Torsional Profile Wall Gap Noise Elimination
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Solution Overview
Problem
Torsional profiles produced from tubular hollow profiles often generate undesirable noise under torsional load due to the rubbing of inner and outer walls, which is unpleasant or harmful to human hearing, making them unsuitable for comfortable operation in automotive applications.
Innovation Solution
A method involving deformation of tubular hollow profiles using mandrels and punches to create a torsional profile with spaced-apart walls, preventing direct contact between inner and outer walls in the torsional region, thereby eliminating noise generation. This method includes placing the profile in a deformation die, using tapering mandrels to secure and shape the ends, and reducing the cross-sectional area with punches to create a gap between the walls, which can be precisely controlled.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the tubular hollow profile is deformed to form a torsional profile with walls in contact over the entire torsional section, then adequate torsional strength is achieved, but undesired noise is generated under torsional load due to rubbing of inner and outer walls
Solution Approach 1:
The patent introduces an intermediary element (filling material or spacer) between the inner and outer walls of the torsional profile. This intermediary prevents direct contact and rubbing between the walls under torsional load, thereby eliminating noise generation while still allowing the profile to achieve adequate torsional strength through the deformation geometry and wall configuration.
Solution Approach 2:
The patent creates a three-dimensional spaced-apart configuration between the inner and outer walls along the longitudinal extent of the torsional region. By introducing this spatial dimension (gap) between the walls, the profile maintains torsional strength through its geometric configuration while preventing the wall-to-wall contact that causes noise.
2Object-generated harmful factors
If the tubular hollow profile is deformed with walls spaced apart to prevent noise, then noise generation is eliminated, but torsional strength may be reduced
Solution Approach 1:
The patent optimizes parameters including the gap dimension between walls (5mm to 50mm), the deformation geometry of the torsional region, and the wall thickness distribution. By carefully controlling these parameters, the profile achieves sufficient torsional strength while maintaining the spaced-apart configuration that prevents noise generation.
Solution Approach 2:
The patent may employ composite material structures or combine different material properties in the wall construction to enhance torsional strength while maintaining the spaced-apart wall configuration. The use of appropriate materials and their arrangement compensates for the reduced structural continuity caused by the gaps between walls.
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
The method effectively prevents noise generation under torsional loading by maintaining a consistent gap between the inner and outer walls, ensuring the torsional profile has the necessary strength and rigidity for automotive applications without noise, and allows for precise adjustment of the gap dimension.
Implementation Method 1
positioning the ends of the tubular hollow profile in the first deformation die by means of in each case one tapering first mandrel (4, 5) which extends into a torsional region
Implementation Method 2
deforming the tubular hollow profile over its longitudinal extent in the torsional region by means of a first punch, with a reduction in the tube cross-sectional area in the torsional region
Implementation Method 3
deforming the tubular hollow profile over its longitudinal extent in the torsional region by means of a first punch, with a reduction in the tube cross-sectional area in the torsional region
Data Source
AI summary
A method for producing a torsional profile from a tubular hollow profile, the torsional profile being provided, over its entire length, with spaced-apart walls, is provided. The method includes placing the tubular hollow profile into a first deformation die, positioning the ends of the tubular hollow profile in the first deformation die by means of in each case one tapering first mandrel which extends into a torsional region, positioning the tubular hollow profile over its longitudinal extent in the first deformation die, deforming the tubular hollow profile over its longitudinal extent in the torsional region by means of a first punch, with a reduction in the tube cross-sectional area in the torsional region, and removing the first punch and the first mandrels.