes for vehicle panels, especially those made of high-strength materials like magnesium and ultra-high tensile steel, often result in hemming defects such as insufficient bend degree, spring back, and cracks due to the spring back phenomenon and material properties.
Innovation Solution
A roller hemming apparatus equipped with a tool body mounted on a robot arm, featuring a pre-hemming roller and a main hemming roller, and at least one heater that locally heats the flange portion of the outer panel using a hot wind to soften the material during the hemming process, preventing spring back and cracks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high strength materials such as magnesium and ultra-high tensile steel are used for vehicle body panels, then weight reduction and collision safety are improved, but hemming defects such as spring back and cracks frequently occur
Solution Approach 1:
The patent applies thermal energy to change the temperature parameter of the flange portion, softening the high strength material to reduce its elasticity and prevent spring back phenomenon during hemming, thereby improving hemming quality while maintaining the use of high strength materials for collision safety
Solution Approach 2:
The patent introduces a heater as an intermediary device that generates thermal energy to heat the flange portion, acting as a mediator between the hemming process and the high strength material to enable successful hemming without direct mechanical force that would cause defects
2Productivity
If conventional roller hemming process is used for high strength materials, then the hemming process can be performed, but hemming defects such as insufficiency of bend degree and cracks occur
Solution Approach 1:
The patent changes the temperature parameter of the material during the hemming process by applying thermal energy, which softens the high strength material and enables sufficient bend degree to be achieved without compromising the efficiency of the roller hemming process
3Reliability
If the flange portion is heated before hemming, then spring back and cracks are prevented, but additional equipment and process complexity are required
Solution Approach 1:
The patent merges the heater with the roller hemming apparatus by positioning it adjacent to the rollers, combining the thermal softening function with the mechanical hemming function in a single integrated tool, thereby preventing spring back and cracks without significantly increasing overall device complexity
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 apparatus effectively suppresses hemming defects by softening the flange portion, improving the quality of the hemmed part and reducing the occurrence of insufficiency in bend degree, thereby enhancing the overall hemming process.
Implementation Method 1
The heater may be configured to generate heat by receiving electric power and blowing a hot wind to the flange portion.
Implementation Method 2
The heater may be configured to generate heat by receiving electric power and blowing a hot wind to the flange portion.
Implementation Method 3
the flange portion is softened by the hot wind while the flange portion is hemmed. In addition, spring back and cracks can be prevented from being generated in the flange portion by heating the flange portion
Data Source
AI summary
A roller hemming apparatus is disclosed. A roller hemming apparatus for hemming an outer panel with respect to an inner panel according to an exemplary embodiment of the present invention may include a tool body mounted at a front end of an arm of a robot, a pre-hemming roller mounted to a front side of a mounting block, which is disposed at a lower portion of the tool body, through a first mounting bracket, a main hemming roller mounted to a rear side of the mounting block through a second mounting bracket, and at least one heater mounted at a lateral side of the mounting block and configured to heat a flange portion of the outer panel.