Multichamber Hollow Profile Forming for Oversized Vehicle Components
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing motor vehicle structural components from extruded multichamber hollow profiles are limited by the dimensions of the extrusion tools, requiring larger machines and increased logistical and economic complexity when producing components that exceed these dimensions.
Innovation Solution
A method involving an extruded profile with precursor hollow chambers separated by an inner wall, where at least one outer wall has a non-linear course that is partially straightened to change the cross-section, allowing for the production of larger components using existing equipment by altering the width and height of the hollow chambers.
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 machines must be procured which increases logistical complexity and economic costs
Solution Approach 1:
The outer wall of the precursor hollow chamber is divided into multiple segments along its longitudinal extent. At least one segment has a non-linear course (curved, angled, or undulating) instead of being perfectly straight. This segmentation allows the extruded profile to fit within the dimensions of existing extrusion tools while the non-linear segments provide the necessary clearance for web protrusion during clamping in the forming tool.
Solution Approach 2:
The solution moves the problem from the linear dimension (component size) to the spatial arrangement dimension. By introducing non-linear courses in the outer wall segments, the profile creates additional space within the same extrusion tool dimensions, effectively using spatial optimization rather than increasing machine size to accommodate larger components.
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 machines must be procured which increases economic costs
Solution Approach 1:
The outer wall is segmented into multiple portions along the longitudinal extent, with at least one segment having a non-linear course. This allows the profile to be produced on existing extrusion equipment without requiring investment in larger, more expensive machines, thereby reducing economic costs while still enabling production of larger final components after forming.
Solution Approach 2:
The geometry of the outer wall segments is changed from linear to non-linear (curved, angled, or undulating). This parameter change in the profile design allows the same extrusion tool to produce profiles that, after forming, result in larger final components, avoiding the need to procure expensive larger-capacity extrusion machines.
3Reliability
If the web protrusion is provided for clamping the extruded hollow chamber profile in the forming tool, then the profile can be securely clamped, but the component size is restricted by the available extrusion tool dimensions
Solution Approach 1:
The outer wall is divided into multiple segments along its longitudinal extent, with at least one segment having a non-linear course. This segmentation creates the necessary space for web protrusion in specific regions while maintaining overall profile dimensions that fit within existing extrusion tools, thus preserving both clamping security and component size flexibility.
Solution Approach 2:
Instead of making the entire outer wall non-linear or increasing overall profile dimensions, the non-linear course is applied locally to specific segments of the outer wall. This localized approach provides the necessary clearance for web protrusion in clamping regions while keeping other portions of the profile compact enough for existing extrusion tools.
Data Source
AI summary
A method for manufacturing a motor vehicle structural component from an extruded multichamber hollow profile. The method includes providing an extruded profile with at least two precursor hollow chambers which are separated from one another by an inner wall, wherein in at least one outer wall of at least one precursor hollow chamber in cross-section perpendicularly to a longitudinal extent of the extruded profile has a region with non-linear course. The extruded profile is formed in at least one of its end regions into the motor vehicle structural component, wherein at least the region with non-linear course of the at least one outer wall of the at least one precursor hollow chamber, with non-linear course in cross-section, 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.