EP3010664B1 - Device for producing at least one undercut in a slotted or closed profiled sheet section - Google Patents

Description

The invention relates to a device for producing at least one undercut in a slotted or closed sheet metal profile, comprising a core which is inserted into the sheet metal profile or as a support core for a sheet metal semi-finished product, from which the sheet metal profile is generated, the core having at least two outer core sections of which at least one has at least one recess or at least one projection for forming an undercut in the sheet-metal profile, and that between the at least two outer core portions, an inner core portion is arranged, which is movable relative to the outer core portions and has at least one active surface, which is inclined or cam-shaped in a predetermined direction of movement of the inner core portion relative to the outer core portions, wherein by moving the inner core portion in the predetermined direction of movement relative to the outer core portions last re moved apart and then moved toward each other when moving the inner core portion in the reverse direction of movement.

For the production of at least partially closed profiles (slot profiles) or semi-finished products, continuous or discontinuous forming processes can be used. The continuous forming takes place, for example, by roll forming. Discontinuous methods are suitable if, due to complex profile or semi-finished product geometry, continuous roll forming can not be used. For example, the so-called U-O-forming for the discontinuous production of at least partially closed profiles or semi-finished products is known.

The production of three-dimensionally shaped components made of sheet metal in the progressive compound process belongs to the prior art (see, eg US 2002/0162297 A1 . FIGS. 6 to 8 ).

In vehicle construction, closed profiles made of sheet metal are used as structural components, for example, as bumpers and impact energy absorbing hollow beams. Sometimes also slotted or closed sheet metal profiles are required, the undercuts, such. Transverse to the longitudinal axis of a hollow carrier extending beads, indentations, elevations or similar form elements having. Such undercuts can serve, for example, to increase the component rigidity and / or to influence the deformation behavior in the event of a crash.

The production of secondary features, such as beads or similar imprints, in longitudinally welded hollow sections by means of a mandrel arranged in the hollow profile produced from a sheet metal blank is in the DE 10 2004 046 687 B3 proposed (see paragraph [0032]). The mandrel has an embossing device for embossing the sheet placed around it. Such a mandrel may not have length-constant secondary structures for embossing, provided that it is possible to remove the mandrel after the forming, which is the case for example in a conical basic structure. In order to form even larger-volume mold elements safely, for this purpose, the embossing device can be designed as an embossing die which can be moved beyond the circumference of the mandrel and mold elements can be provided in recesses of the tool halves enclosing the mandrel as a counterpart to the shaping produced by the embossing device.

The from the DE 10 2004 046 687 B3 However, known proposal is not or hardly suitable to produce substantially cylindrical hollow sections with undercuts, in particular with inwardly directed undercuts, since the mandrel described in such cases can not be removed from the closed hollow profile after impressing the undercut.

A generic device is the Japanese Patent Application JP-A 59 220 225 refer to.

Based on this, the object of the invention was to provide a device that allows the cost-effective production of undercuts in a slotted or closed sheet metal profile in a simple manner.

This object is achieved according to the invention by a device having the features of claim 1. Further advantageous embodiments of the device according to the invention will become apparent from the dependent claims.

The device according to the invention comprises a core, which is inserted into the slotted or closed sheet metal profile or serves as a support core for a sheet metal semi-finished product, from which the slotted or closed sheet metal profile is produced, wherein the core has at least two outer core sections, of which at least one at least a recess or at least one projection for forming an undercut in the sheet metal profile, and that between the at least two outer core portions, an inner core portion is arranged, which is movable relative to the outer core portions and at least one active surface, which in a predetermined direction of movement of the inner Core portion is inclined or cam-shaped relative to the outer core portions, wherein by moving the inner core portion in the predetermined direction of movement relative to the outer core portions latter are moved apart and then End in moving the inner core portion to be moved towards each other in the reverse direction, and is further characterized in that the active surface of the inner core portion is wave-shaped, wherein at least one of the outer core portions has an active surface associated with the inner surface, which is also wave-shaped.

With the device according to the invention can be produced in a simple manner slotted and closed sheet metal profiles with undercuts inexpensively and realize a very reliable way a parallel, stepless moving apart and then approaching the outer core sections. In particular, in this embodiment, a flushness of the surface of the outer core portions and the inner core portion defined support surfaces are maintained substantially during the moving apart of the outer core portions.

An advantageous embodiment of the device according to the invention is characterized in that the inner core portion is linearly displaceable relative to the outer core portions. This embodiment corresponds particularly well to the working steps in a transfer or line process, so that a core unit formed according to the invention can be relatively easily and reliably integrated in such a process. The core unit divided into the outer core sections and the inner core section may also be referred to as an incident core.

A further advantageous embodiment of the device according to the invention provides that the active surface of the inner core portion is made double, wherein the two active surfaces are formed on opposite sides of the inner core portion, and wherein the outer core portions each have a wavy inner surface which is one of the active surfaces associated with the inner core section. This can be effected by a relatively small linear displacement of the inner core portion, a relatively large spread of the outer core portions.

According to a further advantageous embodiment of the device according to the invention, the outer core portions are movably supported on a holder, wherein the holder has an opening penetrated by the inner core portion. This embodiment simplifies the handling of the three said core sections. The holder is preferably provided with a guide for the movably held on her outer core sections. This contributes to a reliable function of the core unit composed of said core sections. In addition, the arrangement of the guide on the holder is favorable for a compact design of the device according to the invention, in particular the said core unit.

A further advantageous embodiment of the device according to the invention is characterized in that the inner core portion against the action of at least one compression spring in the predetermined direction of movement is displaceable relative to the outer core portions, wherein the compression spring is supported on the holder. As a result, in a simple and reliable manner, a provision (reverse displacement) of the inner core portion relative to the outer core portions and, consequently, a provision (ie, to move toward each other) of the outer core sections, when the core unit in the slotted after production of the at least one undercut or closed sheet metal profile is to be pulled out of this. For this purpose, the inner core portion may be advantageously attached to a pressure body having at least one of a guide rod interspersed opening, wherein the guide rod is fixed in this case to said holder. Furthermore, in this case, the guide rod can be arranged in the compression spring, so that the latter is supported radially on the guide rod. The spring force of the compression spring or compression springs is chosen to be greater than the frictional forces that must be overcome for an automatic resetting of the inner core portion relative to the outer core portions.

In a particularly preferred embodiment of the device according to the invention, the outer core portions are linearly movable together with the inner core portion, the outer core portions is associated with an end stop, and wherein the inner core portion is moved in the predetermined direction of movement relative to the outer core portions, when the outer Core sections are pressed against the end stop. As a result of this refinement, the device according to the invention is further improved with regard to a simple and reliable function and the integration into a transfer or line process.

According to a further embodiment of the invention, said end stop is provided with a guide for the outer core sections in the movement apart and the subsequent approaching the same. Through this guide, the reliable operation of the device according to the invention in a transfer or Optimize line process further. Preferably, this guide is formed from a web-shaped guide element which has a tapering in the direction of the outer core portions cross-sectional profile, wherein in the guide element facing the front ends of the outer core portions and the inner core portion recesses for receiving the guide element are formed. The guide element serves at the same time for locking the outer core portions and the inner core portion.

A particularly reliable locking of the outer core portions and the inner core portion results when the end stop according to a further preferred embodiment facing each other stop surfaces, which limit the Auseinanderbewegung the outer core portions.

Fig. 1 - Fig. 5

verschiedene Positionen einer Kerneinheit einer bevorzugten, erfindungsgemäßen Vorrichtung während eines Arbeitszyklus zur Herstellung von Hinterschnitten in ein geschlitztes oder geschlossenes Blechprofil (Hohlprofil);

Fig. 6

einen Abschnitt der Kerneinheit der Fig. 1 in einer anderen Perspektive mit Blick auf die Seite einer Kernhalteplatte, an welcher die äußeren Kernabschnitte geführt sind;

Fig. 7

einen Abschnitt des mit einem Endanschlag verbindbaren Endes der Kerneinheit entsprechend Fig. 3, in vergrößerter Detaildarstellung;

Fig. 8

ein geschlossenes Blechprofil, in das mittels einer bevorzugten, erfindungsgemäßen Vorrichtung gemäß den Figuren 1 bis 5 nach innen gerichtete Hinterschnitte hergestellt wurden; und

Fig. 9

ein weiteres Beispiel eines geschlossenen Blechprofils, in das mittels einer bevorzugten, erfindungsgemäßen Vorrichtung nach außen gerichtete Hinterschnitte hergestellt wurden.

The invention will be explained in more detail with reference to a drawing illustrating several embodiments. They show schematically and in each case in a perspective view:

Fig. 1 - Fig. 5

various positions of a core unit of a preferred, inventive device during a work cycle for the production of undercuts in a slotted or closed sheet metal profile (hollow profile);

Fig. 6

a section of the core unit of Fig. 1 in a different perspective looking at the side of a core plate on which the outer core portions are guided;

Fig. 7

a portion of the connectable with an end stop end of the core unit accordingly Fig. 3 , in enlarged detail;

Fig. 8

a closed sheet metal profile into which by means of a preferred, inventive device according to the FIGS. 1 to 5 inwardly directed undercuts were made; and

Fig. 9

Another example of a closed sheet metal profile, in which by means of a preferred, inventive device outwardly directed undercuts were made.

The device shown in the drawing is used to produce undercuts in a slotted or closed hollow profile, which is made of sheet metal. The device comprises a three-part core 1, which may also be referred to as a core unit or core.

The core unit 1 is elongate and comprises two outer core sections 1.1, 1.2, each having, for example, a plurality of recesses 2, 3 for forming inwardly directed undercuts in a closed sheet metal profile. Between the two outer core sections 1.1, 1.2 an inner core section 1.3 is arranged, which is linearly displaceable relative to the outer core sections 1.1, 1.2 and wavy active surfaces 1.31, 1.32 has. The active surfaces 1.31, 1.32 of the inner core section 1.3 facing inner surfaces 1.11, 1.21 of the outer core sections 1.1, 1.2 are also formed wave-shaped. The wave-shaped active surfaces 1.31, 1.32 of the inner core section 1.3 and the inner surfaces 1.11, 1.21 of the outer core sections 1.1, 1.2 are preferably substantially complementary to one another. The three core sections 1.1, 1.2, 1.3 have substantially the same width or depth, so that the mutually parallel side surfaces of the incident core 1 each have flush-mounted side faces 1.12, 1.22, 1.33.

By linear displacement of the inner core portion 1.3 relative to the outer core portions 1.1, 1.2 in the by the arrow P1 in Fig. 1 displayed direction of movement the core unit 1 is spread, wherein the outer core sections 1.1, 1.2 are moved apart.

The recesses 2, 3 for forming inwardly directed undercuts in the slotted or closed sheet-metal profile are arranged on the outer core section 1.3 facing away from the outer side of the respective outer core portion 1.1, 1.2. The recesses 2, 3 are formed, for example, channel-shaped and extend transversely to the longitudinal axis of the incident core (core unit) 1. Furthermore, the recesses 2, 3 may be formed dellen- or dome-shaped.

The outer core sections 1.1, 1.2 are held movably at one of their ends on a plate-shaped holder 4. The holder (core holding plate) 4 has a passage opening 4.1, which is penetrated by a substantially straight section 1.34 of the inner core section 1.3. The straight portion 1.34 of the inner core portion has, for example, a substantially rectangular cross-section, wherein the passage opening 4.1 of the core holding plate 4 has a corresponding cross-sectional profile and serves as a guide. On the outer core sections 1.1, 1.2 facing side of the core plate 4, this is provided with a guide 4.2 for the outer core sections 1.1, 1.2 (see Fig. 6 ). The guide 4.2 is formed groove-like and intersects the passage opening 4.1.

On the outer core sections 1.1, 1.2 side facing away from the core holding plate 4 parallel to each other guide pins (guide rods) 5 are attached. The guide pins 5 extend parallel to the longitudinal axis of the incident core (core unit) 1 and are guided (through hole 6.1) in a plate-shaped pressure body (pressure plate) 6. The pressure plate 6 is fixedly connected to the end of the straight portion of the inner core portion 1.3, for example, welded or screwed. The guide pins 5 are provided with compression springs (coil springs) 7, which are arranged between the core holding plate 4 and the pressure plate 6 and are pushed onto the guide pins 5.

The outer core sections 1.1, 1.2 are substantially linearly movable together with the inner core section 1.3, the core sections 1.1, 1.2, 1.3 being assigned an end stop 8. In the in Fig. 2 illustrated position of the incident core 1, the outer core sections 1.1, 1.2 with their core plate 4 facing away from the end stop against the end stop 8, wherein the core stop plate 4 facing away from the inner core portion 1.3 (initially) with a clear distance from the end stop 8. If now the inner core section 1.3 moves further towards the end stop 8 by further displacement of the pressure plate 6 while compressing the compression springs 7 relative to the outer core sections 1.1, 1.2, then the outer core sections 1.1, 1.2 become wavy due to their wavy inner surfaces 1.11, 1.21 Active surfaces 1.311.32 of the inner core section 1.3 moved apart. This is in Fig. 3 indicated by the oppositely directed arrows P2, P3.

The end stop 8 is provided with a guide 8.1 for the outer core sections 1.1, 1.2. The guide 8.1 is designed as a web-shaped guide element, which has a tapered in the direction of the outer core sections 1.1, 1.2 cross-sectional profile, for example, a trapezoidal profile. In the guide element 8.1 facing front ends of the outer core sections 1.1, 1.2 and the inner core section 1.3 recesses 1.13, 1.23, 1.35 for receiving the guide element 8.1 are formed. The guide element 8.1 serves as a locking of the core sections 1.1, 1.2, 1.3. Furthermore, the end stop 8 facing each other abutment surfaces 8.2, 8.3, which limit the Auseinanderbewegung the outer core sections 1.1, 1.2.

Hereinafter, the operation of the incident core according to the invention based on the FIGS. 1 to 5 briefly explained again.

In Fig. 1 is shown a starting position in which the compression springs 7 largely relaxed and the three-part core unit (incident core) 1 is not spread.

Fig. 2 shows an intermediate position after the core unit 1 has been moved linearly in the direction of the end stop 8 and the two outer core sections 1.1, 1.2 with their core plate 4 facing away from the end stop 8 touch.

In Fig. 3 is one according to the intermediate position Fig. 2 subsequent end position shown. In this end position, the pressure plate 6 was previously moved against the spring force of the compression springs 7 linearly in the direction of the arrow P1. As a result, a displacement of the inner core portion 1.3 has been effected, whereby the two outer core portions were 1.1, 1.2 displaced to the outside and thus perform a lifting or spreading movement. Here, for example forked or U-shaped end stop 8 serves as a limitation of the lifting or spreading movement of the two outer core sections.

In Fig. 4 a situation during the retraction movement of the core unit 1 is shown. It can be seen that the core unit 1 is pulled away linearly in the direction of the arrow P4 from the end stop 8, due to the previously compressed compression springs 7 first the pressure plate 6 is moved together with the inner core portion 1.3 and the two outer core sections 1.1, 1.2 first still remain in engagement with the end stop 8. As a result, the inner core section 1.3 is thus pulled and at the same time reduces the total height of the three-part incidence core 1 or the distance of the outer core sections 1.1, 1.2, which in Fig. 4 additionally indicated by the arrows P5 and P6. As a result, the production of closed hollow profiles and slot profiles with undercuts in a transfer or line process is possible.

In Fig. 5 the situation is shown at the end of the work cycle. After pulling the inner core section 1.3, the entire core unit 1 has been moved away from the end stop 8 and retracted (see arrow P4). The core unit 1 thus releases the sheet metal profile provided with undercuts for further transport in the transfer or line process. The situation according to Fig. 5 corresponds to the in Fig. 1 shown starting position.

An example of a closed sheet metal profile B with inwardly directed undercuts 9.1, 9.2, by means of the core unit 1 according to the FIGS. 1 to 7 can be made is in Fig. 8 to see. The undercuts 9.1 are channel-shaped or bead-shaped, while the undercuts are 9.2 dellenförmig. Of course, other geometry forms for the hollow profile to be produced are possible. In particular, closed sheet-metal profiles B 'can be produced with outwardly directed undercuts 10 with a device according to the invention, as shown by way of example in FIG Fig. 9 is shown.

The embodiment of the device according to the invention is not limited to the embodiments shown in the drawing. On the contrary, numerous variants are conceivable which make use of the invention specified in the appended claims even in the case of a design modified from the exemplary embodiments shown. For example, it is also conceivable to carry out the spreading apart (spreading) of the outer core sections 1.1, 1.2 by means of a (not shown here) rotatable inner core section, the latter then having at least one active surface in a predetermined direction of movement, namely rotational direction relative to the outer core sections 1.1, 1.2 is cam-shaped. The cam-shaped active surface or the cam of the rotatable inner core portion (not shown here) is received in the non-expanded position of the outer core portions, for example, in a hollow chamber in one of the outer core portions with play, from which he swung out by rotation of the inner core portion and against an inner surface of the other outer core portion can be pressed, so that when continuing this rotary or pivoting movement apart (spreading) of the outer core sections 1.1, 1.2 results.

Claims (12)

1. Device for manufacturing at least one undercut in a slotted or closed sheet-metal profile (B, B'), the device comprising a core (1) which is inserted into the sheet-metal profile or serves as a support core for a semifinished sheet-metal product from which the sheet-metal profile (B, B') is produced wherein the core (1) has at least two outer core portions (1.1, 1.2) of which at least one has at least one depression (2, 3) or at least one protrusion for shaping an undercut (9.1, 9.2; 10) in the sheet-metal profile (B, B'), and that an inner core portion (1.3) which is movable in relation to the outer core portions (1.1, 1.2) and has at least one active face (1.31, 1.32) which in a predefined movement direction of the inner core portion (1.3) is configured so as to be inclined or cam-shaped in relation to the outer core portions (1.1, 1.2), is disposed between the at least two outer core portions (1.1, 1.2), wherein by moving the inner core portion (1.3) in the predefined movement direction (P1) in relation to the outer core portions (1.1, 1.2) the latter are made to diverge and subsequently, by moving the inner core portion (1.3) in the opposite movement direction (P4), the latter are made to converge, characterized in that the active face (1.31, 1.32) of the inner core portion (1.3) is configured so as to be undulated, wherein at least one of the outer core portions (1.1, 1.2) has an inner face (1.11, 1.21) which is assigned to the active face (1.31, 1.32) and which is likewise configured so as to be undulated.
2. Device according to Claim 1, characterized in that the inner core portion (1.3) is displaceable in a linear manner in relation to the outer core portions (1.1, 1.2).
3. Device according to Claim 1 or 2, characterized in that the active face of the inner core portion (1.3) is embodied in duplicate, wherein the two active faces (1.31, 1.32) are configured on opposite sides of the inner core portion (1.3), and wherein the outer core portions (1.1, 1.2) in each case have an inner face (1.11, 1.21) which is configured so as to be undulated and which is assigned to one of the active faces (1.31, 1.32) of the inner core portion (1.3).
4. Device according to one of Claims 1 to 3, characterized in that the outer core portions (1.1, 1.2) are held on a mounting (4) so as to be movable, wherein the mounting (4) has an opening (4.1) which is penetrated by the inner core portion.
5. Device according to Claim 4, characterized in that the mounting (4.1) is provided with a guide (4.2) for the outer core portions (1.1, 1.2) which are held thereon so as to be movable.
6. Device according to Claim 4 or 5, characterized in that the inner core portion (1.3) is displaceable counter to the effect of at least one compression spring (7) in the predefined movement direction (P1) in relation to the outer core portions (1.1, 1.2), wherein the compression spring (7) is supported on the mounting (4).
7. Device according to one of Claims 4 to 6, characterized in that the inner core portion (1.3) is fastened to a compression body (6) which has at least one through bore (6.1) which is penetrated by a guide bar (5), wherein the guide bar (5) is fastened to the mounting (4).
8. Device according to Claims 6 and 7, characterized in that the guide bar (5) is disposed in the compression spring (7) such that the compression spring (7) is radially supported on the guide bar (5).
9. Device according to one of Claims 1 to 8, characterized in that the outer core portions (1.1, 1.2) are moveable in a substantially linear manner together with the inner core portion (1.3), wherein the outer core portions (1.1, 1.2) are assigned a terminal stop (8), and wherein the inner core portion (1.3) is moved onward in the predefined movement direction (P1) in relation to the outer core portions (1.1, 1.2) when the outer core portions (1.1, 1.2) are forced against the terminal stop (8).
10. Device according to Claim 9, characterized in that the terminal stop (8) is provided with a guide (8.1) for the outer core portions (1.1, 1.2) for when the latter are made to diverge and to subsequently converge.
11. Device according to Claim 10, characterized in that the guide (8.1) is formed from a web-shaped guide element which has a cross-sectional profile which tapers off in the direction of the outer core portions (1.1, 1.2), wherein clearances (1.13, 1.23, 1.35) for receiving the guide element (8.1) are configured in those end sides of the outer core portions (1.1, 1.2) and of the inner core portion (1.3) that face the guide element (8.1).
12. Device according to one of Claims 9 to 11, characterized in that the terminal stop (8) has mutually facing stop faces (8.2, 8.3) which delimit the diverging movement of the outer core portions (1.1, 1.2).

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