JPH08155568A - Production of door sash - Google Patents

Abstract

PURPOSE: To reduce production cost and to improve designability by bending a roll forming body so as to form both upper part and side part of a door sash. CONSTITUTION: A long size flat sheet is roll formed to each outer surface part of an upper part 1 and side part 2, after the edge of lapels parts are seam welded to the rear of glass run accommodating part, the parts are subjected to cutting/straightening by roll cutter and then roll forming by roll, etc., to be bent inward. While a formed body B is placed on the upper face of the obtained formed body A and both formed bodies are spot welded, further, the edge of outer surface part of formed body A is subjected to hemming so as to hold the upper edge part of side wall of one side of weather strip accommodating part of formed body B. By this method, the formed bodies A, B are integrated to obtain a long size base material. Next, a prescribed position of the base material is bent to obtain the door sash having the upper part 1 and side part 2.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing an automobile door sash. Specifically, the present invention relates to a method of manufacturing a door sash having an upper portion and a side portion by bending one long raw material having a predetermined cross-sectional shape.

[0002]

2. Description of the Related Art FIG. 2 shows an example of a conventional door sash. The illustrated door sash is composed of an upper part 1 and a side part 2, and a boundary part 3 between both parts is welded together. The outer surface portion 11 of the upper portion 1 (the portion shown in the figure) has a substantially uniform width from the upper end portion 11a to the lower end portion 11b, but the outer surface portion 21 of the side portion 2 has a lower end portion. twenty one
It is formed so that it becomes wider toward the part closer to b, and the design is enhanced. As shown in FIG. 4A, the cross section of the upper portion 1 has a flat outer surface portion 11, a groove-shaped glass run accommodating portion 12, and a groove-shaped weather strip accommodating portion 13.
The side portion 2 has a flat outer surface portion 21 and a groove-shaped glass run housing as shown in FIG. 4 (b). Part 22
Are integrally formed by roll forming of a long plate, and a weather strip accommodating portion 23 formed by roll forming of another long plate is integrated by spot welding.

Japanese Patent Publication No. 4-22728 discloses an example of a door sash and a manufacturing method thereof. In the door sash of this publication, the width of the upper end portion of the outer surface portion of the side portion is formed wider than that of the door sash of FIG. Note that the upper part 1 and the side part 2 are integrated by welding, and the outer surface part of the side part is formed wider toward the lower end part, as shown in FIG. Similar to sash.

[0004]

Since the boundary portion 3 between the upper portion 1 and the side portion 2 is integrated by welding or the like, there is also a desire to shorten the manufacturing process by eliminating this process. Further, there is a demand to improve the design by forming the outer surface portion 11 of the upper portion 1 to be wider toward the lower end portion 11b like the outer surface portion 21 of the side portion 2. The present invention aims to meet the above needs.

[0005]

SUMMARY OF THE INVENTION The present invention comprises an upper portion and a side portion, the outer surface portions of both portions are formed wider toward the lower end, and their cross-sectional shapes are the same in the longitudinal direction except the outer surface portion. A method of manufacturing a door sash having substantially the same shape in each part, comprising: (1) an elongated shape having the cross-sectional shape and a portion corresponding to the outer surface portion having a uniform width. Roll forming step of obtaining a member by roll forming a long flat plate, (2) the edge of the wide portion of the long member is cut at a predetermined inclination along the substantially longitudinal direction, and becomes narrower toward the center Outer surface shaping step to obtain a long raw material of shape, (3) into each through hole of a fixed side jig and a movable side gyro jig having a through hole through which the long raw material can be inserted, The long raw material is inserted by being conveyed in the longitudinal direction so that the bending target portion of the long raw material is in the front. Bending preparation step in which it is stopped while being positioned between the fixed side jig and the movable side gyro jig and is supported by both through holes, The side gyro jig is rotated about the longitudinal direction as a central axis, is displaced in a direction orthogonal to the longitudinal direction, and is rotated about the central axis, and the side gyro jig is moved in the longitudinal direction and the longitudinal direction. By performing a bending step of bending by displacing in a direction orthogonal to the orthogonal direction and rotating about the direction as a central axis, the upper portion and the side portion are formed from the long raw material. It is a method of manufacturing a door sash to obtain the door sash. In the above, if the step of heating the bending target portion is added before the bending preparation step, the bending step is shortened and the bending condition is further improved. This heating temperature range varies depending on the material, but for normal door sash material, it is 800 ℃.
~ 1200 ℃ is good, preferably 900 ℃ ~ 110
It is preferably about 0 ° C, more preferably about 1000 ° C. The material of a normal door sash is, for example, JISG314
It is SPCC material etc. of 1 cold-rolled steel plate.

[0006]

[Operation] Roll forming of a long flat plate (the long flat plate is conveyed in the longitudinal direction through a large number of roller pairs whose pressing surface shapes are gradually changed in the order of arrangement, and the cross section which was initially flat plate-shaped. Forming method to process the shape to the desired cross-sectional shape)
As a result, a long member in which the width of the portion corresponding to the outer surface portion is uniformly wide is obtained. The edge of the wide part of this long member,
A long raw material is obtained by cutting at a predetermined inclination that becomes narrower toward the middle along the substantially longitudinal direction. This long raw material is stopped so that the part to be bent is located between the fixed side jig and the movable side gyro jig and supported by both jigs, and then the movable side gyro jig is bent. The desired bending process is performed by displacing it according to. This bending process is necessary for the door sash shown in Fig. 1 (upper part 1
The desired door sash can be obtained by applying it to the boundary portion between the side portion 2 and the side portion 2).

[0007]

Embodiments of the present invention will be described below. FIG. 1 is a front view of a door sash manufactured by an example method, and FIG. 3 is a cross-sectional view of the door sash of FIG. 1 taken along the line A-A (a), the line BB (b), and the line C-C. It is sectional drawing (c). Also,
5 to 9 show a manufacturing process of the door sash of the embodiment.
Note that portions having the same functions as those of the conventional example shown in FIGS. 2 and 4 are denoted by the same reference numerals.

As shown in FIG. 1, the door sash includes an upper portion 1 and a side portion 2. As shown in FIG. 3A, the upper portion 1 includes an outer surface portion 11 that is formed flat so as to be substantially flush with the outer surface of the door, a glass run accommodating portion 12 that has a groove shape, and a groove shape. And a weather strip accommodating portion (13). As shown in FIGS. 3 (b) and 3 (c), the side portion 2 also has an outer surface portion 21 formed flat so as to be substantially flush with the outer surface of the door, and a glass run accommodating portion having a groove shape. 22 and a weather strip accommodating portion 23 having a groove shape. In the above, the Grass Run accommodation section
12, 22 and the weather strip accommodating portions 13, 23 are provided in a positional relationship in which the bottoms of the grooves are back to back, and the outer surface portions 11, 21 are formed on the outer surface side of one side wall of the grooves of both portions.
The back side of is located. In addition, 14 and 24 are hollow parts, 15 and 25 are ridges, and 16 and 26 are ridge bases.

The outer surface portions 11 and 21 of the upper portion 1 and the side portion 2 and the glass run accommodating portions 12 and 22 are formed into a shape as shown in FIG.
After seam spot welding S of the edge of the folded back portion to the back surface of the glass run accommodating portions 12 and 22 as shown in FIG. 5B, it is cut and shaped by the roll cutter 5 as shown in FIG. The edges of the surface portions 11 and 21 are gradually widened toward both ends (= gradually narrowed toward the center, gradually deformed). Further, as shown in FIG. 62
The edges of the outer surface portions 11 and 21 are gradually roll-formed by, for example, and bent inward, and then cut by the flying cutter 7 to a predetermined length as shown in FIG. 6B. In addition, the weather strip accommodating portions 13 and 23 of the upper portion 1 and the side portion 2 are formed into a shape as shown in the right side of FIG. It is formed by cutting into the same predetermined length.

The two roll compacts thus obtained (the compact A of the outer surface parts 11,21 and the grass run accommodating parts 12,22 and the compact B of the weather strip accommodating parts 13,23) are
Next, they are integrated as shown in FIG. That is, the upper surface of the molded body A (the rear surface side of the bottom portions of the glass run accommodating portions 12 and 22)
Then, the molded body B is placed so that the open portions of the weather strip accommodating portions 13 and 23 face upward, both the molded bodies are spot-welded, and the weather strip accommodating portion 1 of the molded body B is further placed.
The edge of the outer surface portion 11,21 of the molded body A (the portion bent inward in the above step) is hemmed so as to sandwich the upper edge of the one side wall 130,230 of the 3,23. As a result, the molded body A
And the molded body B are integrated to obtain the long raw material 100 referred to in the claims.

The long raw material 100 thus obtained is then bent at a predetermined position in the longitudinal direction by the device shown in FIG. 7 (a), and as shown in FIG.
And a side sash 2 having a side portion 2. The degree of bending at the boundary between the upper portion 1 and the side portion 2 is, for example, about R30. The details of the bending process will be described below.

FIG. 7 (a) is a schematic diagram showing the overall construction of the bending apparatus, and FIG. 7 (b) is a hollow bar of the long raw material 100 and a core metal 32.
8 is a perspective view showing the state of inserting 0, FIG. 8A is a perspective view showing the state of feeding the long raw material 100 into the bending apparatus,
9B is a perspective view showing the booth 34 for heating the long raw material 100, and FIG. 9A is a fixed side jig 35 and a movable side gyro jig.
36 is a perspective view showing each of the cores 350 and 360 of 36, and (b) is an explanatory view showing the movement of the movable side gyro jig 36.

The bending device 3 includes a stocker loader 31.
A core bar feeder 32, a feed unit 33, a high frequency booth 34, a fixed side jig 35, a movable side gyro jig 36,
A base for supporting them is provided, and these are controlled by a control controller (not shown). Also,
A robot 37 is installed at a position in the subsequent step of the bending apparatus 3, and the robot 37 pulls out the work after the bending, that is, the completed door sash, from the jig.

In the stocker loader 31, a large number of long raw materials 100 are arranged side by side in parallel. These are 1
After being taken out one by one, the core metal 320 is first inserted into the hollow portions 14 and 24 (see FIG. 3) by the core metal feeder 32. The core metal 320 is, as shown in FIG.
A tip portion 320a and a base portion 320b that supports the tip portion 320a so that it can swing in all directions (= universal) at the connecting portion 320c.
Consists of.

After inserting the core metal 320 into the hollow portions 12 and 24,
The long raw material 100 has many rollers 330 of the feeding unit 33.
7 is conveyed to the right in FIG. 7A, and further passes through a guide 331 having a through hole having a shape corresponding to the cross-sectional shape of the long raw material 100, and reaches the high frequency booth 34. In the high frequency booth 34, the bending target portion of the long raw material 100 is heated to about 1000 ° C., and then quickly inserted into the through hole (see FIG. 9) of the core 350 of the stationary jig 35. Is
Then, the movable side gyro jig 36 is inserted into the through hole (see FIG. 9) of the core 360.

When the portion of the long raw material 100 to be bent reaches the middle of the movable side gyro jig 36 and the fixed side jig 35, the conveyance is stopped. At this time, the connection part of the core metal 320
The 320c is located between the fixed-side jig 35 and the movable-side gyro jig 36. Further, the core metal 320 does not proceed any further.

Thus, the long raw material 100 is supported while being inserted into the through holes of the cores 360 and 350 of the movable side gyro jig 36 and the fixed side jig 35, respectively. Where each core 36
Each of 0 and 350 is composed of a plurality of members as shown in FIG. 9 (a). By displacing these members in a substantially central direction so as to be in close contact with each other, respective through holes are formed. ing. The shape of the through hole is a shape corresponding to the cross-sectional shape of the long raw material 100 so that the long raw material 100 can be inserted and supported. The hollow part of the long raw material 100 is
Since the core metal 320 is inserted into the core, as described above, it is not crushed by being supported by the cores 360 and 350.

Next, the movable gyro jig 36 is displaced in the direction corresponding to the bending work to be performed on the relevant portion by an amount corresponding to the bending work to be performed on the relevant portion to fix the bending work. It will be held in that position for as long as necessary. The displacement direction, displacement amount, and holding time are realized by numerically controlling the movement of the movable gyro jig 36 in accordance with a command from a controller (not shown).

Specifically, as shown in FIG. 9B,
The movable gyro jig 36 is rotated around the X-axis (conveying direction of the long material 100) by an angle designated by the controller, and is moved in the Y-axis direction by a distance designated by the controller. And rotate about the Y-axis by the angle specified by the controller, and displace in the Z-axis direction by the distance specified by the controller and Z by the angle specified by the controller. This is accomplished by rotating around the axis. The X axis, Y axis, and Z axis are axes that are orthogonal to each other. In addition,
The rotation angles and the displacement distances designated by LA are set in accordance with the bending process to be performed on the site and the cross-sectional shape of the site.

When the bending work to be performed on the relevant part is completed in this way, the conveyance of the long raw material 100 is restarted, and the next bending work part is moved to the above-mentioned working position (the movable side gyro jig 36 and the fixed side). When it reaches the position (with respect to the jig 35), the conveyance is stopped again, and the bending process is performed on the relevant portion as described above. When all the bending work to be performed on the long raw material 100 is completed, the long raw material 100 is transferred to the robot 37.
Then, the subsequent long raw material 100 is bent in the same manner as above.

[0021]

As described above, according to the present invention, the uniform wide portion (the uniform wide portion corresponding to the outer surface portion) of the elongated member is cut and shaped so that the width becomes narrower toward the center, After the door sash is completed, this portion becomes the outer surface portions of the upper portion and the side portion that are gradually wider toward the lower end portion, so that the design is improved. Also, since the bending process is performed by the displacement of the fixed side jig and the movable side gyro jig, it becomes possible to configure the upper part and the side part by bending the long raw material (roll forming body). Therefore, the welding process at the boundary between the two parts is unnecessary, and the entire process is shortened. Also, as a result,
This has the effect of reducing manufacturing costs.

[Brief description of drawings]

FIG. 1 is a front view of a door sash according to an embodiment.

FIG. 2 is a front view of a conventional door sash.

3 is a sectional view taken along the line AA in FIG. 1, a sectional view taken along the line BB, and a sectional view taken along the line CC.

4 is a sectional view (a) and a sectional view (b) taken along the line BB of FIG.

FIG. 5 is an explanatory view showing a manufacturing process of the door sash of the embodiment.

FIG. 6 is an explanatory view showing a continuation of FIG. 5;

FIG. 7 is a schematic diagram showing an overall configuration of a bending device (a).
And a perspective view (b) showing how the core metal is inserted into the hollow portion of the elongated raw material in the bending apparatus.

FIG. 8 is a perspective view (a) showing a state where a long raw material is conveyed in a bending apparatus, and a perspective view (b) showing a booth for heating the long raw material.

FIG. 9A is a perspective view showing a fixed side jig and a movable side gyro jig of the bending apparatus, and FIG. 9B is an explanatory view showing the movement of the movable side gyro jig.

[Explanation of symbols]

 1 Upper part 2 Side part 11,21 Outer surface part 12,22 Glass run accommodation part 13,23 Weather strip accommodation part 3 Bending device 31 Aligner (stocker loader) 32 Core bar feeder 33 Feed unit 34 High frequency booth 35 Fixed side Jig 36 Movable side gyro jig 37 Robot 100 Long material

Claims (2)

[Claims] 1. An upper part and a side part, wherein the outer surface portions of both parts are formed wider toward the lower end, and the cross-sectional shape is substantially the same in each part in the longitudinal direction except the outer surface part. A method of manufacturing a door sash that comprises a long member having the cross-sectional shape and a width corresponding to the outer surface portion that is uniformly wide, by roll forming a long flat plate. Roll forming step for obtaining, outer surface portion shaping step for cutting the edge of the wide portion of the long member at a predetermined inclination along the substantially longitudinal direction to obtain a long raw material having a shape that becomes narrower toward the center , By inserting the long raw material in the longitudinal direction into the respective through holes of a fixed-side jig and a movable-side gyro jig having a through hole through which the long raw material can be inserted, The parts to be bent of the long raw material are the fixed jig and the movable gyro. A bending preparation step in which the movable side gyro jig is stopped in a state of being positioned between the jigs and supported by both through holes, and the movable side gyro jig is moved in the longitudinal direction according to the bending work to be performed on the bending work target portion. As well as displacing in the direction orthogonal to the longitudinal direction and rotating about that direction as a central axis, and displacing in the direction orthogonal to the longitudinal direction and the direction orthogonal to the longitudinal direction. A door sash manufacturing method for obtaining a door sash having the upper portion and the side portion from the long raw material by performing a bending step of bending by rotating about the direction as a central axis. 2. The method of manufacturing a door sash according to claim 1, wherein the step of heating the bending target portion is performed before the bending preparation step.