Rolling Device for Metal Strip Thickness Variation
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Solution Overview
Problem
Current methods for producing structural elements for motor vehicles with varying thicknesses and shapes in the direction of rolling are limited, leading to inefficiencies in joining technologies such as riveted connections and resistance spot welding, which require high forces, energy, and can result in contact corrosion and material degradation.
Innovation Solution
A method involving a rolling device with groups of upper and lower rollers arranged in a direction of rolling, where each group has shape-changing profiles with constant volume, allowing for a metal strip to be produced with varying thicknesses in all directions (X, Y, Z) in a single pass, enabling the creation of complex contours and reducing material consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional rolling methods are used to produce metal strips with varying thickness, then the production process requires multiple steps and subsequent processing, but this leads to increased manufacturing complexity and loss of time
Solution Approach 1:
The rolling device is segmented into multiple independently controllable roller groups (first, second, and third roller groups) arranged in the rolling direction. Each roller group can be controlled individually to achieve different thickness reductions in different sections of the metal strip, enabling complex thickness profiles to be produced in a single pass through coordinated action of segmented rollers
Solution Approach 2:
The invention transitions from conventional two-dimensional thickness control (transverse direction only) to three-dimensional thickness control by adding variation in the rolling direction. The roller groups are positioned at different locations along the rolling direction and can be independently controlled, enabling thickness variation in both transverse and longitudinal dimensions simultaneously
2Strength
If conventional joining technologies such as riveted connections are used, then structural elements can be connected, but this requires high forces and results in contact corrosion
Solution Approach 1:
The metal strip is produced with locally optimized thickness and material properties at different locations. Connecting surfaces are designed with specific thickness and geometric characteristics tailored to joining requirements, while other areas maintain different properties for structural performance. This local differentiation allows optimized joining without compromising overall structure and reduces corrosion susceptibility through precise material distribution
3Productivity
If resistance spot welding is used to join structural elements, then connections can be made, but this requires high energy consumption and can cause material degradation
Solution Approach 1:
The invention optimizes material parameters (thickness, density, composition) at connecting surfaces through controlled rolling processes. By pre-adjusting these parameters, the material becomes more suitable for joining processes, reducing the energy required for welding and minimizing thermal effects that cause material degradation
4Quantity of substance
If conventional rolling produces metal strips with uniform thickness, then the production process is simple, but this leads to increased material consumption and weight
Solution Approach 1:
Instead of producing uniformly thick metal strips, the invention creates strips with locally optimized thickness variations. Material is concentrated where structurally necessary and reduced where not needed, minimizing overall material consumption while maintaining structural integrity and simplifying subsequent processing
Solution Approach 2:
The invention employs curved and contoured surface profiles on rollers to impart complex three-dimensional thickness variations to the metal strip in a single rolling pass, enabling organic, non-linear thickness distributions that optimize material usage for complex structural geometries
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 structural elements with optimized thickness distribution and shapes, reducing material usage, energy consumption, and avoiding subsequent processing steps, while allowing for precise cutting and thin connecting surfaces, enhancing weld quality and durability.
Implementation Method 1
Groups of upper and lower rollers arranged one after the other in a direction of rolling are rolled onto a metal strip so that the metal strip has a varying thickness
Data Source
AI summary
The present disclosure relates to a method for producing a structural element. A number of upper and/or lower rollers arranged one after the other in a direction of rolling is rolled in a metal strip to produce a varying thickness in the metal strip. The method includes providing the upper and/or lower rollers of each group with shape-changing profiles in the direction of rolling. The shape-changing profile of each group in each case exhibits a constant volume. The method may further include prefabricating the metal strip with partial contours produced on the basis of the shape-changing profiles to a desired final contour. The method may also include feeding the prefabricated metal strip with the desired final contour for further processing steps.