KR20100073276A - Method of manufacturing bracket for overhead console lamp using progressive mold - Google Patents

Method of manufacturing bracket for overhead console lamp using progressive mold Download PDF

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Publication number
KR20100073276A
KR20100073276A KR1020080131906A KR20080131906A KR20100073276A KR 20100073276 A KR20100073276 A KR 20100073276A KR 1020080131906 A KR1020080131906 A KR 1020080131906A KR 20080131906 A KR20080131906 A KR 20080131906A KR 20100073276 A KR20100073276 A KR 20100073276A
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KR
South Korea
Prior art keywords
bracket
forming
pilot
manufacturing
mold
Prior art date
Application number
KR1020080131906A
Other languages
Korean (ko)
Inventor
김수열
김창호
김철호
Original Assignee
조일공업주식회사
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Application filed by 조일공업주식회사 filed Critical 조일공업주식회사
Priority to KR1020080131906A priority Critical patent/KR20100073276A/en
Publication of KR20100073276A publication Critical patent/KR20100073276A/en

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    • 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
    • B21D28/00—Shaping by press-cutting; Perforating
    • B21D28/02—Punching blanks or articles with or without obtaining scrap; Notching
    • B21D28/06—Making more than one part out of the same blank; Scrapless working
    • 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
    • B21D28/00—Shaping by press-cutting; Perforating
    • B21D28/02—Punching blanks or articles with or without obtaining scrap; Notching
    • B21D28/22—Notching the peripheries of circular blanks, e.g. laminations for dynamo-electric machines
    • 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
    • B21D28/00—Shaping by press-cutting; Perforating
    • B21D28/24—Perforating, i.e. punching holes
    • 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
    • B21D37/08—Dies with different parts for several steps in a process
    • 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
    • B60—VEHICLES IN GENERAL
    • B60Q—ARRANGEMENT OF SIGNALLING OR LIGHTING DEVICES, THE MOUNTING OR SUPPORTING THEREOF OR CIRCUITS THEREFOR, FOR VEHICLES IN GENERAL
    • B60Q3/00—Arrangement of lighting devices for vehicle interiors; Lighting devices specially adapted for vehicle interiors
    • B60Q3/20—Arrangement of lighting devices for vehicle interiors; Lighting devices specially adapted for vehicle interiors for lighting specific fittings of passenger or driving compartments; mounted on specific fittings of passenger or driving compartments

Abstract

PURPOSE: A method of manufacturing a bracket for an overhead console lamp is provided to remove the need of a press by manufacturing the bracket using a single set of progressive mold. CONSTITUTION: A method of manufacturing a bracket for an overhead console lamp using a progressive mold includes the steps of: forming a plurality of pilot holes on a metal plate continuously supplied to the mold; forming notches(104,106) of the predetermined shape on the plate in which the pilot holes are formed; forming concave and convex parts on the plate so as to obtain a preform; and punching a slot in the concave parts of the preform and forming openings(114,116) in the convex parts.

Description

METHODS OF MANUFACTURING BRACKET FOR OVERHEAD CONSOLE LAMP USING PROGRESSIVE MOLD}

The present invention relates to a method of manufacturing a bracket of an overhead console lamp for a vehicle, and more particularly, to a method of manufacturing a bracket of an overhead console lamp using a progressive mold and a bracket manufactured by the manufacturing method. .

In general, overhead console lamps are installed in the car roof for night vehicle interior lighting. Overhead console lamps may be installed in the center of the car roof for use by both the driver and the passenger seat and rear seat passengers, or may be installed at the front and rear of the roof separately for front and rear seat occupants.

In order to install such an overhead console lamp in the roof of the vehicle, the bracket is screwed to the interior roof portion of the vehicle, and the head lining of the lamp is mounted on the bracket. Thereafter, the lamp body is inserted into the opening of the head lining and assembled. The console bracket not only supports the combination of the vehicle roof and the console box, but also assists the assembly process of the console box by holding the console box in place.

Such brackets are typically manufactured using tandem molds. Tandem mold refers to a mold that requires a number of presses and molds to produce a part by applying a process to one mold. The method of forming a product using a tandem mold includes a method of seating a molded product on a mold in a next process using a robot, a method in which a worker directly uses a hand, and a method using a vacuum suction method.

However, in the case of forming a product using a tandem mold in any manner, the number of molds consisting of punches and dies is large, and thus the number of presses for operating the punches also increases. In addition, an operator must be fixedly placed for each press to operate the press. Therefore, since the number of molds and presses increases and the number of workers increases, there is a problem that the production cost of the product increases.

In order to solve this problem, a method of manufacturing an automotive part using a progressive mold is disclosed in Korean Patent No. 10-0794452. The method disclosed in this patent will be described with reference to FIG.

In the piercing step S1, when the plate-type iron plate A is introduced between the upper and lower molds, four holes 10 are simultaneously drilled in the iron plate. The holes 10 are located on the same line and are continuously drilled to the same diameter.

In the notching steps S2 and S3, notching portions 12 are formed on both sides of the center of the iron plate, respectively. More specifically, the notching part 12 is formed on one side of the iron plate to form the right bracket 26 in the first notching step S2. In the second notching step S3, the notching part 12 is formed on the other side of the iron plate to form the left bracket 26.

In the marking step S4, the 'L' letter mark is marked on the upper surface of the iron plate in a state of being fixed by the pilot pin installed on the bottom surface of the upper mold. In this case, pilot pins are respectively inserted into the holes 10 formed in the iron plate to firmly fix the iron plate.

The bending part 18 is formed by bending the protrusions 16 formed at both sides of the two iron plates continuously moving in the forming step S5.

In the restriking step S6, the positions of the iron plates are set while pressing both sides of the iron plate, that is, the bending part 18, to assist the steel plates to move to the next step.

Finally, in the cutting steps S7 and S8, the side and center portions of the two steel sheets are cut, respectively. In more detail, each side portion 20 of the iron plate is cut in the first cutting step S7, and the center portion of the steel sheet in which the side portion is cut in the second cutting step S8 is cut. After the second cutting step, the central cutting chip 22 is separated from the central portion of the iron plate.

According to the above-described manufacturing process, the iron plate introduced into the press apparatus sequentially forms the left bracket 24 and the right bracket 26 at the same time.

The inventors of the present invention have attempted to improve productivity by developing a technology for manufacturing a bracket of a vehicle console lamp that is produced using a tandem mold with a progressive mold.

However, until recently there have been several attempts to manufacture automotive parts using progressive molds, but with no successful results. In the case of manufacturing a part using a progressive mold, it is necessary to have a structure design technique, a precision machining technique, and a molding / mould simulation technique of a separate mold for each component. However, much remains to be studied as the technology associated with progressive molds is currently in its infancy. In particular, since the shape of the part is complicated, there is a part to be examined from the press equipment to the molding analysis technique.

In the process of manufacturing the bracket of the console lamp by using a progressive mold, the inventors of the present invention have a number of process parameters, namely 1) calculation of bending allowance according to bending angle and radius and shape factor, and 2) calculation of moving distance of a plane according to bending allowance. 3) Flat pattern-layout calculation length, 4) Flat pattern-layout drawing, 5) Die blank calculation to withstand die surface pressure by lateral force, 6) Machining force of each process, 7) Complex process Data were accumulated for the process sequence determination for the product having 8, 8) strip-layout drawing, and the like.

That is, the present inventors found suitable molding conditions according to the verification and correction by the simulation program based on the empirical data on the molding conditions such as mold method, molding force, material properties, production speed, and applied them to the mold design.

It is an object of the present invention to provide a method of manufacturing a bracket of an overhead console lamp of a vehicle using a progressive mold to improve the productivity of the bracket.

In order to achieve the above and other objects of the present invention, according to an aspect of the present invention, a method for manufacturing a bracket of a vehicle overhead console lamp, comprising: forming a plurality of pilot holes in a metal plate continuously supplied to a mold; Step 1; A second step of forming a notch having a predetermined shape in the plate member on which the pilot hole is formed; A third step of forming a preform by forming a concave portion and a convex portion in the notched plate member; And a fourth step of drilling a slot in the concave portion of the preform and simultaneously forming an opening in the convex portion.

At least two notches are formed in the second step, and the notches are preferably interconnected by a bridge.

The recess is formed at the left and right edges of the plate, another recess is formed between the left and right recesses, and a circular convex portion is formed adjacent to the left and right recesses.

Preferably, a pilot step is added between the third step and the fourth step to insert the pilot pin into the pilot hole to position the preform in which the recess and the convex part are formed.

In the fourth step, a slot is drilled in the left and right recesses, and an elliptical opening and a circular opening are respectively formed in the convex portion.

According to the above-described configuration, the manufacture of the bracket of the overhead console lamp using the progressive mold increases the productivity by about four times as compared to the manufacture using the tandem mold. In addition, compared to tandem molds requiring 3 to 4 sets of molds, there is an advantage in that only one set of molds is used and only one expensive press is installed.

Hereinafter, a method of manufacturing a bracket of an overhead console lamp of a vehicle according to a preferred embodiment of the present invention will be described in detail with reference to the drawings.

1 is a perspective view schematically showing a bracket 10 of an overhead console lamp according to an embodiment of the present invention.

The bracket 10 is made of a steel plate, and the main body 12, the left and right recesses 16 and 18 formed at positions where both front edges of the main body 12 are lower than the main body, and the left and right recesses 16 and 18) a central recess 14 formed therebetween. The extension part 22 is arrange | positioned between the left and right recessed part 16 and 18 and the center recessed part 14, respectively.

In addition, the bracket 10 has convex portions 24 and 26 formed adjacent to the point where the main body 12 and the extension portion 22 meet, and at the center of the convex portions 24 and 26, the first and second portions are provided. Openings 28 and 30 are formed. The first opening 28 is circular while the second opening 30 is elliptical. Rectangular notches 20 are formed in the left and right recesses 16 and 18, respectively.

2 is a diagram illustrating a strip layout for manufacturing a bracket of an overhead console lamp using a progressive mold according to an embodiment of the present invention.

Referring to FIG. 2, first, when a metal plate 200 having a predetermined width is supplied to an upper portion of a lower mold, the metal plate 200 undergoes a piercing step S100. The piercing step S100 forms a plurality of pilot holes 202, preferably four pilot holes 202, in the metal plate 200.

The plate 200 on which the pilot holes 202 are formed is continuously moved to go through the notching step S102. In the notching step S102, notches 104 and 106 having a predetermined shape are formed in the plate 200. A bridge 108 is formed between the notch 104 and the notch 106, and an opening is formed in the bridge 108.

The plate 200 on which the notches 104 and 106 are formed forms a preform of the bracket through the forming / pilot step S104. In the forming / pilot step S104, a central recess 112 is formed between the left and right recesses 110a and 110b and the left and right recesses 110a and 110b at left and right edges of the surface of the plate 200. At the same time, circular convex portions 111a and 111b having a predetermined diameter are formed adjacent to the corners of the left and right recesses 110a and 110b.

The preform in which the concave portions 110a and 110b and the convex portions 110a and 110b are formed is subjected to an idle / pilot step S106. In the idle / pilot step S106, the pilot pin (not shown) formed in the upper mold is inserted into the pilot hole 202 to position the preform, and the preform is transferred to the next step.

The preform positioned at idle / pilot step S106 goes through a piercing / pilot step S108. In the piercing / pilot step S108, the slots 116 and 118 are drilled in the left and right recesses 110a and 110b, and the elliptical opening 114 and the circular opening 116 are formed in the convex portions 111a and 111b. To form the final bracket.

The bracket finally formed in the separating step S110 is separated from the previous preform and discharged to the next step.

3 shows a lower mold of a progressive mold for producing a bracket of an overhead console lamp according to a preferred embodiment of the present invention.

Referring to FIG. 3, an opening 52 for forming a pilot pin 102 is formed in the steel plate 200 to receive a piercing member (not shown) formed in the upper mold. In addition, the lower mold includes a die 54 for notching step S102, a die 56 for forming / pilot step S104, a die 56 for idle / pilot step S106, and an idle / A die 58 for pilot step S108 and a die 60 for piercing / pilot step S110 are sequentially provided.

4 is a photograph showing a result of performing an analysis on a preform that has been formed and piloted. According to the results of analysis, the minimum thickness was 0.939 mm and the maximum thickness was 1.47 mm, resulting in thickness changes of 32, 9% and 5.0%, respectively.

In order to reduce the defect rate caused by the thickness by the part with the greatest thickness and the part with the greatest thickness during the molding process, the thickness change rate in the unstable molding area is examined while varying the blank holder force and the clearance between the molds. It was.

As a result, as can be seen in the table below, it can be seen that the thickness reduction rate according to the clearance was insignificant.

Clearance (mm) Thickness (mm) Thickness (mm) Thickness reduction rate (%) Thickness increase rate (%) 0.01 0.938 1.47 33.0 4.53 0.05 0.950 1.47 32.2 5.06 0.1 0.962 1.47 31.3 5.08

Although the present invention has been described with reference to the above embodiments, the protection scope to be protected is not limited by the above embodiments. The protection scope of the present invention is determined by the following claims.

1 is a perspective view schematically showing a bracket of an overhead console lamp according to an embodiment of the present invention;

2 shows a strip layout for manufacturing a bracket of an overhead console lamp using a progressive mold in accordance with an embodiment of the present invention.

3 shows a lower mold of a progressive mold for producing a bracket of an overhead console lamp according to a preferred embodiment of the present invention.

4 is a photograph showing the results of performing an analysis on a preform that has been formed and piloted.

5 is a view showing a process of manufacturing an automotive part using a conventional progressive mold.

<Explanation of symbols for the main parts of the drawings>

10: bracket 12: main body

54, 56, 58, 60: die 104, 106: notch

108: bridge 110a, 110b: recessed portion

110a, 110b: Convex portion 202: Pilot hole

114, 116: opening

Claims (6)

In the method for manufacturing a bracket of a vehicle overhead console lamp, Forming a plurality of pilot holes in the metal plate continuously supplied to the mold (S100); Forming a notch having a predetermined shape in the plate member on which the pilot holes are formed (S102); Forming a preform by forming a concave portion and a convex portion in the notched plate member (S104); And drilling a slot in the concave portion of the preform and forming an opening in the convex portion (S108). The method of claim 1, At least two notches are formed in the step (S102), wherein the notches are interconnected by a bridge. The method of claim 1, The concave portion is formed at the left and right corners of the plate, another concave portion is formed between the left and right concave portion, the manufacturing method characterized in that the circular convex portion is formed adjacent to the left and right concave portion. The method of claim 1, And a pilot step of positioning the plate material by inserting the pilot pin into the pilot hole using the pilot pin between the step (S104) and the step (S108). The method of claim 1, In the step (S108), while drilling a slot in the left and right concave portion, and at the convex portion, an elliptical opening and a circular opening are formed, respectively. Bracket of an overhead console lamp manufactured according to the method of any one of claims 1 to 5.
KR1020080131906A 2008-12-23 2008-12-23 Method of manufacturing bracket for overhead console lamp using progressive mold KR20100073276A (en)

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Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102974674A (en) * 2012-08-17 2013-03-20 苏州吴中经济开发区搏宇模具加工厂 Working method of mobile phone lens support frame continuous punching die
KR101519741B1 (en) * 2013-11-25 2015-05-12 현대자동차주식회사 Guide mounting bracket for cockpit module of vehicle
CN107952878A (en) * 2017-11-07 2018-04-24 武汉华滋东江汽车零部件有限公司 A kind of continuous automatic press mould of automobile ESP stent and stamping procedure
KR102023301B1 (en) * 2019-01-24 2019-09-19 김종규 Method for manufacturing bus bar of battery
KR20220064063A (en) 2020-11-11 2022-05-18 하순원 Real-time detection device for scrap discharge of progressive mold and its detection method

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102974674A (en) * 2012-08-17 2013-03-20 苏州吴中经济开发区搏宇模具加工厂 Working method of mobile phone lens support frame continuous punching die
KR101519741B1 (en) * 2013-11-25 2015-05-12 현대자동차주식회사 Guide mounting bracket for cockpit module of vehicle
CN107952878A (en) * 2017-11-07 2018-04-24 武汉华滋东江汽车零部件有限公司 A kind of continuous automatic press mould of automobile ESP stent and stamping procedure
CN107952878B (en) * 2017-11-07 2023-07-14 武汉华滋东江汽车零部件有限公司 Continuous automatic stamping die and stamping process for automobile ESP (electronic stability program) support
KR102023301B1 (en) * 2019-01-24 2019-09-19 김종규 Method for manufacturing bus bar of battery
KR20220064063A (en) 2020-11-11 2022-05-18 하순원 Real-time detection device for scrap discharge of progressive mold and its detection method

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