Double-Walled Support Profile Welding for Smooth High-Strength Surfaces
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Solution Overview
Problem
Existing methods for producing carrier profiles from sheet metal result in inhomogeneous outer surfaces and weakened joints due to outwardly bowed hems and filler metals, making it difficult to achieve both high strength and surface quality, especially for beam profiles requiring precise surface fits.
Innovation Solution
The method involves bending the longitudinal edges of the sheet metal by 180° so that they form inward folds, which are then welded using high-frequency induction welding or fusion welding, creating a double-walled structure that increases stability and surface quality without additional reinforcement, and includes a finishing step like grinding to enhance the weld seam's quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If outwardly bent folds are used to join longitudinal edges, then the support profile can be manufactured, but the outer surface becomes inhomogeneous with additional joints and edges
Solution Approach 1:
The patent inverts the conventional approach by bending the longitudinal edges inward instead of outward. The edges are bent 180° so that the folds abut the future inside of the support profile, with the fold edges facing each other for welding. This inversion eliminates external joints and edges, providing a homogeneous outer surface while maintaining manufacturability through the welding process.
2Strength
If filler metals are used in welding to join folds, then the joints can be strengthened, but the outer surface becomes uneven and requires reworking
Solution Approach 1:
The patent extracts and eliminates the use of filler metals from the welding process. By using high-frequency induction welding or fusion welding without filler metals, the joint strength is maintained through direct fusion of the base materials, while the outer surface remains homogeneous and free from the unevenness caused by filler metal deposition and subsequent reworking.
3Manufacturing precision
If reworking of welded joints is performed to improve surface quality, then the surface becomes more uniform, but the joint strength is weakened
Solution Approach 1:
The patent applies preliminary anti-action by preventing the creation of surface unevenness in the first place. Through inward bending of edges and using welding processes without filler metals, the outer surface remains homogeneous from the outset, eliminating the need for reworking that would compromise joint strength. The design inherently avoids the problem rather than correcting it afterward.
4Stability of the object's composition
If additional reinforcing elements are welded on to increase stability, then the section modulus and area moment of inertia increase, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent merges the reinforcement function into the basic structural design by creating a double-walled structure through inward bending of longitudinal edges. The folds themselves form the reinforcing elements, eliminating the need for separate reinforcing components. This integration maintains structural stability while reducing device complexity and manufacturing steps.
5Strength
If high-frequency welding is used to join fold edges, then exceptional bond strength is achieved without filler metals, but the heat input must be concentrated precisely on the edges
Solution Approach 1:
The patent applies local quality by concentrating the welding action precisely at the fold edges where the inward-bent longitudinal edges meet. The high-frequency induction welding or fusion welding process focuses heat input locally at these specific locations, creating strong bonds without affecting the overall structure. This localized approach achieves exceptional bond strength while maintaining control over heat input and preserving surface quality.
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 results in a carrier profile with high strength and surface quality, allowing for precise fits and increased rigidity without external dimension increases, while minimizing heat input and reducing the risk of cracking during the welding process.
Implementation Method 1
the eddy currents generated by the induction coils allow heat input to be concentrated on the edges being welded
Implementation Method 2
a step of high-frequency welding or by a step of fusion welding
Data Source
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AI summary
The invention relates to a method for producing a support profile from a sheet metal part, wherein the sheet metal part has a first longitudinal edge and a second longitudinal edge, wherein the first longitudinal edge and the second longitudinal edge are parallel to each other; the method comprising a step of bending the sheet metal part to form a support profile, wherein the first longitudinal edge is bent to form a first fold with a first fold edge and the second longitudinal edge is bent to form a second fold with a second fold edge, wherein the first fold edge and the second fold edge are in direct contact; further comprising a step of welding the first fold edge and the second fold edge together.According to the invention, the sheet metal is bent to the support profile in such a way that the first and second longitudinal edges lie within the support profile, with the welding being formed by a step of high-frequency welding or by a step of fusion welding, thereby increasing the resistance and area moment of inertia.