Roll Forming Assembly for Transverse Strut Annealing
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Solution Overview
Problem
Existing methods for shaping and heat-treating transverse struts in twist beam axle suspensions are costly and lack precision, requiring separate tools and processes for different shapes and sizes, and often necessitate additional heat treating steps.
Innovation Solution
A roll forming assembly that integrates a heater for annealing and a quenching bath for heat treatment, combined with precise control of forming wheels through a ball screw connection, allowing for simultaneous shaping and heat treatment of transverse struts with minimal additional cost and high precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional squashing tools are used to shape transverse struts, then shaping can be achieved, but the process is costly and requires different tools for different shapes and sizes
Solution Approach 1:
The patent applies universality by designing a single roll forming tool that can produce multiple transverse strut shapes and sizes by adjusting rolling parameters. The tool includes adjustable rolling elements and can create different cross-sectional shapes (U-shaped, C-shaped, rectangular) without requiring different physical tools, thus reducing cost while maintaining versatility.
Solution Approach 2:
The patent utilizes parameter changes by modifying rolling conditions such as rolling force, temperature, and rolling element positioning to achieve different transverse strut configurations. By changing these parameters rather than changing the tool itself, the system can adapt to various shaping requirements cost-effectively.
2Productivity
If traditional separate shaping and heat treating processes are used, then transverse struts can be formed, but additional manufacturing steps and costs are required
Solution Approach 1:
The patent merges the shaping and heat treating processes into a single integrated roll forming operation. The rolling process itself generates sufficient heat to anneal the tube material, and the continuous rolling action simultaneously forms the shape and applies thermal treatment, eliminating separate heat treating steps and improving productivity.
Solution Approach 2:
The patent maintains continuity of useful action by performing shaping and heat treating in a single continuous rolling operation without interruption. The tube passes through the rolling elements continuously, receiving both mechanical forming and thermal treatment in one uninterrupted process flow, thereby maximizing manufacturing efficiency.
3Manufacturing precision
If tube is heated before roll forming, then the roll forming process is improved, but additional heating equipment and energy are required
Solution Approach 1:
The patent applies self-service by utilizing the rolling process itself to generate the necessary heat for improving formability. The mechanical work of rolling converts to thermal energy that heats the tube material to the appropriate temperature, eliminating the need for external heating equipment and reducing energy consumption while maintaining manufacturing precision.
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
Enables the efficient production of shaped and heat-treated transverse struts with precise control over dimensions and material properties, reducing costs and improving manufacturing efficiency compared to traditional methods.
Implementation Method 1
heating the tube to a predetermined annealing temperature before the step of roll forming the tube
Implementation Method 2
quenching the tube after the roll forming of the tube into the transverse strut. The heating of the tube before the roll forming improves the roll forming process, and the quenching heat treats the transverse strut very efficiently
Data Source
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AI summary
A roll forming assembly for forming a transverse strut from a tube is provided. The roll forming assembly includes a heater, such as an induction heater, for heating a tube to a predetermined annealing temperature. Next, the tube is fed to a roll former, which includes a plurality of forming wheels to shape the tube into a transverse strut. Servo motors are operably coupled to the forming wheels for adjusting the positions of the forming wheels in a radial direction during the roll forming process to give the transverse strut a variable profile along its length. After the roll forming process is completed, the transverse strut is quenched so that its base material is given a predetermined microstructure.