Multichamber Hollow Profile Forming for Larger Vehicle Components
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing motor vehicle structural components from extruded multichamber profiles are limited by the dimensions of the extrusion tools, requiring larger machines for components exceeding tool dimensions, leading to logistical complexity and economic disadvantages.
Innovation Solution
The method involves producing an extruded profile with precursor hollow chambers separated by an inner wall, where at least one outer wall has a non-linear course, which is then partially straightened to increase the cross-section, allowing the production of larger components using existing equipment by forming the profile into a motor vehicle structural component with enhanced dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the component size is increased beyond the dimensions of the extrusion tool, then larger motor vehicle structural components can be produced, but larger extrusion machines must be procured which increases logistical complexity and economic costs
Solution Approach 1:
The outer wall of the precursor hollow chamber is segmented into regions with different courses (linear and non-linear), allowing the extrusion process to work with smaller dimensions while the non-linear region provides the necessary forming capability during subsequent deformation into the final component shape
Solution Approach 2:
The non-linear course region is prepared in advance during extrusion, creating a pre-formed structure that enables subsequent expansion into larger dimensions during the forming process, eliminating the need for larger extrusion equipment
2Length of moving object
If the component size is increased beyond the dimensions of the extrusion tool, then larger motor vehicle structural components can be produced, but larger extrusion machines must be procured which increases economic costs
Solution Approach 1:
The outer wall is divided into regions with different courses, allowing the extrusion tool to maintain standard dimensions while the non-linear region enables subsequent forming into larger component sizes, avoiding the need for expensive larger extrusion machines
Solution Approach 2:
The non-linear course region is created during standard extrusion as a preliminary feature that enables subsequent expansion into larger dimensions, allowing production on existing equipment and avoiding additional capital investment
3Area of moving object
If the cross-section of the hollow chamber is increased, then larger motor vehicle structural components can be produced, but the web configuration must be redesigned which complicates the extrusion process
Solution Approach 1:
The outer wall is segmented into regions with different courses, where the non-linear region specifically addresses the cross-section expansion need while the linear regions maintain structural integrity, avoiding complete redesign of the entire web configuration
Solution Approach 2:
Only the specific region of the outer wall that needs expansion is given a non-linear course, while other regions maintain their linear configuration, allowing localized cross-section increase without complicating the entire web structure
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 enables the production of motor vehicle structural components with larger dimensions than the original extrusion tools allow, reducing the need for new machinery and simplifying logistics and costs, while maintaining stability through unchanged inner walls and controlled cross-sectional changes.
Implementation Method 1
at least the region with non-linear course, in transverse extent, of the at least one outer wall of the at least one precursor hollow chamber is at least partially straightened, with a change in cross-section of the respective precursor hollow chamber into the cross-section of the corresponding hollow chamber of the motor vehicle structural component
Data Source
AI summary
The invention concerns a method for manufacturing a motor vehicle structural component (1) from an extruded multichamber hollow profile, with the following steps:a) provision of an extruded profile (2) with at least two precursor hollow chambers (8, 9) which are separated from one another by an inner wall (7), wherein at least one outer wall (3, 4) of at least one precursor hollow chamber (8, 9), in cross-section perpendicularly to the longitudinal extent of the extruded profile (2), has a region (16) with non-linear course,b) forming of the extruded profile (2) in at least one of its end regions into the motor vehicle structural component (1), wherein at least the region (16) with non-linear course of the at least one outer wall (3, 4) of the at least one precursor hollow chamber (8, 9), with non-linear course in cross-section, is at least partially straightened, with a change in cross-section of the respective precursor hollow chamber (8, 9) into the cross-section of the corresponding hollow chamber (14, 15) of the motor vehicle structural component (1).