Vehicle Roof Panel Molding With Integrated Trimming and Flanging
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Solution Overview
Problem
The existing manufacturing processes for vehicle body panels, particularly roof panels, require multiple molds and processes, leading to increased costs, manufacturing time, and complex production management, necessitating a simplification of molds and processes.
Innovation Solution
A manufacturing apparatus for vehicle roof panels utilizing a three-mold system comprising a first mold for shaping, a second mold for trimming and forming undercut faces, and a third mold for flanging and restriking, reducing the number of molds and processes required.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the number of molds is increased to perform drawing, trimming, flanging, restriking, and piercing processes, then the manufacturing precision and completeness of the roof panel is improved, but the manufacturing cost, factory site area, and manufacturing period increase
Solution Approach 1:
The patent combines multiple mold functions into a single integrated mold system. The mold includes drawing means for forming the panel, trimming means for cutting edges, flanging means for creating flanges, and piercing means for making holes, all integrated into one mold assembly that can perform multiple operations simultaneously or sequentially on the panel blank.
Solution Approach 2:
The mold is designed as a multi-functional device that can perform drawing, trimming, flanging, and piercing operations. This universal mold structure eliminates the need for separate specialized molds for each operation, reducing the total number of molds required while maintaining comprehensive manufacturing capabilities.
2Manufacturing precision
If the number of molds is increased to perform multiple processes, then the manufacturing precision of the roof panel is improved, but the manufacturing period and production management complexity increase
Solution Approach 1:
Multiple manufacturing operations are merged into a single mold system that can perform drawing, trimming, flanging, and piercing in one integrated process. This consolidation reduces the total manufacturing time by eliminating the need for sequential operations with multiple separate molds and reduces setup time between operations.
3Adaptability or versatility
If the number of molds is increased to perform comprehensive processes, then the completeness of the roof panel features is improved, but the mold investment cost and factory site area increase
Solution Approach 1:
The patent integrates drawing, trimming, flanging, and piercing functions into a single mold assembly. This merging of functions reduces the total number of molds from multiple separate molds to one integrated mold system, thereby reducing mold investment cost and factory site requirements while maintaining the ability to produce complete roof panel features.
Solution Approach 2:
The mold is designed as a universal multi-functional device that can perform all necessary operations (drawing, trimming, flanging, piercing) in one system. This multi-functionality eliminates the need for multiple specialized molds, reducing overall manufacturing investment while achieving complete panel feature production.
Data Source
AI summary
A manufacturing apparatus of a roof panel includes a first mold, a second mold including first trimming units provided in a second lower die and a second upper die to trim an edge portion of a first processed plate processed by the first mold, second trimming units to trim a sunroof hole in the first processed plate, first restriking units to form first undercut faces on both edge portions of the sunroof hole, and first cam forming units to form a hinge mounting portion and a third mold including flange forming units provided in a third lower die and a third upper die to form a down flange on an edge portion of the sunroof hole of a second processed plate processed by the second mold, and second restriking units provided in the third lower die and the third upper die to form a water receiving portion.