CN117943496A - System for producing a component by thermoforming - Google Patents
System for producing a component by thermoforming Download PDFInfo
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- CN117943496A CN117943496A CN202410058324.4A CN202410058324A CN117943496A CN 117943496 A CN117943496 A CN 117943496A CN 202410058324 A CN202410058324 A CN 202410058324A CN 117943496 A CN117943496 A CN 117943496A
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- blank
- patch
- temperature
- preheating
- platen
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- 238000003856 thermoforming Methods 0.000 title claims abstract description 16
- 230000006698 induction Effects 0.000 claims abstract description 13
- 238000000034 method Methods 0.000 claims description 21
- 230000008569 process Effects 0.000 claims description 15
- 230000005855 radiation Effects 0.000 claims description 2
- 238000005096 rolling process Methods 0.000 claims 1
- 238000000465 moulding Methods 0.000 abstract description 17
- 238000010438 heat treatment Methods 0.000 description 28
- 239000000463 material Substances 0.000 description 16
- 229910000831 Steel Inorganic materials 0.000 description 10
- 239000010959 steel Substances 0.000 description 10
- 238000012546 transfer Methods 0.000 description 6
- 238000003466 welding Methods 0.000 description 5
- 230000001939 inductive effect Effects 0.000 description 3
- 239000002184 metal Substances 0.000 description 3
- 229910052751 metal Inorganic materials 0.000 description 3
- 239000007789 gas Substances 0.000 description 2
- 229910000734 martensite Inorganic materials 0.000 description 2
- 238000012544 monitoring process Methods 0.000 description 2
- 238000010791 quenching Methods 0.000 description 2
- 229910018125 Al-Si Inorganic materials 0.000 description 1
- 229910000851 Alloy steel Inorganic materials 0.000 description 1
- 229910018520 Al—Si Inorganic materials 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 229910010293 ceramic material Inorganic materials 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 239000000567 combustion gas Substances 0.000 description 1
- 239000002826 coolant Substances 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 230000008878 coupling Effects 0.000 description 1
- 238000010168 coupling process Methods 0.000 description 1
- 238000005859 coupling reaction Methods 0.000 description 1
- 238000007723 die pressing method Methods 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 238000005553 drilling Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000005496 eutectics Effects 0.000 description 1
- 239000011261 inert gas Substances 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 230000000171 quenching effect Effects 0.000 description 1
- 230000002787 reinforcement Effects 0.000 description 1
- 230000004044 response Effects 0.000 description 1
- 238000003756 stirring Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
- B21D22/20—Deep-drawing
- B21D22/208—Deep-drawing by heating the blank or deep-drawing associated with heat treatment
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J1/00—Preparing metal stock or similar ancillary operations prior, during or post forging, e.g. heating or cooling
- B21J1/06—Heating or cooling methods or arrangements specially adapted for performing forging or pressing operations
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D37/00—Tools as parts of machines covered by this subclass
- B21D37/16—Heating or cooling
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D53/00—Making other particular articles
- B21D53/88—Making other particular articles other parts for vehicles, e.g. cowlings, mudguards
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J17/00—Forge furnaces
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J17/00—Forge furnaces
- B21J17/02—Forge furnaces electrically heated
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
- C21D1/34—Methods of heating
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
- C21D9/0068—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for particular articles not mentioned below
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
- C21D1/62—Quenching devices
- C21D1/673—Quenching devices for die quenching
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D2211/00—Microstructure comprising significant phases
- C21D2211/001—Austenite
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D2211/00—Microstructure comprising significant phases
- C21D2211/008—Martensite
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D2221/00—Treating localised areas of an article
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Physics & Mathematics (AREA)
- Thermal Sciences (AREA)
- Crystallography & Structural Chemistry (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Shaping Metal By Deep-Drawing, Or The Like (AREA)
- Heat Treatments In General, Especially Conveying And Cooling (AREA)
Abstract
The invention relates to a system for producing components by thermoforming, comprising a preheating station, a furnace and a moulding press. The preheating station is configured to receive the blank and preheat at least a portion of the blank to a preheating temperature by thermal conduction, and the preheating station includes a plurality of induction coils configured to heat the blank by thermal conduction. The oven is constructed and arranged to receive the preheated blank from the preheating station and heat the entire blank to a deformation temperature. The deformation temperature is higher than the preheating temperature. The molding press is constructed and arranged to receive the heated blank from the oven and shape the heated blank into the shape of the part.
Description
The application is a divisional application of the application patent application with the application date of 2019, 5-10, the application number of 201980031281.8 (PCT/CA 2019/050627) and the name of conduction preheating of a plate for thermoforming.
Cross Reference to Related Applications
The present application claims priority from U.S. provisional patent application No. 62/670,103 filed on 5/11 of 2018, the entire contents of which are expressly incorporated herein by reference.
Technical Field
The present application relates to a system for producing components by thermoforming (hot forming).
Background
Thermoforming typically involves heating a blank in a furnace, then stamping the heated blank between a pair of dies to shape the shaped part, and quenching the shaped part between the dies. The blank is typically heated in a furnace to obtain an austenitic microstructure and then quenched in a mold to transform the austenitic microstructure into a martensitic microstructure.
Furthermore, steel is still the material of choice when referring to modern and cost-effective vehicle bodies. In terms of materials, in response to the demand of the automotive industry for lightweight structural materials, new steels have been developed that combine high strength with good formability. In particular, multiphase steels are widely used in hot stamping or hot forming in the region where the steel blank is heated to fully austenitized (typically 920 ℃). The heated steel blank is then inserted into a forming tool or die press while still in a hot state and rapidly cooled during the die pressing operation.
Advantages of the press hardening process include less forming resistance and better formability of the steel at this temperature, as well as high strength and good dimensional stability of the obtained part. In general, hot stamping methods and the use of new steel materials produce high strength but lightweight vehicle bodies.
As hot stamping technology is increasingly used in the automotive industry, the press hardening mechanism becomes faster. Machines that complete five strokes per minute have been in use for some time, and newer machines are known that complete seven strokes per minute. The efficiency of the hot stamping process is improved due to the shortened cycle length. However, heating the supplied blanks via a heating furnace has been a limiting factor so far. Since the blank has to be heated to a processing temperature exceeding 900 ℃, a heating furnace configured as a continuous furnace is used. On such a continuous oven 30m long, the blanks were heated to 30 ℃ per meter. Thus, the blank passing speed and the length of the furnace limit the cycle length of the hot stamping system.
Furthermore, hot stamping ovens often have bottlenecks in the belt patch blanks, resulting in reduced throughput. Induction heating and open flame preheating methods have been used to preheat the blanks. These methods have the problem of providing uniform heat to the sheet material, which can result in significant distortion (bending) of the blank.
The present application provides improvements to thermoforming/stamping systems and operations.
Disclosure of Invention
One aspect of the present application provides a system for producing a component by thermoforming. The system comprises a preheating station, a furnace and a molding press. The preheating station is configured to: receiving the blank; and preheating at least a portion of the blank to a preheating temperature by heat conduction. The oven is constructed and arranged to receive the preheated blank from the preheating station and heat the entire blank to a deformation temperature. The deformation temperature is higher than the preheating temperature. The molding press is constructed and arranged to receive the heated blank from the oven and shape the heated blank into the shape of the part.
These and other aspects of the present application, as well as the methods of operation and functions of the related elements of structure and the combination of parts and economies of manufacture, will become more apparent upon consideration of the following description and the appended claims with reference to the accompanying drawings, all of which form a part of this specification, wherein like reference numerals designate corresponding parts in the various figures. In one embodiment of the present patent application, the structural components shown herein are drawn to scale. It is to be expressly understood, however, that the drawings are for the purpose of illustration and description only and are not intended as a definition of the limits of the present patent application. It should also be understood that features of one embodiment disclosed herein may be used in other embodiments disclosed herein. As used in the specification and in the claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.
Drawings
FIG. 1 illustrates a system for producing a component by a hot stamping process or a thermoforming process according to an embodiment of the present application;
Fig. 2 shows an exploded view of a preheating station of a system for producing components by a hot stamping/thermoforming process, wherein for clarity and to better illustrate other parts of the preheating station according to embodiments of the present application, some parts of the preheating station are not shown, wherein fig. 2 also shows blank members received and heated by the preheating station;
FIG. 2A illustrates a blank member being received and heated by a preheating station according to an embodiment of the present application;
Fig. 3 shows a side view of a preheating station of a system for producing components by a hot stamping/thermoforming process, wherein parts of the preheating station are not shown for clarity and to better illustrate other parts of the preheating station according to embodiments of the present patent application;
Fig. 4 shows a top perspective view of a preheating station of a system for producing components by a hot stamping/thermoforming process, wherein some parts of the preheating station are not shown for clarity and to better illustrate other parts of the preheating station according to embodiments of the present patent application;
Fig. 5 shows another top perspective view of a preheating station of a system for producing components by a hot stamping/thermoforming process, wherein some parts of the preheating station are not shown for clarity and to better illustrate other parts of the preheating station according to embodiments of the present patent application;
FIG. 6 shows a table providing a comparison of various residence times for the system of the present patent application and prior art systems;
FIG. 7 shows a graphical representation of various temperature profiles of a blank member being heated in a prior art system;
FIG. 8 shows a graphical representation of various temperature profiles of a blank member being heated in the system of the present patent application; and
Fig. 9 and 10 illustrate an exemplary preheating station according to an embodiment of the present application.
Detailed Description
Referring to fig. 1,2 and 2A, in one embodiment, a system 100 for producing a component by thermoforming or hot stamping is provided. In one embodiment, the system 100 includes a preheating station 102, a furnace 104, and a molding press 106. In one embodiment, the preheat station 102 is configured to receive a blank 108. In one embodiment, blank 108 includes a patched region 112 and a non-patched region 116. In one embodiment, the preheating station 102 is configured to preheat at least a portion of the blank 108 (e.g., the tape patch area 112) to a preheating temperature PH T by thermal conduction. In one embodiment, the oven 104 is constructed and arranged to receive the preheated blank 108 from the preheating station 102 and heat the entire blank 108 to the deformation temperature D T. In one embodiment, deformation temperature D T is higher than preheat temperature PH T. In one embodiment, the molding press 106 is constructed and arranged to receive the heated blank 108 from the oven 104 and shape the heated blank 108 into the shape of the part.
In one embodiment, thermally conductive preheating is a method of transferring energy/heat into the blank 108 using conduction as a heat transfer mode. In one embodiment, the thermally conductive preheating includes contact heating of the blank. In one embodiment, conduction is the most efficient form of heat transfer and provides the least heating time.
In one embodiment, the blank 108 used to make the shaped part or component is typically formed from metal, but may be formed from other materials. In one embodiment, the blank 108 is formed from a steel material, such as pure steel or a steel alloy.
In one embodiment, at least a portion of the blank 108 comprises the entire blank. In one embodiment, at least a portion of the blank 108 includes a patched area (patched area of the blank 108, wherein the blank 108 includes both patched and non-patched areas). In one embodiment, at least a portion of the blank 108 comprises a strip patch blank (strip patch blank of the blank 108, wherein the blank comprises a base blank and the patch blank is attached to the base blank).
In one embodiment, the blank 108 is a splice welded blank (tailor welded blank). In one embodiment, the tailor welded blank is formed by a tailor welded blank process. In one embodiment, the tailor welded blank comprises blank members welded together during the tailor welded blank process. In one embodiment, the blank members welded together during the tailor welded blank process may have different strengths and/or different thicknesses. In one embodiment, at least a portion of the tailor welded blank is preheated to a preheat temperature PH T by heat conduction in a preheat station.
In one embodiment, the blank 108 is a unitary blank. In one embodiment, at least a portion of the unitary blank is preheated in a preheating station to a preheating temperature PH T by heat conduction. In one embodiment, at least a portion of the unitary blank comprises the entire blank.
In one embodiment, the blank 108 is a continuous variable cross-section rolled blank (tailor rolled blank). In one embodiment, the continuous variable cross-section rolled blank is formed by a continuous variable cross-section rolled blank process. In one embodiment, the continuously variable cross-section rolled blank includes a variable thickness portion. In one embodiment, at least a portion of the continuously variable cross-section rolled blank is preheated in a preheating station to a preheating temperature PH T by heat conduction.
In one embodiment, referring to fig. 2 and 2A, the blank 108 includes a base blank 110 and a patch blank 112 attached to the base blank 110. In one embodiment, the base blank 110 and the patch blank 112 are integrally formed.
In one embodiment, the tape patch area 112 includes a patch blank 112 and a portion 114 of the base blank 110 attached to the patch blank 112. In one embodiment, the non-patch carrying region 116 includes a portion 116 of the base blank 110 surrounding the patch blank 112. In one embodiment, the portion 116 of the base blank 100 surrounding the patch blank 112 is not preheated to a preheat temperature in the preheat station 102. In one embodiment, the non-patch carrying region 116 includes portions 116 of the base blank 110 surrounding at least two sides of the patch blank 112. In one embodiment, the non-patch carrying region 116 includes a portion 116 of the base blank 110 surrounding at least three sides of the patch blank 112. In one embodiment, the non-patch carrying region 116 includes a portion 116 of the base blank 110 that surrounds the entire patch blank 112 (e.g., all four sides of the patch blank 112). In one embodiment, the non-patch carrying region 116 includes a portion 116 of the base blank 110 adjacent to the patch blank 112. In one embodiment, the non-patch area 116 does not include the patch blank 112.
In one embodiment, the base blank 110 may also be referred to as a parent blank. In one embodiment, the base blank 110 and the patch blank 112 have the same thickness. In another embodiment, the base blank 110 and the patch blank 112 have different thicknesses. In one embodiment, the base blank 110 and the patch blank 112 are made of the same material. In another embodiment, the base blank 110 and the patch blank 112 are made of different materials. In one embodiment, the base blank 110 and the patch blank 112 are made of the same grade of material. In another embodiment, the base blank 110 and the patch blank 112 are made of different material grades.
In one embodiment, the non-patch area 116 includes a portion 116 of the blank 108 surrounding the patch area 112. In one embodiment, the non-patch area 116 includes a portion 116 of the blank 108 adjacent to the patch area 112. In one embodiment, the banded patch region 112 and non-banded patch region 116 have different thicknesses. In one embodiment, the thickness of the belt patch area 112 is greater than the thickness of the non-belt patch area 116. In one embodiment, the patched and non-patched regions 112, 116 are made of the same material. In another embodiment, the patched and non-patched regions 112, 116 are made of different materials. In one embodiment, the patched and non-patched areas 112, 116 are made of the same material grade. In another embodiment, the patched and non-patched areas 112, 116 are made of different material grades.
In one embodiment, the patch blank 112 has an area that is smaller than the area of the blank 108. In one embodiment, the patch blank 112 is surrounded by a portion of the base blank 110 (e.g., the non-patched portion or the remainder 116). In one embodiment, the portion of the base blank 110 surrounding the patch blank 112 is referred to as the non-patched/non-patched portion or remainder of the blank 108. In one embodiment, the patch blank 112 is configured to overlap (i.e., portion 114) at least a portion of the base blank 110. In one embodiment, the patch blank 112 is attached to the base blank 110 by welding, adhesive, or mechanical bonding operations/processes. In one embodiment, the edge or interior portion of the patch blank 112 is bonded to the base blank using a Resistance Spot Welding (RSW), metal inert gas welding (MIG), laser welding, friction stir welding, self-piercing rivet (SPR), or Flow Drilling Screw (FDS) process. In one embodiment, the patch blank 112 may be used to provide localized reinforcement (i.e., with improved load transfer and/or stress distribution) to the blank 108. In another embodiment, the patch blank 112 is provided where greater strength, stiffness, and noise, vibration, and harshness ("NVH") performance are desired.
In one embodiment, the system 100 includes one or more robots 500, 502, 504, 506 operatively connected to the controller C. In one embodiment, the number of robots may vary.
In one embodiment, the robot 502 is constructed and arranged to detach (i.e., for removal) the topmost (i.e., individual) blank 108 from the stack of sheet metal blanks 510 and automatically arrange the blank 108 in the preheating station 102.
In one embodiment, the system 100 is constructed and arranged to imprint date and/or fiducial marks on the blank 108 after the blank 108 is removed and before the blank 108 is positioned in the preheat station 102.
In one embodiment, the controller C comprises a computer and is configured to control the operation of the various components of the system 100 (robots, ovens, preheat stations, molding presses, etc.). In one embodiment, the controller C is configured to verify that each component of the system 100 is operating properly in order to maximize efficiency. In one embodiment, each of the components (robot, oven, preheat station, molding press, etc.) is independently controlled by the component's own controller, but the controller C is configured to share signals between the controllers of the robot, oven, preheat station, molding press, etc.
In one embodiment, the thermally conductive preheating of the strip patch blank 108 provides a heating solution to reduce the total oven residence time of the blank in the oven 104.
In one embodiment, as shown in fig. 1 and 2, the preheat station 102 includes an induction contact oven. In one embodiment, the preheat station 102 includes an upper contact platen 118 and a lower contact platen 120. In one embodiment, the upper contact platen 118 and the lower contact platen 120 are configured to heat only the patch area/blank 112 of the blank 108 to an intermediate or preheat temperature PH T.
In one embodiment, the intermediate or preheat temperature PH T is below the eutectic temperature for the Al-Si coating used to coat the steel. In another embodiment, the intermediate or preheat temperature PH T is below 700 ℃. In yet another embodiment, the intermediate or preheat temperature PH T is in the range of 200 ℃ and 700 ℃.
In one embodiment, at least one of upper platen 118 and lower platen 120 is a movable platen. In one embodiment, the preheat station 102 is operatively connected to a controller C. In one embodiment, the controller C is configured to actuate the upper platen 118 and the lower platen 120 (after the blank 108 is properly placed (e.g., by the robot 500) between the upper platen 118 and the lower platen 120) such that the upper platen 118 and the lower platen 120 are in contact with each other.
In one embodiment, as shown in fig. 2-4, a plurality of induction coils 516 are included in each of the upper platen 118 and the lower platen 120. In one embodiment, the inductive coil 516 is made of a copper material. In one embodiment, induction coil 516 is configured to heat respective lower platen 120 and upper platen 118. In one embodiment, the inductive coil 516 is connected to an external power source 522. For example, as shown in fig. 3, the inductive coil 516 may have an offset sense lead 518. In one embodiment, offset sense leads 518 are configured to prevent electrical coupling. In one embodiment, as shown in fig. 4, the induction coil 516 is connected to a coolant source (e.g., via a connector 520) located at an end of the induction coil 516. In one embodiment, the induction coil 516 is water cooled.
In one embodiment, the induction coil 516 is used to provide energy into the platens 118 and 120 to heat the respective platens 118 and 120 and to maintain the platens 118 and 120 at a desired temperature (i.e., at or above the preheat temperature PH T). In one embodiment, any heating source may be used to heat platens 118 and 120 and maintain platens 118 and 120 at the desired temperature (i.e., at or above preheat temperature PH T) so long as the heating source provides energy to platens 118 and 120. For example, in one embodiment, a heating source such as a cartridge (cartridge), open flame, or the like may be used to provide energy/heat to platens 118 and 120 and maintain platens 118 and 120 at a desired temperature (i.e., at or above preheat temperature PH T).
In one embodiment, the blank 108 is the following work piece: the patch area/blank 112 of the workpiece is configured to receive thermal energy from the platens 118 and 120. In one embodiment, heated platens 118 and 120 are used to preheat the sheet for hot stamping purposes. In one embodiment, only the patch area/blank 112 of the sheet or blank 108 is preheated in the preheating station 102 by a heat transfer process.
In one embodiment, the upper platen 118 is constructed and arranged to provide pressure to the patch blank 112. In one embodiment, the upper platen 118 is heated to a desired platen temperature (i.e., at or above the preheat temperature PH T) and then moved into contact with the patch area 112 of the blank 108. In one embodiment, lower platen 120 is constructed and arranged to serve as a base for blank 108 to be placed on lower platen 120. In one embodiment, lower platen 120 is also heated to a desired platen temperature (i.e., at or above preheat temperature PH T). In one embodiment, the upper platen 118 or the lower platen 120 is configured to apply a contact pressure on at least a portion of the blank 108 received in the preheating station 102.
In one embodiment, the upper platen or lower platen is configured to apply a contact pressure on the tape patch area of the blank received in the preheating station. In one embodiment, each of the upper platen and the lower platen is heated by at least one process selected from the group consisting of conduction, convection, resistance, induction, thermal radiation, and gas configured to provide energy to heat and maintain the respective upper platen and lower platen at a desired platen temperature. In one embodiment, the desired platen temperature is higher than the preheat temperature. In another embodiment, the desired platen temperature is equal to the preheat temperature.
In one embodiment, as shown in FIG. 5, one or more thermocouples 514 are included in each of lower platen 120 and upper platen 118. In one embodiment, thermocouples 514 are configured to control and/or monitor the surface temperatures of respective lower platen 120 and upper platen 118.
In one embodiment, the controller C is configured to determine whether the patch blank 112 of the blank 108 has reached the preheat temperature PH T in the preheat station 102. In one embodiment, this may be determined by a sensor or thermocouple 514 associated with the preheating station 102, or may be determined by monitoring the amount of time each blank 108 remains in the preheating station 102. In one embodiment, the controller C is further configured to adjust the amount of time the blank 108 is in the preheating station 102.
In one embodiment, controller C is further configured to adjust the surface temperatures of lower platen 120 and upper platen 118 based on monitored surface temperature data of lower platen 120 and upper platen 118 obtained from respective thermocouples 514. In one embodiment, controller C is further configured to adjust the amount of time blank 108 is heated between upper platen 118 and lower platen 120. In one embodiment, the surface temperatures of lower platen 120 and upper platen 118 may also be adjusted by a controller associated with preheat station 102.
In one embodiment, the system 100 includes a robot 502, the robot 502 being constructed and arranged to lift the blank 108 from the preheating station 102 and place the blank 108 on a blank load 506 of the oven 104. In another embodiment, the system 100 includes a blank feeder disposed between the preheating station 102 and the oven 104 and operatively connected to both the preheating station 102 and the oven 104. In one embodiment, the blank feeder is constructed and arranged to transfer the blanks 108 from the preheating station 102 to the oven 104. That is, the blank feeder is constructed and arranged to extend continuously from the preheating station 102 to the oven 104. In one embodiment, the blank feeder is an indexing blank feeder (indexing blank feeder) and includes a plurality of driven rollers. In one embodiment, the indexing features of the blank feeder include a plurality of indexing fingers for aligning the blank 108 in a predetermined position prior to entering the oven 104. In one embodiment, the blank feeder is isolated from the ambient environment, or includes a heater (not shown), such that the temperature of the patch blank 112 of the heated blank 108 is maintained at the desired pre-heat temperature PH T as the blank 108 enters the oven 104.
Fig. 9 and 10 illustrate an exemplary preheating station according to an embodiment of the present application.
In one embodiment, with the temperature of the remaining region/portion (i.e., without preheating) 116 heated to the deformation temperature D T and the temperature in the patch region/blank 112 heated to the deformation temperature D T, the blank 108 is then transferred from the preheating station 102 into the roller hearth furnace 104. In one embodiment, the final/deformation temperature may be different between the non-patched and patched regions.
In one embodiment, the non-patched area 116 of the blank 108 is first heated to a pre-heat temperature in the roller hearth furnace 104, and the non-patched area 116 of the blank 108 is then further heated to a deformation temperature. In one embodiment, the strip patch area 112 of the blank 108 is heated to the deformation temperature in the roller hearth furnace 104 while being received by the roller hearth furnace 104 when the strip patch area 112 of the blank 108 is already at the pre-heat temperature.
In one embodiment, the oven 104 includes a housing 124 and a heating system 126 (e.g., directly or indirectly). In one embodiment, the oven 104 may include a plurality of driven rollers. In one embodiment, the oven 104 may include a planar surface 122 to support the preheated blank 108 during oven heating. In one embodiment, the furnace 104 is a continuous furnace. In one embodiment, furnace 104 is a roller hearth furnace. In one embodiment, the heating in the oven 104 is not limited to roll-to-roll radiant heating, but may include other heating methods such as induction, conduction, resistance, flame impingement, and the like.
In one embodiment, the preheated blank 108 received from the preheating station 102 is conveyed through the oven 104 using driven rollers. That is, in one embodiment, a plurality of driven rollers are configured to convey the blank through the oven 104. In one embodiment, the driven rollers comprise mechanically driven (e.g., ceramic material) rollers or rollers of the type used in hearth furnaces. In one embodiment, the driven rollers of the oven 104 are constructed and arranged to rotate continuously, remain stationary for a period of time, or vibrate forward and backward depending on the amount of heating desired.
In one embodiment, the heating system 126 includes a gas burner, an electric heater, or another type of heater. In one embodiment, heating system 126 includes a single heating element or multiple heating elements. For example, the heating system 126 includes a plurality of tubes containing combustion gases, or a plurality of heating coils.
In one embodiment, the oven 104 is operatively connected to the controller C. In one embodiment, the controller C is configured to determine whether the blank 108 in the oven 104 has first reached the preheat temperature PH T and then has reached the deformation temperature D T. In one embodiment, this may be determined by a sensor associated with the oven 104, or may be determined by monitoring the amount of time each blank 108 remains in the oven 104. In one embodiment, the controller C is further configured to adjust the amount of time the blank 108 is in the oven 104. In one embodiment, the deformation temperature D T is higher than 700 ℃. In another embodiment, the deformation temperature D T is in the range of 700 ℃ and 1000 ℃.
In one embodiment, the system 100 includes a robot 503, the robot 503 being constructed and arranged to lift the blank 108 from the blank load 508 of the oven 104 and to place the blank 108 in position in the molding press 106. In another embodiment, the system 100 includes a blank feeder disposed between the oven 104 and the die press 106 and operatively connected to both the oven 104 and the die press 106. In one embodiment, the blank feeder is constructed and arranged to transfer blanks 108 from oven 104 to die press 106. That is, the blank feeder is constructed and arranged to extend continuously from the oven 104 to the molding press 106. In one embodiment, the blank feeder is an indexing blank feeder and includes a plurality of driven rollers. In one embodiment, the indexing features of the blank feeder include a plurality of indexing fingers for aligning the blank 108 in a predetermined position prior to entering the die press 106. In one embodiment, the blank feeder is isolated from the ambient environment, or includes a heater (not shown), such that the temperature decrease from the deformation temperature D T of the heated blank 108 can be minimized as the blank 108 enters the die press 106.
In one embodiment, the molding press 106 includes a pair of dies 128 and 130. In one embodiment, the molding press 106 is constructed and arranged to stamp the heated blank 108 between a pair of dies 128 and 130 to shape a shaped part or component. That is, the heated blank 108 (i.e., heated to the deformation temperature D T in the furnace 104) is stamped between a pair of dies 128 and 130 to shape the formed part or component.
In one embodiment, at least one of the molds 128 and 130 is movable. In one embodiment, the molding press 106 is operatively connected to the controller C. In one embodiment, the controller C is configured to actuate the molds 128 and 130 (after the heated blank 108 from the oven 104 is properly placed (e.g., by the robot 503) between the molds 128 and 130) such that the molds 128 and 130 contact each other to shape the shaped part or component between the molds 128 and 130. For example, in one embodiment, the shaped part or component may comprise a part or component that is used as a chassis or body component of an automobile. In one embodiment, the shaped part or component may alternatively be used in other applications.
In one embodiment, the molding press 106 is also constructed and arranged to quench the formed part between the dies 128 and 130. In one embodiment, controller C is further configured to adjust the amount of time the part is quenched between dies 128 and 130. In one embodiment, the blank 108 is heated generally in the furnace 104 to obtain an austenitic microstructure, and then quenched in the dies 128 and 130 to transform the austenitic microstructure into a martensitic and/or mixed microstructure. In one embodiment, the thermoforming process (i.e., preheating in the preheating station 102, heating in the furnace 104, and forming in the molding press 106) is run continuously to produce a plurality of shaped parts at high rates and low cost.
In one embodiment, the system 100 includes a robot 504, the robot 504 being constructed and arranged to lift the formed part or part from the molding press 106 and place the formed part or part in place on a cooling rack 512.
The table shown in fig. 6 provides a comparison of various residence times between the system of the present patent application and the prior art system. For example, in one embodiment, the residence time of the central portion of the patch blank 112 in the oven 104 is reduced from 361 seconds when using the prior art system to 273 seconds when using the system 100 of the present patent application. In one embodiment, the residence time of the edge of the patch blank 112 in the oven 104 is reduced from 300 seconds when using the prior art system to 249 seconds when using the system 100 of the present patent application. In one embodiment, the dwell time of the strip patch area/blank 112 of the blank 108 in the present application is reduced by 24% as compared to the dwell time of the blank 108 in prior art systems. In one embodiment, the dwell time of the non-patched portion 116 of the blank 108 (i.e., the portion surrounding the patch blank 112) remains about the same with prior art systems and with the system 100 of the present application.
Figures 7 and 8 show graphical representations of various temperature profiles of a blank heated using a prior art system and using the system of the present patent application, respectively. The temperatures (i.e., measured in degrees celsius) of the various portions of the blank are shown on the left hand side Y-axis of the graphs in fig. 7 and 8, and the dwell times (i.e., dwell times measured in seconds) of the various portions of the blank are on the X-axis of the graphs in fig. 7 and 8.
As can be seen from the graph of fig. 7, in the prior art system, all heating of the blank is done in the oven, and in the prior art system there is no preheating of the blank. Referring to fig. 7, the temperature profiles of the Patch Center (PC), patch Edge (PE) and non-patch-carrying portion (UP) show their respective gradual increases in temperature due to furnace heating (until they reach deformation temperature D T). The temperature profile clearly shows: the temperature of the patch area/blank did not reach the deformation temperature D T until the residence time in the oven was 361 seconds.
Referring to the graph of fig. 8, in the system of the present patent application, the patch area of the blank/blank is preheated in the preheating station 102 by contact heating, heat conduction heating. The temperature profile of the Patch Center (PC) and Patch Edge (PE) shows: when the patch blank/area is preheated in the preheating station 102, the temperature of the Patch Center (PC) and Patch Edge (PE) reach the intermediate/preheating temperature PH T, while the temperature profile of the non-patch portion (UP) shows that the temperature of the non-patch portion is very slightly elevated or not elevated when the patch blank/area is preheated in the preheating station 102. The temperature profile of the non-patched part (UP) shows: as the blank is heated in the oven 104, the temperature of the unpatched portion first catches up with the intermediate/preheat temperature PH T of the Patch Center (PC) and Patch Edge (PE) and reaches the deformation temperature D T from the intermediate/preheat temperature PH T. The temperature profile of the Patch Center (PC) and Patch Edge (PE) shows: when the blank is heated in the oven 104, the temperatures of the Patch Center (PC) and Patch Edge (PE) reach the deformation temperature D T at residence times of approximately 273 seconds and 249 seconds, respectively.
In one embodiment, the times of the present patent application shown in fig. 6 and 8 (i.e., the oven residence time with preheating of the patch center, patch edges, and non-patch areas) are exemplary and are not to be construed as limiting in any way. In one embodiment, the time (i.e., oven residence time of the patch center, patch edges, and non-patch areas with preheating) may vary and depend on various factors such as the thickness of the blank, the geometry of the blank, the preheat temperature, contact pressure, and the like, as well as any combination thereof.
Although the present patent application has been described in detail for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that the patent application is not limited to the disclosed embodiments, but, on the contrary, is intended to cover modifications and equivalent arrangements that are within the spirit and scope of the appended claims. In addition, it is to be understood that this patent application contemplates that, to the extent possible, one or more features of any embodiment can be combined with one or more features of any other embodiment.
Claims (19)
1. A system for producing a component by thermoforming, the system comprising:
A preheating station configured to receive a blank and preheat at least a portion of the blank to a preheating temperature, and comprising a plurality of induction coils configured to heat the blank by thermal conduction;
a furnace constructed and arranged to receive a preheated blank from the preheating station and to heat the entire blank to a deformation temperature, wherein the deformation temperature is higher than the preheating temperature; and
A die press constructed and arranged to receive the heated blank from the oven and shape the heated blank into the shape of the part.
2. The system of claim 1, wherein the preheating station comprises an upper platen and a lower platen configured to cooperate to receive the blank therebetween.
3. The system of claim 2, wherein the upper platen or the lower platen is configured to apply a contact pressure to the at least a portion of the blank received in the preheating station.
4. The system of claim 2, wherein each of the upper platen and the lower platen is heated by at least one process selected from the group consisting of conduction, convection, resistance, induction, thermal radiation, and gas configured to provide energy to heat and maintain the respective upper and lower platens at a desired platen temperature.
5. The system of claim 2, wherein each of the upper platen and the lower platen includes a thermocouple therein configured to monitor and control a surface temperature of the respective upper platen and lower platen.
6. The system of claim 1, wherein the blank comprises a base blank and a patch blank attached to the base blank, and wherein the at least a portion of the blank comprises the patch blank and a portion of the base blank attached to the patch blank.
7. The system of claim 6, wherein a portion of the base blank surrounding the patch blank is not preheated to the preheat temperature in the preheat station.
8. The system of claim 1, wherein the blank is a unitary blank.
9. The system of claim 1, wherein the blank is a tailor welded blank formed by a tailor welded blank process, and wherein the tailor welded blank comprises blank members welded together during the tailor welded blank process, and wherein the blank members have different strengths and/or different thicknesses.
10. The system of claim 1, wherein the blank is a continuous variable cross-section rolled blank formed by a continuous variable cross-section rolling blank process, and wherein the continuous variable cross-section rolled blank comprises a variable thickness portion.
11. The system of claim 1, wherein the at least a portion of the blank comprises an entire blank.
12. The system of claim 1, wherein the blank comprises a banded patch region and a non-banded patch region, wherein the at least a portion of the blank comprises the banded patch region, and wherein the preheating station is configured to preheat the banded patch region of the blank to the preheating temperature by thermal conduction.
13. The system of claim 12, wherein the preheating station comprises an upper platen and a lower platen configured to cooperate to receive the blank therebetween, and wherein the upper platen or the lower platen are configured to apply a contact pressure to the tape patch area of the blank received in the preheating station.
14. The system of claim 12, wherein the blank comprises a base blank and a patch blank attached to the base blank, and wherein the tape patch area comprises the patch blank and a portion of the base blank attached to the patch blank.
15. The system of claim 14, wherein the non-banded patch region comprises a portion of the base blank surrounding the patch blank.
16. The system of claim 14, wherein the non-banded patch region comprises a portion of the base blank adjacent to the patch blank.
17. The system of claim 14, wherein the non-banded patch region does not include the patch blank.
18. The system of claim 12, wherein the non-patch area comprises a portion of the blank surrounding the patch area.
19. The system of claim 12, wherein the non-patch area comprises a portion of the blank adjacent to the patch area.
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
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| US201862670103P | 2018-05-11 | 2018-05-11 | |
| US62/670,103 | 2018-05-11 | ||
| PCT/CA2019/050627 WO2019213774A1 (en) | 2018-05-11 | 2019-05-10 | Conduction pre-heating of sheet for hot forming |
| CN201980031281.8A CN112118922B (en) | 2018-05-11 | 2019-05-10 | Conductive preheating of sheet material for thermoforming |
Related Parent Applications (1)
| Application Number | Title | Priority Date | Filing Date |
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| CN201980031281.8A Division CN112118922B (en) | 2018-05-11 | 2019-05-10 | Conductive preheating of sheet material for thermoforming |
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| CN117943496A true CN117943496A (en) | 2024-04-30 |
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| CN201980031281.8A Active CN112118922B (en) | 2018-05-11 | 2019-05-10 | Conductive preheating of sheet material for thermoforming |
| CN202410058324.4A Pending CN117943496A (en) | 2018-05-11 | 2019-05-10 | System for producing a component by thermoforming |
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| CN201980031281.8A Active CN112118922B (en) | 2018-05-11 | 2019-05-10 | Conductive preheating of sheet material for thermoforming |
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| EP (1) | EP3790687A4 (en) |
| CN (2) | CN112118922B (en) |
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| US20220176434A1 (en) * | 2019-05-06 | 2022-06-09 | Magna International Inc. | Conductive post-furnace heating of sheet for hot forming |
| DE102022108513A1 (en) * | 2021-04-16 | 2022-10-20 | Aerospace Transmission Technologies GmbH | Control device and method for controlling a system and a process for the heat treatment of metal workpieces |
| EP4074845A1 (en) * | 2021-04-16 | 2022-10-19 | Aerospace Transmission Technologies GmbH | Control device and method of controlling a press hardening system |
| DE102022108515A1 (en) * | 2021-04-16 | 2022-10-20 | Aerospace Transmission Technologies GmbH | Control device and method for controlling a press hardening plant |
| DE102022108512A1 (en) * | 2021-04-16 | 2022-10-20 | Aerospace Transmission Technologies GmbH | Process for the heat treatment of metallic workpieces |
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| US3528276A (en) * | 1968-01-26 | 1970-09-15 | Sheridan Gray Inc | Hot-forming press |
| US20170183757A1 (en) | 2008-10-02 | 2017-06-29 | Ms Autotech Co., Ltd. | Hot stamping method for manufacturing vehicle body parts |
| CN102266900B (en) * | 2010-06-07 | 2015-11-25 | 蒂森克虏伯金属成型技术有限公司 | For the manufacture of method and the thermal formation apparatus of the steel plate forming component of forging and stamping |
| AU2011264399B2 (en) * | 2010-06-10 | 2015-06-18 | Magna International Inc. | Bi-metallic component and method |
| DE102011053698C5 (en) * | 2011-09-16 | 2017-11-16 | Benteler Automobiltechnik Gmbh | Process for the manufacture of structural and chassis components by thermoforming and heating station |
| CN202276485U (en) * | 2011-10-13 | 2012-06-13 | 浙江盾翔节能科技有限公司 | Device for lowering interference in wiring of electromagnetic induction coils |
| DE102011120681A1 (en) * | 2011-12-08 | 2013-06-13 | Linde Aktiengesellschaft | Plant and method for preheating boards during hot forming |
| DE102012110649C5 (en) | 2012-11-07 | 2018-03-01 | Benteler Automobiltechnik Gmbh | Thermoforming line and method for producing a hot-formed and press-hardened motor vehicle component |
| CN103157959B (en) * | 2013-03-18 | 2015-05-20 | 四川友麒双金属复合材料有限公司 | Preparation method for stainless steel clad plate |
| CN103286235A (en) * | 2013-04-18 | 2013-09-11 | 重庆市科学技术研究院 | Automatic production line for hot stamping formation of magnesium alloy boards |
| CA2923583A1 (en) * | 2013-09-10 | 2015-03-19 | Kabushiki Kaisha Kobe Seiko Sho (Kobe Steel, Ltd.) | Hot-pressing steel plate, press-molded article, and method for manufacturing press-molded article |
| DE102013222243A1 (en) * | 2013-10-31 | 2015-04-30 | Magna International Inc. | Plant for hot forming of components and method |
| DE102014211241A1 (en) * | 2014-06-12 | 2015-12-17 | Sms Elotherm Gmbh | Method and heating system for the standard heating of sheet metal blanks with formation of different temperature zones |
| KR101585802B1 (en) * | 2014-11-21 | 2016-01-18 | 주식회사 포스코 | Uniformly coated tailor rolled steel sheet, method for manufacturing same, method for press forming using same and product thereof |
| CN104569043B (en) * | 2015-01-09 | 2017-01-11 | 上海交通大学 | Device and method for measuring heat transfer coefficient of metal thermoforming interface |
| CN104942109B (en) * | 2015-07-01 | 2017-03-01 | 上海凌云汽车模具有限公司 | Produce the equipment of intensity adjustable thermoforming part |
| CN106734715A (en) * | 2017-01-16 | 2017-05-31 | 兰州兰石重型装备股份有限公司 | 904L+Q345R pressure container of composite board end socket thermoforming process |
| CN107186029A (en) * | 2017-06-22 | 2017-09-22 | 苏州普热斯勒先进成型技术有限公司 | A kind of heater, production line and method for producing subregion intensity heat-punch member |
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- 2019-05-10 CN CN201980031281.8A patent/CN112118922B/en active Active
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- 2019-05-10 EP EP19799148.2A patent/EP3790687A4/en active Pending
- 2019-05-10 WO PCT/CA2019/050627 patent/WO2019213774A1/en active Application Filing
- 2019-05-10 CA CA3096907A patent/CA3096907A1/en active Pending
- 2019-05-10 US US17/054,320 patent/US20210237138A1/en active Pending
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| CN112118922B (en) | 2024-02-02 |
| EP3790687A1 (en) | 2021-03-17 |
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| US20210237138A1 (en) | 2021-08-05 |
| CA3096907A1 (en) | 2019-11-14 |
| EP3790687A4 (en) | 2022-01-26 |
| CN112118922A (en) | 2020-12-22 |
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