WO2003000440A1 - Apparatus and method for manufacturing an automotive beam - Google Patents

Apparatus and method for manufacturing an automotive beam Download PDF

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Publication number
WO2003000440A1
WO2003000440A1 PCT/SE2002/001055 SE0201055W WO03000440A1 WO 2003000440 A1 WO2003000440 A1 WO 2003000440A1 SE 0201055 W SE0201055 W SE 0201055W WO 03000440 A1 WO03000440 A1 WO 03000440A1
Authority
WO
WIPO (PCT)
Prior art keywords
profile element
profile
rollers
sheet
welding station
Prior art date
Application number
PCT/SE2002/001055
Other languages
French (fr)
Inventor
Anders Sundgren
Mats Lindberg
Göran Berglund
Original Assignee
Accra Teknik Ab
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Accra Teknik Ab filed Critical Accra Teknik Ab
Priority to DE60236434T priority Critical patent/DE60236434D1/en
Priority to EP02739014A priority patent/EP1397218B1/en
Priority to JP2003506671A priority patent/JP4119362B2/en
Priority to US10/481,317 priority patent/US7073259B2/en
Priority to AT02739014T priority patent/ATE468183T1/en
Publication of WO2003000440A1 publication Critical patent/WO2003000440A1/en

Links

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
    • B21D5/00—Bending sheet metal along straight lines, e.g. to form simple curves
    • B21D5/06—Bending sheet metal along straight lines, e.g. to form simple curves by drawing procedure making use of dies or forming-rollers, e.g. making profiles
    • B21D5/08—Bending sheet metal along straight lines, e.g. to form simple curves by drawing procedure making use of dies or forming-rollers, e.g. making profiles making use of forming-rollers
    • B21D5/086—Bending sheet metal along straight lines, e.g. to form simple curves by drawing procedure making use of dies or forming-rollers, e.g. making profiles making use of forming-rollers for obtaining closed hollow profiles
    • 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
    • B21D47/00—Making rigid structural elements or units, e.g. honeycomb structures
    • B21D47/01—Making rigid structural elements or units, e.g. honeycomb structures beams or pillars
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R19/00—Wheel guards; Radiator guards, e.g. grilles; Obstruction removers; Fittings damping bouncing force in collisions
    • B60R19/02—Bumpers, i.e. impact receiving or absorbing members for protecting vehicles or fending off blows from other vehicles or objects
    • B60R19/18—Bumpers, i.e. impact receiving or absorbing members for protecting vehicles or fending off blows from other vehicles or objects characterised by the cross-section; Means within the bumper to absorb impact
    • B60R2019/1806—Structural beams therefor, e.g. shock-absorbing
    • B60R2019/1813—Structural beams therefor, e.g. shock-absorbing made of metal
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49616—Structural member making
    • Y10T29/49622—Vehicular structural member making
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49616—Structural member making
    • Y10T29/49623—Static structure, e.g., a building component
    • Y10T29/49634—Beam or girder
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/51—Plural diverse manufacturing apparatus including means for metal shaping or assembling
    • Y10T29/5136—Separate tool stations for selective or successive operation on work
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/53—Means to assemble or disassemble
    • Y10T29/53313—Means to interrelatedly feed plural work parts from plural sources without manual intervention
    • Y10T29/53348—Running-length work

Definitions

  • the present invention relates to an apparatus and method for manufacturing an automotive beam and in particular to an apparatus and method for roll forming a closed profile beam.
  • Beams used on the body structure of an automobile and beams mounted at the front and rear of automobiles are required to absorb impact from collisions with other vehicles and with other objects. Beams manufactured for these purposes need to have a high resistance to torsion and good strength characteristics in order to prevent local buckling of the beam.
  • a number of prior art patent and patent application specifications have disclosed beams for use in the automotive industry and apparatuses and methods for manufacturing such beams.
  • US Patent No. 5,934,544 provides an apparatus and method for manufacturing automotive bumper beams by a single roll forming process.
  • the apparatus includes an uncoiler, a straightner, a group of roll formers, a sweep roll former, a welding member and a cutting member.
  • the method of manufacturing the bumper beam includes preparing the sheet metal, forming the cross sectional profile, forming a sweep, adjusting the tubular cross sectional shape of the sheet metal and welding the sheet metal prior to cutting the beam into desired lengths.
  • the objects of the invention are to provide a beam with strengthened impact resistance, reduced weight and to simplify the manufacturing processes of the prior art.
  • a vehicle body comprising a beam structure consisting of thin- walled flange-free profile parts with closed cross sections made by means of roll forming.
  • the component parts of the beam structure are hardened so that the boron steel or other high tensile steel has a yield limit of the order of 900-1100 MPa.
  • the object of the invention is to produce a new and lighter type of vehicle body with an increased body strength and stiffness.
  • the present invention provides an apparatus for manufacturing roll formed profile beams characterised in that the apparatus comprises a plurality of material dispensers, a first set of rollers and a second set of rollers and a first welding station mounted between and being in communication with the two sets of rollers and a second welding station in communication with the outlet of the second set of rollers, wherein one dispenser is in communication with the inlet of the first set of rollers and another dispenser is in communication with the inlet of the first welding station.
  • the material dispensers are provided by uncoilers each carrying a coil of sheet material.
  • the sheets are manufactured from high strength steel.
  • Steel provides the desired characteristics for beams to be used in the automotive industry as impact absorbers.
  • the sheets are made from the same steel.
  • the sheets are manufactured from different steels. This allows the manufacturer greater flexibility and allows for the manufacture of beams of different strength characteristics depending on their specified end-use.
  • the sheet material is boron steel.
  • Hardened boron steel has a yield limit of the order of 900-1100 MPa and is a particularly suitable for beams used in the automotive industry.
  • the present invention describes a preferred embodiment utilising steel and in particular high strength boron steel, it will of course be appreciated that other steels or metal alloys providing desired characteristics regarding torsional rigidity and strength could also be used.
  • the sheets of material have the same thickness.
  • the sheets of material have different thicknesses. Again this provides flexibility for the manufacturer and the end user.
  • the sheet material defines pre-punched apertures at predefined locations. Both sheet materials or only one sheet may be pre-punched which results in a reduction of weight to the overall beam structure. Additionally, the pre-punched holes may act as ventilation for the beam during the heat treatment procedures.
  • An apparatus for manufacturing roll formed closed profile beams comprising a first dispenser carrying a roll of sheet material, a first group of rollers for forming the sheet into a predefined profile in communication with both the first dispenser and a first welding station, a second dispenser carrying a second roll of sheet material in communication with a first welding station, wherein the first welding station welds the profile element formed by the first group of rollers onto a predefined location on the sheet fed from the second dispenser, a second group of rollers for receiving the newly welded profile element and sheet from the first welding station and for forming the sheet around the first formed profile element by bringing the longitudinal free edges of the sheet to a meeting point enclosing the first profile element and a second welding station for welding the longitudinal free edges together with a surface of the first profile element to form a closed profile beam having an internal support structure.
  • the present invention also provides a method of manufacturing roll formed profile beams characterised in that the method comprises the steps of roll forming a first profile element followed by roll forming a second profile element enclosing the first profile element and forming a closed profile beam having an internal support structure.
  • the first profile element is formed as an internal support profile.
  • the profile element is substantially U-shaped having a base and a pair of legs extending substantially perpendicularly from the base in the same direction as one another.
  • the legs of the profile element include ribs.
  • the ribs improve the strength of the profile element.
  • the internal support profile element is welded to a second sheet material at a welding station.
  • the second sheet material is subsequently roll formed into a beam enclosing the first profile element.
  • the second profile element is closed around the first profile element by welding the longitudinal ends of the second profile element together with a portion of the first profile element.
  • the first profile element is welded to the second sheet by means of seam welding.
  • the two longitudinal edges of the second profile element are laser welded together with a portion of the second profile element.
  • a method for forming closed profile beams comprising the steps of; dispensing a first sheet from a first dispenser to a first set of rollers, forming the sheet to a predefined profile and feeding the profile element to a first welding station, dispensing a second sheet from a second dispenser to the first welding station, welding the profile element to the second sheet at the first welding station, feeding the newly formed sheet and profile element to a second set of rollers, forming the sheet by bringing the free longitudinal edges of said sheet to a meeting point thereby enclosing the first profile element, feeding the workpiece to a second welding station and welding the longitudinal free edges of the second sheet together with a surface of the first profile element to form a closed profile beam having an internal support structure.
  • Figure 1 is a schematic drawing showing an elevation view of the apparatus
  • Figure 2 is an end view of a first profile element in accordance with the invention.
  • Figure 3 is an end view of a second profile element in accordance with the invention.
  • Figure 4 is a schematic end view of the second roll forming process step by step.
  • a first dispenser 2 contains a coil of sheet material 3 and a first sheet 4 extends from the first dispenser 2 to a first set of forming rollers 5.
  • a second dispenser 6 contains a second coil of sheet material 7 and a second sheet 8 extends from the second dispenser 6 to a first set of support rollers 9.
  • a first welding station 10 is located between the first set of forming rollers 9 and a second set of forming rollers 11.
  • a second welding station 12 is mounted between the second set of forming rollers 11 and a second set of support rollers 13.
  • An induction warming oven containing two separate ovens 14 and 15 is mounted either side of a third set of support rollers 16 and the outlet of the separate oven 15 leads to a quenching station 17.
  • a set of stretching rollers 18 are mounted between the quenching station 17 and a knife 19, which is the final station in the production line apparatus 1.
  • the profile element 21 is substantially U-shaped having a base 23 and a pair of legs 24 extending substantially perpendicularly from the base 23 in the same direction as one another. Each leg 24 terminates with an integrally formed flange 25, the flanges 25 extending in opposite directions to each other and in a plane parallel with the base 23.
  • the second profile element 47 is shown having two parallel sides 51, 52 connected by two sides 53, 54 forming a tubular closed profile element 47.
  • Figure 4 there is shown a step by step view of the roll forming process which occurs between the first welding station 10 and the second welding station 1 (see Figure 1).
  • Two weld joints 31 are shown between the flanges 25 of the profile element 21 and the second sheet 8.
  • a number of stages of the roll forming process from 32, in which the second sheet 8 is in a flat orientation, to 47 in which the second sheet 8 is formed as a second profile element 47 enclosing the profile 21 are shown.
  • a third weld joint 48 is shown between the longitudinal edges 49, 50 of the sheet 8 and the base 23 of the profile element 21.
  • a first sheet 4 extends from a first dispenser 2 to a first set of rollers 5 which form the sheet 4 to a predefined profile.
  • the profile element 21 is fed from the first set of rollers 5 to the first welding station 10.
  • the second sheet of metal 8 is dispensed from the second dispenser 6 to the first welding station 10 via the first set of support rollers 9.
  • the profile element 21 is welded to the second sheet of metal 8 at the first welding station 10.
  • the newly combined profile element 21 and sheet 8 is fed to the second set of rollers 11 which form the sheet 8 by bringing the free longitudinal edges 49, 50 of the second sheet of metal 8 to a meeting point thereby enclosing the first profile element 21.
  • the forming process is completed when the work-piece is fed to a second welding station 12 and the longitudinal free edges 49, 50 of the second sheet 8 are welded together with the base 23 of the first profile element 21 to form a closed profile beam having an internal support structure.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Bending Of Plates, Rods, And Pipes (AREA)
  • Laser Beam Processing (AREA)
  • Body Structure For Vehicles (AREA)
  • Welding Or Cutting Using Electron Beams (AREA)
  • Manufacture Of Motors, Generators (AREA)

Abstract

The present invention concerns an apparatus and method for manufacturing an automotive beam for use as a beam in structural components of automobiles with significant improvements in terms of torsional rigidity and yield strength. The beam improves the overall safety of passengers and maintains the simplicity of the manufacturing process. The apparatus (1) for manufacturing roll formed profile beams comprises a plurality of material dispensers (2,6), a first set of rollers (5), a second set of rollers (11), a first welding station (10) mounted between the two sets of rollers (5, 11) and a second welding station (12) at the outlet of the second set of rollers (11). The method of manufacturing roll formed profile beams comprises the steps of roll forming a first profile element followed by roll forming a second profile element enclosing the first profile element and forming a closed profile beam having an internal support structure.

Description

APPARATUS AND METHOD FOR MANUFACTURING AN AUTOMOTIVE BEAM.
The present invention relates to an apparatus and method for manufacturing an automotive beam and in particular to an apparatus and method for roll forming a closed profile beam.
Beams used on the body structure of an automobile and beams mounted at the front and rear of automobiles are required to absorb impact from collisions with other vehicles and with other objects. Beams manufactured for these purposes need to have a high resistance to torsion and good strength characteristics in order to prevent local buckling of the beam. A number of prior art patent and patent application specifications have disclosed beams for use in the automotive industry and apparatuses and methods for manufacturing such beams.
US Patent No. 5,934,544 provides an apparatus and method for manufacturing automotive bumper beams by a single roll forming process. The apparatus includes an uncoiler, a straightner, a group of roll formers, a sweep roll former, a welding member and a cutting member. The method of manufacturing the bumper beam includes preparing the sheet metal, forming the cross sectional profile, forming a sweep, adjusting the tubular cross sectional shape of the sheet metal and welding the sheet metal prior to cutting the beam into desired lengths. The objects of the invention are to provide a beam with strengthened impact resistance, reduced weight and to simplify the manufacturing processes of the prior art.
International Patent Application No. PCT/SE97/00305 discloses a vehicle body comprising a beam structure consisting of thin- walled flange-free profile parts with closed cross sections made by means of roll forming. The component parts of the beam structure are hardened so that the boron steel or other high tensile steel has a yield limit of the order of 900-1100 MPa. The object of the invention is to produce a new and lighter type of vehicle body with an increased body strength and stiffness.
In order to maintain an efficient manufacturing process for beams it is important to use a production line technique manufacturing beams in a relatively small number of steps while maintaining their structural integrity and safety characteristics. The safety and structural integrity aspects are particularly important when the beams are manufactured for use as protective members in an automobile. Although the techniques disclosed in the above referenced specifications maintain an efficient manufacturing process and address the issues of improved strength characteristics and weight of the beam, significant improvements could still be made regarding the safety aspects of beams for use in automobiles which would inevitably result in improvements to human safety.
It is an object of the present invention to provide a beam for use in structural components of automobiles with significant improvements in terms of torsional rigidity and yield strength to improve the overall safety of passengers travelling in such automobiles in addition to maintaining the simplicity of the manufacturing process.
The present invention provides an apparatus for manufacturing roll formed profile beams characterised in that the apparatus comprises a plurality of material dispensers, a first set of rollers and a second set of rollers and a first welding station mounted between and being in communication with the two sets of rollers and a second welding station in communication with the outlet of the second set of rollers, wherein one dispenser is in communication with the inlet of the first set of rollers and another dispenser is in communication with the inlet of the first welding station.
Preferably, the material dispensers are provided by uncoilers each carrying a coil of sheet material.
Ideally, the sheets are manufactured from high strength steel. Steel provides the desired characteristics for beams to be used in the automotive industry as impact absorbers.
In one embodiment, the sheets are made from the same steel.
In another embodiment, the sheets are manufactured from different steels. This allows the manufacturer greater flexibility and allows for the manufacture of beams of different strength characteristics depending on their specified end-use.
In a particularly preferred embodiment, the sheet material is boron steel. Hardened boron steel has a yield limit of the order of 900-1100 MPa and is a particularly suitable for beams used in the automotive industry. Although the present invention describes a preferred embodiment utilising steel and in particular high strength boron steel, it will of course be appreciated that other steels or metal alloys providing desired characteristics regarding torsional rigidity and strength could also be used.
In one embodiment, the sheets of material have the same thickness.
In another embodiment, the sheets of material have different thicknesses. Again this provides flexibility for the manufacturer and the end user.
In a further aspect of the invention, the sheet material defines pre-punched apertures at predefined locations. Both sheet materials or only one sheet may be pre-punched which results in a reduction of weight to the overall beam structure. Additionally, the pre-punched holes may act as ventilation for the beam during the heat treatment procedures.
An apparatus for manufacturing roll formed closed profile beams comprising a first dispenser carrying a roll of sheet material, a first group of rollers for forming the sheet into a predefined profile in communication with both the first dispenser and a first welding station, a second dispenser carrying a second roll of sheet material in communication with a first welding station, wherein the first welding station welds the profile element formed by the first group of rollers onto a predefined location on the sheet fed from the second dispenser, a second group of rollers for receiving the newly welded profile element and sheet from the first welding station and for forming the sheet around the first formed profile element by bringing the longitudinal free edges of the sheet to a meeting point enclosing the first profile element and a second welding station for welding the longitudinal free edges together with a surface of the first profile element to form a closed profile beam having an internal support structure.
The present invention also provides a method of manufacturing roll formed profile beams characterised in that the method comprises the steps of roll forming a first profile element followed by roll forming a second profile element enclosing the first profile element and forming a closed profile beam having an internal support structure.
Ideally, the first profile element is formed as an internal support profile. In one embodiment, the profile element is substantially U-shaped having a base and a pair of legs extending substantially perpendicularly from the base in the same direction as one another.
In a further embodiment, the legs of the profile element include ribs. The ribs improve the strength of the profile element.
Ideally, the internal support profile element is welded to a second sheet material at a welding station.
Preferably, the second sheet material is subsequently roll formed into a beam enclosing the first profile element.
Ideally, the second profile element is closed around the first profile element by welding the longitudinal ends of the second profile element together with a portion of the first profile element.
Ideally, the first profile element is welded to the second sheet by means of seam welding.
Preferably, the two longitudinal edges of the second profile element are laser welded together with a portion of the second profile element.
A method for forming closed profile beams comprising the steps of; dispensing a first sheet from a first dispenser to a first set of rollers, forming the sheet to a predefined profile and feeding the profile element to a first welding station, dispensing a second sheet from a second dispenser to the first welding station, welding the profile element to the second sheet at the first welding station, feeding the newly formed sheet and profile element to a second set of rollers, forming the sheet by bringing the free longitudinal edges of said sheet to a meeting point thereby enclosing the first profile element, feeding the workpiece to a second welding station and welding the longitudinal free edges of the second sheet together with a surface of the first profile element to form a closed profile beam having an internal support structure. The invention will now be described with reference to the accompanying drawings, which show, by way of example only, one embodiment of an apparatus and method for manufacturing an automotive beam in accordance with the invention. In the drawings:-
Figure 1 is a schematic drawing showing an elevation view of the apparatus;
Figure 2 is an end view of a first profile element in accordance with the invention;
Figure 3 is an end view of a second profile element in accordance with the invention; and
Figure 4 is a schematic end view of the second roll forming process step by step.
Referring to the drawings and initially to Figure 1 there is shown an apparatus for manufacturing automotive beams indicated generally by the reference numeral 1. A first dispenser 2 contains a coil of sheet material 3 and a first sheet 4 extends from the first dispenser 2 to a first set of forming rollers 5. A second dispenser 6 contains a second coil of sheet material 7 and a second sheet 8 extends from the second dispenser 6 to a first set of support rollers 9. A first welding station 10 is located between the first set of forming rollers 9 and a second set of forming rollers 11. A second welding station 12 is mounted between the second set of forming rollers 11 and a second set of support rollers 13. An induction warming oven containing two separate ovens 14 and 15 is mounted either side of a third set of support rollers 16 and the outlet of the separate oven 15 leads to a quenching station 17. A set of stretching rollers 18 are mounted between the quenching station 17 and a knife 19, which is the final station in the production line apparatus 1.
Referring to Figure 2 there is shown a first profile element indicated generally by the reference numeral 21. The profile element 21 is substantially U-shaped having a base 23 and a pair of legs 24 extending substantially perpendicularly from the base 23 in the same direction as one another. Each leg 24 terminates with an integrally formed flange 25, the flanges 25 extending in opposite directions to each other and in a plane parallel with the base 23.
Referring to Figure 3, the second profile element 47 is shown having two parallel sides 51, 52 connected by two sides 53, 54 forming a tubular closed profile element 47. In Figure 4, there is shown a step by step view of the roll forming process which occurs between the first welding station 10 and the second welding station 1 (see Figure 1). Two weld joints 31 are shown between the flanges 25 of the profile element 21 and the second sheet 8. A number of stages of the roll forming process from 32, in which the second sheet 8 is in a flat orientation, to 47 in which the second sheet 8 is formed as a second profile element 47 enclosing the profile 21 are shown. A third weld joint 48 is shown between the longitudinal edges 49, 50 of the sheet 8 and the base 23 of the profile element 21.
In use, a first sheet 4 extends from a first dispenser 2 to a first set of rollers 5 which form the sheet 4 to a predefined profile. The profile element 21 is fed from the first set of rollers 5 to the first welding station 10. The second sheet of metal 8 is dispensed from the second dispenser 6 to the first welding station 10 via the first set of support rollers 9. The profile element 21 is welded to the second sheet of metal 8 at the first welding station 10. The newly combined profile element 21 and sheet 8 is fed to the second set of rollers 11 which form the sheet 8 by bringing the free longitudinal edges 49, 50 of the second sheet of metal 8 to a meeting point thereby enclosing the first profile element 21. The forming process is completed when the work-piece is fed to a second welding station 12 and the longitudinal free edges 49, 50 of the second sheet 8 are welded together with the base 23 of the first profile element 21 to form a closed profile beam having an internal support structure.
It will of course be understood that the invention is not limited to the specific details as herein described, which are given by way of example only, and that various alterations and modifications may be made without departing from the scope of the invention as defined in the appended claims.

Claims

1. An apparatus (1) for manufacturing roll formed profile beams characterised in that the apparatus comprises a plurality of material dispensers (2, 6), a first set of rollers (5) and a second set of rollers (11) and a first welding station (10) mounted between and being in communication with the two sets of rollers (5, 11) and a second welding station (12) in communication with the outlet of the second set of rollers (11), wherein one dispenser is in communication with the inlet of the first set of rollers (5) and another dispenser is in communication with the inlet of the second welding station (12).
2. An apparatus as claimed in claim 1 , wherein the material dispensers (2, 6) are provided by uncoilers each carrying a coil of sheet material (3, 7).
3. An apparatus as claimed in claim 2, wherein the sheets (3, 7) are manufactured from high strength steel.
4. An apparatus as claimed in claim 3, wherein the sheets (3, 7) are made from the same steel.
5. An apparatus as claimed in claim 3 , wherein the sheets (3, 7) are manufactured from different steels.
6. An apparatus as claimed in any of claims 3 to 5, wherein the steel is boron steel.
7. An apparatus as claimed in any of claims 2 to 6, wherein the sheets (3, 7) have the same thickness.
8. An apparatus as claimed in any of claims 2 to 6, wherein the sheets (3, 7) have different thicknesses.
9. An apparatus as claimed in any of claims 2 to 8, wherein both of the sheet materials define pre-punched apertures at predefined locations.
10. An apparatus as claimed in claim 9, wherein only one sheet defines pre-punched apertures.
11. A method of manufacturing roll formed profile beams characterised in that the method comprises the steps of roll forming a first profile element (21) followed by roll forming a second profile element (47) which encloses the first profile element (21) to form a closed profile beam.
12. A method as claimed in claim 11, wherein the first profile element (21) is formed as an internal support profile.
13. A method as claimed in any of claims 11 to 12, wherein the first profile element (21) is substantially U-shaped.
14. A method as claimed in claim 13, wherein legs (24) of the U-shaped profile element
(21) include ribs.
15. A method as claimed in any of claims 11 to 14, wherein the profile (21) is welded to a second sheet (8) at a welding station (10).
16. A method as claimed in claim 15, wherein the second sheet (8) is subsequently roll formed into a beam (47) enclosing the first profile element (21).
17. A method as claimed in any of claims 12 to 16, wherein longitudinal edges (49, 50) of the second profile element (47) are welded together with a portion of the first profile element (21) thereby enclosing the first profile element (21 within the second profile element (47).
18. A method as claimed in any of claims 15 to 17, wherein the first profile element (21) is welded to the second sheet (8) by means of seam welding.
19. A method as claimed in claim 17, wherein the two longitudinal edges (49, 50) of the second profile element (47) are laser welded together with a portion of the first profile element (21).
PCT/SE2002/001055 2001-06-21 2002-06-03 Apparatus and method for manufacturing an automotive beam WO2003000440A1 (en)

Priority Applications (5)

Application Number Priority Date Filing Date Title
DE60236434T DE60236434D1 (en) 2001-06-21 2002-06-03 DEVICE AND METHOD FOR MANUFACTURING A MOTOR VEHICLE
EP02739014A EP1397218B1 (en) 2001-06-21 2002-06-03 Apparatus and method for manufacturing an automotive beam
JP2003506671A JP4119362B2 (en) 2001-06-21 2002-06-03 Method and apparatus for manufacturing automotive beams
US10/481,317 US7073259B2 (en) 2001-06-21 2002-06-03 Apparatus and method for manufacturing an automotive beam
AT02739014T ATE468183T1 (en) 2001-06-21 2002-06-03 DEVICE AND METHOD FOR PRODUCING A MOTOR VEHICLE HOLDER

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
SE0102240-9 2001-06-21
SE0102240A SE520880C2 (en) 2001-06-21 2001-06-21 Device and method of manufacture of vehicle beams

Publications (1)

Publication Number Publication Date
WO2003000440A1 true WO2003000440A1 (en) 2003-01-03

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PCT/SE2002/001055 WO2003000440A1 (en) 2001-06-21 2002-06-03 Apparatus and method for manufacturing an automotive beam

Country Status (7)

Country Link
US (1) US7073259B2 (en)
EP (1) EP1397218B1 (en)
JP (1) JP4119362B2 (en)
AT (1) ATE468183T1 (en)
DE (1) DE60236434D1 (en)
SE (1) SE520880C2 (en)
WO (1) WO2003000440A1 (en)

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Cited By (10)

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Publication number Priority date Publication date Assignee Title
DE102004016524A1 (en) * 2004-03-31 2005-10-20 Daimler Chrysler Ag Apparatus and method for the production of rolled profiles
DE102005046843B3 (en) * 2005-09-29 2007-04-05 Daimlerchrysler Ag Device for manufacturing an installation-ready component has rolling path to reshape flat blank into rolled profile with a connecting station mounted where subsequently inaccessible area of profile is still accessible for modification
WO2008129654A1 (en) * 2007-04-10 2008-10-30 Honda Motor Co., Ltd. Bumper beam for automobile vehicle
WO2010144517A2 (en) 2009-06-09 2010-12-16 Shiloh Industries, Inc. Apparatus, system and method for manufacturing metal parts
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CN102430581A (en) * 2011-12-21 2012-05-02 中国重型机械研究院有限公司 Deviation-rectification-free uncoiling device and method of cold continuous rolling unit
CN108637049A (en) * 2018-04-28 2018-10-12 宋君能 A kind of mold of processing exhaust pipe
CN108637049B (en) * 2018-04-28 2019-09-17 宋君能 A kind of mold for processing exhaust pipe

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DE60236434D1 (en) 2010-07-01
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SE520880C2 (en) 2003-09-09
EP1397218B1 (en) 2010-05-19
SE0102240D0 (en) 2001-06-21
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US7073259B2 (en) 2006-07-11
US20040154158A1 (en) 2004-08-12

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