Roll-Formed Frame Component With Closed Cross Sections
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Solution Overview
Problem
Existing frame components formed by overlaying multiple plate materials and welding cannot efficiently create closed cross sections with rectangular cross sections, leading to low productivity and insufficient rigidity against lateral loads.
Innovation Solution
A method involving roll forming a single metal plate to create a frame component with a T-shaped abutment portion and double walls, allowing for continuous arrangement of rectangular cross sections, and performing welding from the outside to form closed cross sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple plate materials are overlaid and welded to form a frame component, then productivity is improved, but it is impossible to form a closed cross section portion with continuously arranged rectangular cross sections
Solution Approach 1:
The patent merges multiple plate materials into a single integrated frame component by forming one continuous plate material into a complex three-dimensional shape with multiple closed cross sections. This eliminates the need to overlay and weld separate plates, achieving both high productivity and the desired closed cross section geometry through a single roll-forming process.
Solution Approach 2:
The patent transitions from a two-dimensional plate overlay approach to a three-dimensional formed structure. By roll-forming a single plate material into a multi-chambered three-dimensional shape, the invention creates closed cross sections with continuously arranged rectangular cross sections that cannot be achieved through simple plate overlay and welding.
2Device complexity
If multiple plate materials are overlaid and welded, then manufacturing steps are reduced, but the number of manufacturing steps such as positioning and welding increases
Solution Approach 1:
The patent combines multiple manufacturing operations into a single roll-forming process. Instead of separate steps for positioning and welding multiple plates, the invention forms the complete multi-chambered structure in one continuous operation, significantly reducing manufacturing steps and improving productivity.
Solution Approach 2:
The patent performs the forming action preliminarily by creating the complete three-dimensional shape with all closed cross sections during the roll-forming process itself, before any welding or assembly operations are needed. This preliminary formation eliminates subsequent positioning and welding steps.
3Ease of manufacture
If a frame component is formed by overlaying plate materials, then it can be manufactured, but it has insufficient rigidity against lateral loads
Solution Approach 1:
The patent merges multiple plate structures into a single integrated formed component with continuous material flow. This integration creates a unified structure with superior rigidity against lateral loads compared to assembled plate overlays, while maintaining ease of manufacture through the roll-forming process.
Solution Approach 2:
The patent utilizes curved transition portions in the roll-formed structure to distribute stresses more effectively. The curved geometry at intersections and transitions enhances the structural rigidity against lateral loads while maintaining the ease of manufacture through continuous roll-forming operations.
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 method enhances productivity by reducing manufacturing steps and increases rigidity and energy absorption against lateral impacts through deformation of curved portions.
Implementation Method 1
a method for manufacturing a frame component including a rectangular contour in which a plurality of closed cross sections are formed by roll-forming a plate material
Implementation Method 2
performing welding from outside on an opposite side of the other end portion on the side wall against which the other end portion abuts, thereby welding the other end portion to the side wall
Data Source
Figure 1~2
Figure 3~4
Figure 5A~5G
AI summary
This invention provides a method for manufacturing a frame component (11) including a substantially rectangular contour (11a) in which a plurality of closed cross sections (12 - 14) are formed by roll-forming a plate material (3) made of a metal such that one end portion (15) is left outside and the other end portion (16) is arranged inside. The method includes a step of forming an abutment portion (31) having a T-shaped cross section by making the other end portion (16) of the plate material (3) abut against a first vertical wall (21). The method includes a step of performing welding from outside, thereby welding the other end portion (16) to the first vertical wall (21). It is possible to manufacture a frame component including a plurality of closed cross sections with high productivity.