Vehicle Panel Forming Die with Integrated Cam Press
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Solution Overview
Problem
The existing method of manufacturing vehicle body panels using multiple molds increases manufacturing costs, land usage, and production time due to the high number of molds and processes required.
Innovation Solution
A manufacturing apparatus that uses a single mold with a lower die, upper die, and cam press unit to form vehicle panels, reducing the number of molds and processes by forming flange and cam portions in a vertical and oblique direction, utilizing a swing cam and cam slide to create complex shapes efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple molds are used for forming vehicle body panels, then the panel can be formed with complex shapes including flange and cam portions, but the manufacturing cost increases and the production time increases
Solution Approach 1:
The patent combines multiple separate molds (drawing mold, trimming mold, piercing mold, flanging mold, and cam forming mold) into a single integrated mold system. This mold includes a punch assembly with drawing punch, trimming punch, piercing punch, flanging punch, and cam forming punch that can perform all forming operations in one stamping cycle, thereby resolving the contradiction between manufacturing precision and productivity
Solution Approach 2:
The integrated mold is designed as a universal tool that can perform multiple functions: drawing the blank into panel shape, trimming excess material, piercing holes, forming flange portions, and creating cam forming portions. This multi-functional mold eliminates the need for separate specialized molds, maintaining high manufacturing precision while significantly improving production efficiency
2Manufacturing precision
If multiple molds are used for forming vehicle body panels, then complex panel shapes can be achieved, but the manufacturing cost increases
Solution Approach 1:
The patent merges five separate molds into one integrated mold system, reducing the total number of molds from five to one. This consolidation maintains the ability to produce complex panel shapes with high precision while reducing manufacturing costs through decreased mold investment, lower tooling maintenance expenses, and reduced setup requirements
Solution Approach 2:
The integrated mold serves as a universal tool performing drawing, trimming, piercing, flanging, and cam forming operations. This multi-functionality eliminates the need for multiple specialized molds, thereby reducing overall manufacturing cost while preserving the capability to achieve precise complex panel geometries
3Manufacturing precision
If multiple molds are used for forming vehicle body panels, then the panel can be formed with required features, but the land area used in the factory increases
Solution Approach 1:
The patent consolidates five separate mold stations into a single integrated mold installation. This merging reduces the total floor space required in the factory from five separate mold areas to one consolidated mold area, while still maintaining the capability to form all required panel features including flange portions and cam forming portions with high precision
4Manufacturing precision
If multiple molds are used for forming vehicle body panels, then the panel can be formed with required features, but the setting up time in mass production increases
Solution Approach 1:
The patent combines multiple separate molds into one integrated mold system, eliminating the need to set up and change between five different molds during mass production. This single mold setup maintains the ability to form all required panel features while drastically reducing setup time to near zero during production runs
Solution Approach 2:
The integrated mold performs drawing, trimming, piercing, flanging, and cam forming operations in a single setup. This multi-functionality eliminates repeated setup procedures required when using multiple specialized molds, thereby maintaining complete panel feature formation capability while minimizing time loss during mass production
Data Source
AI summary
An apparatus for manufacturing a panel for a vehicle configured to process a processing plate pre-processed by at least one mold into the panel of a predetermined shape by at least one another mold may include a lower die including a lower base mounted with at least one lower forming steel, an upper die provided vertically movable at a position corresponding to the lower die, and including an upper base mounted with at least one upper forming steel, and at least one cam press unit provided on the lower die and the upper die, and configured to form a flange portion in an edge portion of the processing plate along a vertical direction, and to form a cam forming portion extending from the flange portion along an oblique direction.