U.S. patent application number 11/654859 was filed with the patent office on 2007-07-19 for metal frame and method for manufacturing the same.
This patent application is currently assigned to Shiloh Industries, Inc.. Invention is credited to Jonathan W. Fisk, James F. Keys, Mark A. Schimming.
Application Number | 20070163121 11/654859 |
Document ID | / |
Family ID | 38261762 |
Filed Date | 2007-07-19 |
United States Patent
Application |
20070163121 |
Kind Code |
A1 |
Keys; James F. ; et
al. |
July 19, 2007 |
Metal frame and method for manufacturing the same
Abstract
A method for manufacturing a metal frame, such as a tractor cab
frame, that can reduce scrap material, simplify the manufacturing
process, improve the structural integrity of the frame, and
eliminate the use of overlapping joint areas. According to one
embodiment, the manufacturing method includes the steps of:
blanking a number of individual metal segments, joining the
individual metal segments together to form a welded blank assembly,
stamping the welded blank assembly to form a stamping assembly that
includes the desired perimeter, and forming the stamping assembly
by bending the stamping assembly into the final shape of the
three-dimensional metal frame. The resultant metal frame preferably
includes at least one metal segment that is shared between adjacent
sides of the structure and is bent along its length to form a
smooth transitioning corner lacking overlapping joint areas.
Inventors: |
Keys; James F.; (Northville,
MI) ; Schimming; Mark A.; (Saline, MI) ; Fisk;
Jonathan W.; (Canton, MI) |
Correspondence
Address: |
REISING, ETHINGTON, BARNES, KISSELLE, P.C.
P O BOX 4390
TROY
MI
48099-4390
US
|
Assignee: |
Shiloh Industries, Inc.
Cleveland
OH
|
Family ID: |
38261762 |
Appl. No.: |
11/654859 |
Filed: |
January 18, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60760273 |
Jan 19, 2006 |
|
|
|
Current U.S.
Class: |
29/897.2 ;
29/505 |
Current CPC
Class: |
Y10T 29/49622 20150115;
B21D 35/00 20130101; B62D 33/06 20130101; B21D 53/88 20130101; B23K
2101/185 20180801; Y10T 29/49908 20150115; B62D 33/0617 20130101;
B23K 26/26 20130101 |
Class at
Publication: |
29/897.2 ;
29/505 |
International
Class: |
B21D 53/88 20060101
B21D053/88 |
Claims
1. A method for manufacturing a metal frame having at least first
and: second sides, comprising the steps of: (a) producing a
plurality of individual metal segments; (b) welding the plurality
of individual metal segments together to form a welded blank
assembly; (c) stamping the welded blank assembly to form a stamping
assembly; and (d) forming the stamping assembly into the metal
frame by bending the first and second sides so that they are
aligned relative to one another.
2. The method of claim 1, wherein step (a) further comprises
producing the plurality of individual metal segments by blanking
them generally in the form of simple shapes so that they can be
tightly arranged on a piece of sheet metal stock to minimize the
amount of scrap material.
3. The method of claim 1, wherein step (a) further comprises
producing the plurality of individual metal segments from pieces of
sheet metal stock of varying thickness so that weight bearing
segments of the metal frame can be made from thicker sheet metal
than non-weight bearing segments.
4. The method of claim 1, wherein step (b) further comprises
welding the plurality of individual metal segments together so that
at least one of the plurality of individual metal segments is
shared by both the first and second sides of the metal frame.
5. The method of claim 4, wherein the at least one shared metal
segment is a vertical pillar that is shared by a center windshield
panel and a side window panel.
6. The method of claim 1, wherein step (b) further comprises
welding the plurality of individual metal segments together in an
edge-to-edge arrangement to form a single welded blank assembly
that lacks overlapping joint areas between individual metal
segments.
7. The method of claim 1, wherein step (c) further comprises
stamping the welded blank assembly to form a generally flat
stamping assembly with a different perimeter and three-dimensional
shape than the welded blank assembly.
8. The method of claim 1, wherein step (d) further comprises
forming the stamping assembly into the metal frame by bending the
first and second sides so that they are generally
perpendicularly-aligned relative to one another.
9. The method of claim 1, wherein step (d) further comprises
forming the stamping assembly into the metal frame by bending the
first and second sides of the metal frame so that they are joined
by a shared metal segment that is bent along its length to form a
corner having a smooth transition.
10. The method of claim 9, wherein the first and second sides of
the metal frame include a center windshield panel and a side window
panel, and the shared metal segment is a vertical pillar.
11. The method of claim 1, wherein the metal frame is part of a
tractor cab frame, and first and second sides of the metal frame
include a center windshield panel and a side window panel.
12. A method for manufacturing a metal frame having at least first
and second sides, comprising the steps of: (a) blanking a plurality
of individual metal segments generally in the form of simple shapes
so that they can be tightly arranged on a piece of sheet metal
stock to minimize the amount of scrap material produced; (b)
welding the plurality of individual metal segments to form a welded
blank assembly, wherein the welded blank assembly includes segments
of the first side and segments of the second side joined together
in an edge-to-edge arrangement that lacks overlapping joint areas;
(c) stamping the welded blank assembly to form a stamping assembly
that has a different perimeter than the welded blank assembly; and
(d) forming the stamping assembly into the metal frame by bending
the stamping assembly so that the first and second sides are joined
by a shared metal segment that is bent along its length to form a
corner having a smooth transition.
13. The method of claim 12, wherein step (a) further comprises
blanking the plurality of individual metal segments from pieces of
sheet metal stock of varying thickness so that weight bearing
segments of the metal frame can be made from thicker sheet metal
than non-weight bearing segments.
14. The method of claim 12, wherein the metal frame is part of a
tractor cab frame, first and second sides of the metal frame
include a center windshield panel and a side window panel, and the
shared metal segment is a vertical pillar.
15. A metal frame for use with a piece of movable equipment,
comprising: a first side window panel having a first plurality of
blanked metal segments that are welded together; a second side
window panel having a second plurality of blanked metal segments
that are welded together; and a center windshield panel having a
third plurality of blanked metal segments that are welded together,
wherein the first side window panel and center windshield panel
share a first elongated vertical pillar that is bent along its
length to form a first corner that extends between the first side
window panel and center windshield panel in a smooth transition,
and the second side window panel and center windshield panel share
a second elongated vertical pillar that is bent along its length to
form a second corner that extends between the second side window
panel and center windshield panel in a smooth transition.
Description
REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Ser.
No. 60/760,273 filed on Jan. 19, 2006, the entire contents of which
are incorporated herein.
FIELD OF INVENTION
[0002] The present invention generally relates to a method for
manufacturing a metal frame, and more particularly, to a
manufacturing method that utilizes a combination of blanking,
welding, stamping and forming steps to improve the process and the
structure produced thereby.
BACKGROUND OF THE INVENTION
[0003] A number of different manufacturing processes have been
developed over the years that produce various types of metal
structures, such as frames and other structural components
oftentimes found in vehicles, agricultural machinery, construction
machinery, lawn and garden equipment, etc.
[0004] With reference to FIGS. 1A-B, there is shown a diagrammatic
illustration of one example of a prior art method for manufacturing
part of a tractor cab frame 8 that generally includes a front
windshield panel 10 and a pair of side window panels 12 and 14.
According to this particular method, each of the panels is first
blanked from a sheet metal piece, which results in the basic
rectangular panels or frames 10-14 and interior scrap pieces or
offal 20-24 shown in FIG. 1A. After the blanked panels 10-14 have
been formed, they are loaded into a stamping press and are
individually stamped into a predetermined shape. Finally, the three
blanked and stamped panels are brought together and joined by some
combination of spot welds, seam welds, adhesives, rivets, etc. so
that they form part of a finished, three-dimensional tractor cab
frame 8. Although this type of method has been extensively used in
the industry, there are certain drawbacks. For example, the
above-described method produces both excess scrap material and
joint overlap areas. An example of a joint overlap area 26 is shown
in FIG. 1B, and includes an edge of front windshield panel 10 that
is bent behind an overlapping edge of side window panel 14.
Stamping or forming panels 10-14 before joining them together can
result in greater tolerance discrepancies and increased gaps
between the panels. Thus, it is sometimes necessary to seal overlap
area 26 to prevent leaks or to fill it in order to provide a
smooth, flush surface before the frame can be painted.
[0005] Turning now to FIGS. 2A-B, there is shown a diagrammatic
illustration of another known method for forming part of a tractor
cab frame 28 that includes a front windshield panel 30 and side
window panels 32 and 34. Instead of being stamped from a single
piece of sheet metal as with the previous method, each of the
panels 30-34 is comprised of four individual rectangular segments
or legs making up a different side of the panel. Because of the
similarity between panels 30-34, the following description of front
windshield panel 30 applies equally to side window panels 32 and
34. According to this method, four individual segments 40-46 are
first blanked from a sheet metal piece. Next, segments 40-46 are
laser welded, mash-seam welded or otherwise joined to one another
so that the rectangular-shaped panel 30 of FIG. 2A is formed. At
this point, the three separate rectangular panels 30-34, each of
which includes four welded segments, are stamped into their
required shape. Finally, the three blanked, welded and stamped
panels 30-34 are brought together and attached to one another by
one or more of the joining processes mentioned above. This results
in part of a finished, three-dimensional tractor cab frame 28.
Although this process reduces the excess scrap center material
produced by the previous process, it still produces several joint
overlap areas 48, as explained above.
SUMMARY OF THE INVENTION
[0006] According to one embodiment, there is provided a method for
manufacturing a metal frame having at least first and second sides.
The method generally comprises the steps of: (a) producing a
plurality of individual metal segments; (b) welding the plurality
of individual metal segments together to form a welded blank
assembly; (c) stamping the welded blank assembly to form a stamping
assembly; and (d) forming the stamping assembly into the metal
frame by bending the first and second sides so that they are
aligned relative to one another.
[0007] According to another embodiment, there is provided a method
for manufacturing a metal frame having at least first and second
sides. The method generally comprises the steps of: (a) blanking a
plurality of individual metal segments generally in the form of
simple shapes so that they can be tightly arranged on a piece of
sheet metal stock; (b) welding the plurality of individual metal
segments to form a welded blank assembly, wherein the welded blank
assembly includes segments of the first side and segments of the
second side joined together in an edge-to-edge arrangement that
lacks overlapping joint areas; (c) stamping the welded blank
assembly to form a stamping assembly that has a different perimeter
than the welded blank assembly; and (d) forming the stamping
assembly into the metal frame by bending the stamping assembly so
that the first and second sides are joined by a shared metal
segment that is bent along its length to form a corner having a
smooth transition.
[0008] According to another embodiment, there is provided a metal
frame for use with a piece of movable equipment. The metal frame
generally comprises: a first side window panel having a first
plurality of blanked metal segments welded together; a second side
window panel having a second plurality of blanked metal segments
welded together; and a center windshield panel having a third
plurality of blanked metal segments welded together. The first side
window panel and center windshield panel share a first elongated
vertical pillar that is bent along its length to form a first
corner, and the second side window panel and center windshield
panel share a second elongated vertical pillar that is bent along
its length to form a second corner.
DESCRIPTION OF THE DRAWINGS
[0009] A preferred exemplary embodiment of the invention will
hereinafter be described in conjunction with the appended drawings,
wherein like designations denote like elements, and wherein:
[0010] FIGS. 1A-2B are diagrammatic illustrations of known methods
for forming three-dimensional metal structures;
[0011] FIG. 3 is an example of part of a tractor cab frame formed
by an embodiment of the present method;
[0012] FIG. 4 is a welded blank assembly of the part of the tractor
cab frame of FIG. 3, following blanking and welding steps of the
present method; and
[0013] FIG. 5 is a stamping assembly of the part of the tractor cab
frame of FIG. 3 following blanking, welding and stamping steps of
the present method.
DESCRIPTION OF A PREFERRED EMBODIMENT
[0014] The following description is directed to an improved method
for manufacturing a metal frame, such as a frame or other
structural component found on a vehicle or piece of agricultural
equipment. This method generally reduces the production of scrap
material or offal, decreases the number of manufacturing steps, and
eliminates the use of certain overlapping joint areas, to name but
a few of its attributes. With reference to FIG. 3, there is shown
an example of a three-dimensional metal frame 50, in this case part
of a tractor cab frame, that can be produced by the present method
and generally includes a front windshield panel 52 and side window
panels 54, 56. It should be appreciated, however, that the present
method can be used to generate one of a number of different
three-dimensional metal structures and is not limited to the
particular tractor cab frame 50 shown here. For instance, the
present method could be used to manufacture certain body
components, chassis parts, frames and other structural components
for automobiles, trucks, recreation vehicles (RVs), agricultural
machinery, construction machinery, and lawn and garden equipment,
to name but a few possibilities.
[0015] According to a first step of the present method, a number of
individual metal segments 60-78 are first blanked from one or more
pieces of sheet metal stock. The sheet metal stock can be provided
in the form of coils, flat panels, or any other suitable form known
in the art, and is preferably made of steel, aluminum, or alloys
thereof. Of course, segments 60-78 can all have a uniform thickness
or they can be formed from sheet metal stock of varying
thicknesses, depending on the structural requirements of the
different segments. For example, if one of the metal segments is a
vertical pillar that when assembled carries the weight of a door,
it may be desirable to use thicker sheet metal than is used on
other non-weight bearing segments (sometimes referred to as a
tailor-welded blank). Each of the segments 60-78 shown in FIG. 4 is
in the form of a simple geometric shape, which can include
rectangles, trapezoids, and other polygons lacking complex curves.
By first blanking the segments in a simple shape, as opposed to
initially forming them in the more complex shape that the segments
will ultimately assume, it allows the segments to be nested or
tightly arranged on the sheet metal such that a single blanking
operation creates multiple segments and minimizes the amount of
scrap material or offal produced thereby. Furthermore, the simple
shape configuration of segments 60-78 simplifies the subsequent
joining process, as all of the abutting segments are aligned at 90
angles to one another. It should be recognized that while
rectangular segments are shown in this exemplary embodiment, other
non-rectangular segments like trapezoids and other polygons can
also be used. Also, alternative methods, other than blanking, could
be used for making the individual metal segments; examples of these
other methods include, but are not limited to, laser cutting,
water-jet cutting, roll-forming and extruding.
[0016] Once the blanking step is completed, segments 60-78 are laid
out in the desired arrangement and are joined together via laser
welding, mash seam welding, butt welding or any other appropriate
welding or joining technique known in the art. This results in the
generally planar, unitary welded blank assembly 80 shown in FIG. 4,
which includes segments not only for a front windshield panel, but
also segments for both side window panels. In the prior art methods
previously described, each of the different sides of the tractor
cab frame were produced separately and were then assembled together
at the end of the process. Conversely, the present method assembles
multiple sides of the tractor cab together in the form of a single
welded blank assembly 80, and then performs the necessary stamping
and forming operations. In addition to improvements in the
efficiency of the process, welded blank assembly 80 also reduces
material costs by sharing certain segments between the different
panels. For instance, segment 66 is a vertical pillar that is
shared between the center windshield panel and the side window
panel on the left, and segment 72 is a vertical pillar shared by
the center windshield panel and the side window panel on the right.
Furthermore, the welded blank assembly 80 lacks overlapping joint
areas between metal segments because the various metal segments are
joined together in an edge-to-edge arrangement. Although this
particular embodiment only shows welded joints aligned in a
vertical orientation, it is possible to have horizontal, angular,
curved, and other non-vertical weld joints as well.
[0017] Next, welded blank assembly 80 is loaded into a stamping
press and is stamped to provide it with a different perimeter and
three-dimensional shape, which results in a stamping assembly 88.
With reference to FIG. 5, there is shown the original perimeter 90
of welded blank assembly 80 before the stamping operation, and a
new, more complex perimeter 92 of stamping assembly 88 after it is
stamped. Of course, welded blank assembly 80 is preferably designed
so that the amount of excess material trimmed off during the
stamping operation is kept to a minimum; that is, the amount of
material between perimeters 90 and 92. In addition to forming a new
perimeter, the stamping operation provides stamping assembly 88
with all of the contours, creases, valleys, edges or other
three-dimensional features needed for the final structure. Thus,
while stamping assembly 88 may be generally flat, it preferably
contains the three-dimensional aspects previously cited. The amount
of three-dimensionality primarily depends on the particular
application in which it is used.
[0018] Lastly, stamping assembly 88 is loaded into a metal forming
machine so that it can be formed into the three-dimensional tractor
cab frame 50 shown in FIG. 3. As previously indicated, stamping
assembly 88 already includes all of the segments for front
windshield panel 52 and side window panels 54 and 56, however, they
are all part of a single, generally flat stamping assembly. Thus,
the present metal forming step simply bends the stamping assembly
into the three-sided configuration shown in FIG. 3. In this
particular case, two 90.degree. bends are needed for tractor cab
frame 50 to have three generally perpendicularly-aligned sides.
However, the present method could alternatively be used to form
structures having more or less than three sides (two-sided frames,
four-sided frames, etc.), form non-90.degree. angles such as acute
or obtuse angles, and form the frame by bending it along
horizontal, angular, and other non-vertical junctions. As
demonstrated by the blowup section of FIG. 3, the tractor cab frame
preferably lacks overlapping joints such as those discussed in
connection with the prior art. The smooth, flush transition 96 that
extends around the corner between center windshield panel 52 and
the side window panel 56 is generally the result of segment 72
(FIG. 4) being creased or bent along its length, as opposed to two
separate panels being joined together via an overlapping seam. This
type of junction between sides of the tractor cab frame can improve
structural integrity and manufacturing flexibility, as the bend can
be provided with a sharp edge, a radiused edge or any other
appropriate configuration. Moreover, the welded junctions between
the various segments 60-78 are flush, non-overlapping joints, which
tends to cut down on the weight and amount of material and provides
a smooth surface from segment to segment, to name but a few
qualities. Examples of suitable metal forming equipment include
brake and press-brake machines, although other types of equipment
could be used as well.
[0019] It is to be understood that the foregoing description is not
a definition of the invention, but is a description of one or more
preferred exemplary embodiments of the invention. The invention is
not limited to the particular embodiment(s) disclosed herein, but
rather is defined solely by the claims below. Furthermore, the
statements contained in the foregoing description relate to
particular embodiments and are not to be construed as limitations
on the scope of the invention or on the definition of terms used in
the claims, except where a term or phrase is expressly defined
above. Various other embodiments and various changes and
modifications to the disclosed embodiment(s) will become apparent
to those skilled in the art. All such other embodiments, changes,
and modifications are intended to come within the scope of the
appended claims.
[0020] As used in this specification and claims, the terms "for
example," "for instance," "like," and "such as," and the verbs
"comprising," "having," "including," and their other verb forms,
when used in conjunction with a listing of one or more components
or other items, are each to be construed as open-ended, meaning
that that the listing is not to be considered as excluding other,
additional components or items. Other terms are to be construed
using their broadest reasonable meaning unless they are used in a
context that requires a different interpretation.
* * * * *