U.S. patent application number 15/420314 was filed with the patent office on 2018-08-02 for method for production of sheet metal components.
This patent application is currently assigned to FORD MOTOR COMPANY. The applicant listed for this patent is FORD MOTOR COMPANY. Invention is credited to Peter A. Friedman, Shawn Michael Morgans, Raj Sohmshetty, Richard Taube.
Application Number | 20180214927 15/420314 |
Document ID | / |
Family ID | 62843495 |
Filed Date | 2018-08-02 |
United States Patent
Application |
20180214927 |
Kind Code |
A1 |
Sohmshetty; Raj ; et
al. |
August 2, 2018 |
METHOD FOR PRODUCTION OF SHEET METAL COMPONENTS
Abstract
A process includes producing a group of automotive components by
forming components having various global geometries via a common
tooling configured to bend a blank sheet of metal to create a
variable cross section profile, forming an addendum as an integral
portion of each formed component, and altering the global
geometries in a series of incremental deformations to create local
geometries while each component is affixed to a deforming machine
via the addendum.
Inventors: |
Sohmshetty; Raj; (Canton,
MI) ; Taube; Richard; (Wallan, AU) ; Friedman;
Peter A.; (Ann Arbor, MI) ; Morgans; Shawn
Michael; (Chelsea, MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
FORD MOTOR COMPANY |
Dearborn |
MI |
US |
|
|
Assignee: |
FORD MOTOR COMPANY
Dearborn
MI
|
Family ID: |
62843495 |
Appl. No.: |
15/420314 |
Filed: |
January 31, 2017 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B21D 47/01 20130101;
B21D 22/02 20130101; B21D 47/00 20130101; B21D 31/005 20130101;
B21D 53/88 20130101; B21D 5/083 20130101; B21D 5/06 20130101 |
International
Class: |
B21D 53/88 20060101
B21D053/88; B21D 22/02 20060101 B21D022/02; B21D 47/00 20060101
B21D047/00 |
Claims
1. A process comprising: producing a group of automotive components
by forming components having various global geometries via a common
tooling configured to bend a blank sheet of metal to create a
variable cross section profile; forming an addendum as an integral
portion of each formed component; and altering the global
geometries in a series of incremental deformations to create local
geometries while each component is affixed to a deforming machine
via the addendum.
2. The process of claim 1, wherein the group of automotive
components comprises one component type designated for different
vehicle types.
3. The process of claim 2, wherein the one component type comprises
an underbody member, a roof cross member, a rail, or a rocket
member.
4. The process of claim 1, wherein the group of automotive
components comprises different component types designated for one
vehicle type.
5. The process of claim 1, wherein the component has a longitudinal
profile.
6. The process of claim 1, wherein the variable cross section
profile comprises a variable height cross section.
7. The process of claim 1, wherein the addendum extends beyond the
global geometry of the component.
8. The process of claim 1, wherein the addendum has a shape
universal for each component of the group of the components.
9. The process of claim 1, wherein the addendum is removed after
formation of the local geometries.
10. The process of claim 1, wherein the global geometries and the
local geometries are created separately via different tooling.
11. A method comprising: producing a group of various automotive
longitudinal components by utilizing a common tool to form a
variable cross section profile by bending a sheet metal for each
component of the group in a first process; connecting each deformed
metal sheet to a removable section; and further altering the
profile of the deformed metal sheet in a series of incremental
deformations in a second process to create the longitudinal
component while the sheet metal is attached to a deforming machine
via the removable section.
12. The method of claim 11, wherein the first and second processes
are performed by different machines and tooling.
13. The method of claim 11, wherein the bending forms depressions
in a vertical surface of the sheet metal.
14. The method of claim 11, wherein the incremental deformations
include bending a horizontal surface of the sheet metal.
15. The method of claim 11, wherein the removable section is laser
trimmed after the second process.
16. The method of claim 11, wherein the first process utilizes
flexible roll forming and the second process utilizes incremental
forming.
17. A process of forming automotive sheet metal components, the
process comprising: creating a global geometry of a first
longitudinal sheet metal component by forming a variable cross
section profile in a blank sheet of metal; altering the global
geometry of the first component in a series of incremental
deformations to create local geometries; and creating global and
local geometries of a second component by utilizing tooling which
formed the first component, wherein the first and second components
differ.
18. The process of claim 17, wherein the first and second
components are longitudinal components having at least one
different dimension.
19. The process of claim 17, wherein the first and second
components are roof side railings having at least one different
portion of the profile.
20. The process of claim 17, wherein the first and second
components differ in length, height, depth of depression of at
least one portion of the components, or a combination thereof.
Description
TECHNICAL FIELD
[0001] The disclosure relates to a production method of sheet metal
components.
BACKGROUND
[0002] Prototype vehicles as well as niche and premium vehicles
create a need for manufacturing of parts in low volumes. Such
manufacturing presents a set of challenges. For example, the
tooling which is tailor-made for each individual part is expensive,
and it is time consuming to produce such tooling. In addition,
frequent design changes require update of the tooling on a regular
basis. Yet, traditional manufacturing techniques may not
accommodate the needs associated with the design changes. As a
result, some design changes may not be incorporated into the
prototypes due to the manufacturing limitations. Some manufacturing
processes such as incremental forming are too slow, and processes
such as flexible roll-forming require significant design
concessions to be useful.
SUMMARY
[0003] In at least one embodiment, a process of producing a group
of automotive sheet metal components is disclosed. The method
includes producing a group of automotive components by forming
components having various global geometries via a common tooling
configured to bend a blank sheet of metal to create a variable
cross section profile. The process includes forming an addendum as
an integral portion of each formed component. The process also
includes altering the global geometries of the components in a
series of incremental deformations to create local geometries while
each component is affixed to a deforming machine via the addendum.
The group of automotive components may include one component type
designated for different vehicle types. The component type may
include an underbody member, a roof cross member, a rail, or a
rocker member. The group of automotive components may include
different component types designated for one vehicle type. The
sheet metal component may have a longitudinal profile. The variable
cross section profile may include a variable height cross section.
The addendum may extend beyond the global geometry of the
component. The addendum may have a shape universal for each
component of the group of the components. The addendum may be
removed after formation of the local geometries. The global
geometries and the local geometries may be created separately via
different tooling.
[0004] In another embodiment, a method of producing a group of
various automotive longitudinal components is disclosed. The method
includes utilizing a common tool to form a variable cross section
profile by bending a sheet metal for each component of the group in
a first process. The method may further include connecting each
deformed metal sheet to a removable section. The method may include
altering the profile of the deformed metal sheet in a series of
incremental deformations in a second process to create the
longitudinal component while the sheet metal is attached to a
deforming machine via the removable section. The first and second
processes may be performed by different machines and tooling. The
bending may form depressions in a vertical surface of the sheet
metal. The incremental deformations may include bending a
horizontal surface of the sheet metal. The removable section may be
laser trimmed after the second process. The first process may
utilize flexible roll forming and the second process may utilize
incremental forming.
[0005] In yet another embodiment, a process of forming automotive
sheet metal components is disclosed. The method may include
creating a global geometry of a first longitudinal sheet metal
component by forming a variable cross section profile in a blank
sheet of metal. The method may include altering the global geometry
of the first component in a series of incremental deformations to
create local geometries. The method may further include creating
global and local geometries of a second component by utilizing
tooling which formed the first component, wherein the first and
second components differ. The first and second components may be
longitudinal components having at least one different dimension.
The first and second components may be roof side railings having at
least one different portion of the profile. The first and second
components may differ in length, height, depth of depression of at
least one portion of the components, or a combination thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIGS. 1A-1F depict perspective views of exemplary components
manufactured in accordance with one or more embodiments;
[0007] FIG. 2 schematically depicts a sequence of steps of the
disclosed manufacturing process capable of producing longitudinal
components with variable cross section;
[0008] FIGS. 3A-3C depict perspective views of an example component
with example addendums.
DETAILED DESCRIPTION
[0009] Embodiments of the present disclosure are described herein.
It is to be understood, however, that the disclosed embodiments are
merely examples and other embodiments may take various and
alternative forms. The figures are not necessarily to scale; some
features could be exaggerated or minimized to show details of
particular components. Therefore, specific structural and
functional details disclosed herein are not to be interpreted as
limiting, but merely as a representative basis for teaching one
skilled in the art to variously employ the present invention. As
those of ordinary skill in the art will understand, various
features illustrated and described with reference to any one of the
figures may be combined with features illustrated in one or more
other figures to produce embodiments that are not explicitly
illustrated or described. The combinations of features illustrated
provide representative embodiments for typical applications.
Various combinations and modifications of the features consistent
with the teachings of this disclosure, however, could be desired
for particular applications or implementations.
[0010] Except where expressly indicated, all numerical quantities
in this description indicating dimensions or material properties
are to be understood as modified by the word "about" in describing
the broadest scope of the present disclosure.
[0011] The first definition of an acronym or other abbreviation
applies to all subsequent uses herein of the same abbreviation and
applies mutatis mutandis to normal grammatical variations of the
initially defined abbreviation. Unless expressly stated to the
contrary, measurement of a property is determined by the same
technique as previously or later referenced for the same
property.
[0012] Certain vehicle prototypes, as well as niche and premium
vehicles, and other automotive projects require parts manufactured
in low volume. Because of the relatively low amount of such parts
to be produced, the parts are typically made using tooling which is
tailor made for the parts and discarded after making a relatively
small batch of the parts. While the material used for such tooling
is typically cheaper than materials used for high-performance and
high-volume tooling, production of the tooling remains expensive
and time consuming.
[0013] Example tooling for the low volume parts may be kirksite
tooling incorporating dyes made from relatively non-expensive
alloys. Yet, during a product development process, design changes
are common and the traditional tooling may not accommodate for the
projected changes or respond to the design changes. As a result,
some design changes may not be incorporated into the prototypes to
decrease the cost and process time.
[0014] Some of the low volume parts include a variety of sheet
metal parts. Traditional manufacturing techniques are either
unsuitable for production of the sheet metal such as additive
manufacturing or incapable of providing sufficient detail required
for the automotive parts. For example, traditional roll forming is
capable of producing only profiles with a constant cross-section in
the longitudinal direction. In addition, traditional tooling cannot
be used to produce more than one component from a family of
components. Thus, each part requires a separate tooling which is
impractical from financial and production standpoint.
[0015] According to one or more embodiments, a process for
producing automotive metal sheet components is provided. The
process implements a combination of two separate processes. The
first process enables creating a global geometry of the component.
Global geometry relates to a rough shape of a component without
defining its fine features. The global geometry is subsequently
altered by a second process which defines the fine features and
details in the global geometry. To enable the transition from the
first process to the second process, the component includes an
addendum while or after having the global geometry sculpted.
[0016] Typically, the components are produced by methods such as
press forming which requires large expensive tooling and material
which does not have sufficient longevity. The two processes
disclosed herein work in a synergistic manner to produce components
of specific geometries in an economical and time-saving manner. The
same tooling may be used to produce a variety of components within
the same family or for the same vehicle type on a single production
line. Grouping components which have similar characteristics and
producing them using the same tooling provides time savings of
several days to weeks and is more economical.
[0017] In at least one embodiment, the process includes producing a
group or family of automotive components by forming components
having various global geometries while utilizing a common tooling
configured to bend a blank sheet of metal to create a variable
cross section profile. The process includes forming an addendum
and/or adding a fixture to each formed component. The process also
includes altering the global geometries of the components in a
series of incremental deformations to create local geometries while
each component is affixed to a deforming machine via the addendum
and/or fixture.
[0018] The component 10 may be any metal sheet component. Example
components 10 are depicted in FIGS. 1A-1F. As can be seen in the
examples of FIGS. 1A-1F, the component 10 may be a longitudinal
component having greater dimensions along longitudinal axis x than
along axis y or z. The components 10 may have a cross-section that
is discontinuous or variable on the longitudinal axis x, but may
also vary along axis y, and/or z. The components 10 may have one or
more ends 12 which are closed or open. The components 10 may have
one or more sections 14 which differ in dimensions from at least
one other section 16 or plurality of sections, and the like. The
components 10 may have one or more bends, arches, or curves 18. In
addition, or in the alternative, the components 10 may have one or
more apertures 20. The apertures 20 may be symmetrically or
asymmetrically spaced within the metal component body 22. The
apertures may have any size, shape, or form. For example, an
aperture 20 may be regular, irregular, circular, oval, polygonal,
square, rectangular, or have another shape. The apertures 20 within
the same component 10 may have the same or different shape and/or
dimensions. A component 10 may be free of any aperture. A component
10 may have varying length, height, thickness, or a combination
thereof within its body 22. The component 10 may have a base 24,
sides 26, and one or more flanges 28.
[0019] The component 10 may have a cross-section having a varying
profile. The cross section may vary in longitudinal direction. The
profile may have a variable width, depth/height, or a combination
thereof. The profile may be fully open, partially open, or closed.
The profile may be shaped like U, 0, V, D, or C. The profile may be
symmetrical or asymmetrical.
[0020] The components 10 may be categorized as belonging to various
families of components. The components 10 may be categorized by a
component type or a vehicle type. Thus, a group or family of
components to be produced by a common tooling may include the same
type of component for at least two different vehicle types.
Alternatively, a group of components to be produced by a common
tooling may include different members for the same vehicle type.
Table 1 below provides examples of grouping of component families
and vehicle types. The amount and type of components and vehicle
types are just examples. Other types of components and different
types of vehicles may be included.
TABLE-US-00001 TABLE 1 Component families and vehicle types
Component Families Roof Under- Rocker Side body Reinforce- Center
Vehicle Rail Sled X ment Front Roof Rear Type Outer Runner Member
Member Header Bow Header 1 a1 b1 c1 d1 e1 f1 g1 2 a2 b2 c2 d2 e2 f2
g2 3 a3 b3 c3 d3 e3 f3 g3 4 a4 b4 c4 d4 e4 f4 g4 5 a5 b5 c5 d5 e5
f5 g5
[0021] For example, a common tooling may be used to produce a
component family of roof side rail outer members a1-a5 for vehicle
types 1-5. For example, a family of components 100, 102, 104
depicted in FIG. 1A-1C contains three different roof side rail
outer members from the group a1-a5. Another example family includes
various components 202, 204 categorized as a sled runner, which are
depicted in FIGS. 1D and 1E. An example component 304 depicted in
FIG. 1F belongs to the family of underbody X members c1-c5. Other
example component families may include rocker reinforcement
members, front headers, rear headers, center roof bow components,
cross members, or the like. Each family may include the same type
of a component for a variety of vehicle types or models. For
example, a family may contain sled runners for at least two
different types of vehicle models, as is illustrated in the Table 1
above.
[0022] Alternatively, another common tooling may be used to produce
a family of components a1-g1 for the common vehicle type 1. And yet
another tooling may be used to produce a series of components a5-g5
for the common vehicle type 5.
[0023] Different components within the same family may have the
same or different profile, dimensions such as overall height,
length, width, geometry, the amount, shape, and/or size of
apertures, base section width, side wall height, flange width, and
the like.
[0024] The material of the components 10 may be various grades of
steel. For example, the material may be low strength, high
strength, and ultra-high strength steel, austenitic, ferritic, or
martensitic grade steel, an alloy steel containing Mn, Si, Ni, Ti,
Co, Cr, and/or Al in various proportions, carbon steel, or tool
steel.
[0025] A software may be utilized to determine the most economical
efficient and economical manner of grouping various components into
families. Once the group of components to be produced is
determined, all of the components of the group may be formed in the
first process before the components are finalized in the second
process. For example, if the group contains components a1-g1 for
the vehicle type 1, all of the components of the group will be
formed in the first process before proceeding to the second
process. The desired number of components a1 may be formed first,
followed by the desired number of components b1, followed by the
desired number of components c1, etc. Once all of the components
a1-g1 have been formed in the first process, the components a1-g1
may proceed to the second process. Thus, the components a1-g1 may
be produced consecutively such that a1 components are produced
before b1 components are produced, followed by production of c1,
d1, e1 components, etc. Alternatively, it may be desirable to form
a certain amount of any component within the group a1-g1, such that
a certain amount of components a1 is produced in the first process,
then a certain amount of component c1 is produced, followed by a
certain amount of component a1 again. Alternatively still, the
components a1-g1 may be produced in any order.
[0026] The same principles apply if the group contains the same
type of component for different vehicle types, for example if the
group includes roof side railings a1-a5 for vehicles types 1-5.
[0027] The first process 500, schematically depicted in FIG. 2,
forming the global geometry or the rough shape of the component 10
enables contouring of blanks in such a way that the components may
have a cross-section which is discontinuous on the longitudinal
axis. The first process may be, for example, flexible roll forming,
also called 3D-roll forming. Flexible roll forming is a progressive
motion process utilizing a machine 502 employing a variety of rolls
504 which are independently movable and are capable of contouring
the discontinuous cross section in the metal sheet without a tool
change. A plurality of rolls 504 progressively bends a metal sheet
506 into a final predefined shape. The first process may shape a
flat metal sheet along the longitudinal axis into a convex or
concave strip. The first process may utilize a plurality of
independent rolls 504, each capable of forming an incremental part
of the global geometry in steps, all the rolls 504 together forming
the global geometry of the component 10. The first process may
provide sequential or continuous bending operations. Up to about
50%, 60%, 70%, or 80% of the overall shape or contours of the metal
component 10 may be formed via the first process. The first process
may include creating deformations in vertical, horizontal, or both
surfaces of the component 10. The first process may utilize the
same set of rolls 504 to produce global geometries of different
components. The first process may utilize the same set of tools
(rolls 504) to form global geometries of all the components within
at least one family.
[0028] The thickness of the metal sheet entering the first process
machine may be up to 7 mm. The thickness may be about 1, 2, 3, 4,
5, 6 or 7 mm. The thickness may vary throughout the component 10
before the first, second process, or after the second process. The
metal sheet material may have up to 500 MPa yield strength. The
metal sheet may be precut to one or more strips.
[0029] The dimensions of the metal sheet entering the first process
machine may be sufficient such that one or more addendums 30,
described below, may be formed as integral portions of the
component 10.
[0030] The second process 600, as depicted in FIG. 2, is performed
on a different machine 602, utilizing different tooling than the
first process. The second process enables alteration of the global
geometry to form detailed contours in the global geometry of the
component 10 which the first process may not be suitable to form
for a variety of reasons. For example, creating local geometry with
the first process would be time consuming. Additionally, attempting
to define local geometry with the first process may result in
warping or undesirable stresses in the material. Yet, the second
process may not be suitable to form the global geometry. For
example, the material properties such as ductility may pose
limitations such that the second process may not be able to provide
sufficient bending operations. Thus, the synergic use of the first
process to shape the global geometry while utilizing a second
process, which differs from the first process, to provide the local
or detailed geometry in the preformed global geometry results in a
faster, more economical method of producing metal sheet
longitudinal components with intricate geometries and with
increased bearing capacity as well as reduced structural weight
when compared to similar components produced by different methods.
The second process 600 may utilize the same tooling or set of tools
to provide local geometries of a plurality of or all components of
the same family.
[0031] To allow for the transition from the first process to the
second process, and/or processing of the component 10 in the second
process, one or more addendums 30 and/or fixtures 32 may be formed
as part of or attached to each component 10. Example addendums 30
are depicted in FIGS. 2 and 3B, as portions of the formed component
10. The shape of the addendum 30 may be specific to each part, or
the same addendum 30 may be formed on more than one member of each
component family. The addendum 30 and/or fixture 32 allows for
attachment of the component 10 to the second process machine
without compromising the quality of the part. By providing the
addendum 30 and/or fixture 32, the component 10 itself receives
less contact with the processing machine. As a result, the
component's 10 surface is less prone to obtain scratches, dents,
marks, and/or other imperfections which could otherwise result from
the transition between the first and second process and/or from the
process machines themselves.
[0032] The addendum 30 and/or fixture 32 may have any shape or form
as long as the addendum 30 and/or fixture 32 provides sufficient
support for the component 10. As is depicted in FIG. 2, the
addendum 30 may be an extension of at least one side, flange, or
base of the component 10. The addendum 30 may run along the entire
length of the side or flange. Alternatively, the addendum 30 may be
formed on only a portion of the side, flange, or base. Both the
fixture 32 and/or the addendum 30 may have the same or different
dimensions than a component 10. For example, the addendum 30 and/or
fixture 32 may have the same length as the component 10, or be
longer or shorter than the component 10. The addendum 30 and/or
fixture 32 may have a length which extends beyond the global
geometry of the component 10. More than one addendum 30 may be
formed on the same component 10, as is shown in FIGS. 2 and 3B.
Similarly, more than one fixture 32 may be used to support the
component 10.
[0033] In at least one embodiment, the shape of the addendum 30 may
be a shape common to at least two different addendums 30 of at
least two different components 10 or to all components of at least
one family of components 10. The addendum 30 may be a universal
addendum for each component of a family of components 10.
[0034] Unlike the addendum 30, which forms an integral portion of
the component 10 formed in the first process, the fixture 32 does
not form an integral portion of the component 10. The fixture 32
may be added after the first process. The fixture 32 may be reused
or be used just once. The same fixture 32 may be used for variety
of components within its family. Alternatively, the same fixture 32
may be used for production of a plurality of the same components
within the same family.
[0035] The addendum 30 and/or fixture 32 may be temporarily affixed
to or connected to the component 10 such that the addendum 30
and/or fixture 32 is removable. The addendum 30 may form an
integral portion of the component 10. The addendum 30 and/or
fixture may be in contact with or be attached to the second process
machine via one or more apertures, for example one or more
apertures 20 which are provided in the component 10 for other
purposes. Alternatively, or in addition, the apertures 20 may be
created specifically for the purpose of attaching the addendum 30,
and/or fixture 32 to the second process machine, to the component
10 (for fixture), and/or the second process machine. Alternatively,
or in addition to the apertures 20, the addendum 30 and/or fixture
32 may be affixed second process machine and/or to the component 10
for (fixture) via one or more hooks, bolts, screws, clamps,
connectors, brackets, clasps, fixtures, or the like 34.
[0036] The addendum 30 and/or fixture 32 may be in contact with the
component 10 during or after the component 10 receives its global
geometry during the first process, between the first and second
processes, during or after the component 10 is being shaped to
receive its local geometry features in the second process, or a
combination thereof. For example, the addendum 30 may be formed as
an integral part of the component 10 during the first process
before exiting the first process machine 502. Alternatively, an
addendum 30 and/or fixture 32 may be attached to the component 10
after the global geometry of a certain portion of the component 10
is formed and before the entire global geometry is formed.
[0037] The addendum 30 and/or fixture 32 may be made from a metal,
composite, polymer, wood, glass, or a combination of materials. The
thickness of the addendum 30 and/or fixture may be the same or
different than the thickness of the component 10. For example, a
metal addendum 30 and/or fixture 32 may have a greater or smaller
thickness than the component 10 to be supported. For example, the
addendum 30 and/or fixture 32 may be less malleable and/or have
higher strength than the component 10 as a result of the different
material thickness. The fixture 32 may be made from a different
metal material than the component.
[0038] The addendum 30 and/or fixture 32 may be removed after the
second process. For example, the addendum 30 may be removed by
laser trimming.
[0039] The transition from the first process 500 to the second
process 600 may be done manually or robotically. After the
component 10 is transported to the second process machine 602, the
local geometry is being formed. The second process may be, for
example, incremental sheet forming, which forms detailed contours
in the preformed global geometry. The second process employs a
machine 602 capable of indenting the preformed global geometry in a
series of incremental deformations. The contouring tool may indent
the metal into a certain depth and follow a contour, another indent
may follow with drawing the next contour, etc. The addendum 30
and/or fixture 32 may be used to attach the component 10 to the
second process machine. For example, the component 10 may be
clamped to the second process machine in the xy axis such that the
component 10 is free to move along the z axis. Up to about 50%,
40%, 30%, or 20% of the overall shape or contours of the metal
component 10 may be formed via the second process. The second
process may include forming depressions, deformations, bending,
indentations, and/or the like in the vertical, horizontal, or both
surfaces of the component 10.
[0040] During the first process, second process, or before or after
either the first or second process, additional operations may be
performed on the component 10 and/or the addendum 30. For example,
one or more apertures 20 may be created in the component 10 by a
variety of techniques such as punching or by a laser. Laser
trimming may be employed to form one or more flanges 28, remove or
reshape the addendum 30, or both.
[0041] The first process machine, the second process machine, and
additional machines providing laser trimming, hole punching,
transportation from the first process station to the second process
station, or the like may be connected to one or more controllers.
The one or more controllers may have one or more processing
components such as one or more microprocessor units which enable
the controllers to process input data. The input data may include
information about individual components, individual families of
components, material and dimensions of the components, desired
global geometry of each component, desired local geometries of each
component, dimensions and placement of the addendums, position and
dimensions of the apertures and/or flanges. The input data may
further include information about individual rollers of the first
process machine, their dimensions, position, angle as well as the
desired location of each roller during the first process, providing
a series of deformations resulting in the global geometry of each
component 10. The input data may further include information about
the path of the deforming tool during the second process providing
the local geometries of each individual component.
[0042] The one or more controllers may be programmed to identify
and categorize various families of components, initiate the first
process and/or the second process, stop or temporarily interrupt
either process, coordinate processing of individual components,
forming of apertures, flanges, or the like. The controllers may be
further programmed to switch the tooling paths of the first and
second processes based on which component of which family is to be
formed. For example, the controllers may be programmed to produce
certain amount of component a1 from family 1, followed by certain
amount of component a2 from family 1, and certain amount of
component a3 from family 1, followed by certain amount of component
b1 from family 2, component b2 from family 2, etc.
[0043] The method involving the two phase process for production of
a variety components within the different families of longitudinal
metal sheet components may include identifying and categorizing
families of individual components. The method may further include
developing tooling for the first process for each family of
components. The first process tooling may then be utilized to
achieve global geometry of each component in the family. The method
may further include developing addendums for transportation of the
components between the first and second process and during the
second process, the addendum being specific to a family or to a
specific component within a family. Simulation verifying
feasibility of at least the first process and/or the second process
may be performed. Based on the desired local geometries of each
part within a family, tool paths of the second process machine may
be developed. The second process may then be utilized to complete
the overall geometry of each component. Laser trimming and/or hole
punching is also contemplated.
[0044] The development of tooling for the first process may include
performing simulations for each part of each family and verifying
feasibility of production. The method may further include
development of the first process tooling based on the first process
machine line capabilities. Pre-processing requirements such as the
required developed blanks, pre-punching, laser trimming, or the
like may be identified.
[0045] The method may include changing tooling or the first and/or
second process machine after a desirable amount of components from
one family were produced such that components from a different
family may be produced.
[0046] The processes, methods, or algorithms disclosed herein may
be deliverable to or implemented by a processing device,
controller, or computer, which may include any existing
programmable electronic control unit or dedicated electronic
control unit. Similarly, the processes, methods, or algorithms may
be stored as data and instructions executable by a controller or
computer in many forms including, but not limited to, information
permanently stored on non-writable storage media such as ROM
devices and information alterably stored on writeable storage media
such as floppy disks, magnetic tapes, CDs, RAM devices, and other
magnetic and optical media. The processes, methods, or algorithms
may also be implemented in a software executable object.
Alternatively, the processes, methods, or algorithms may be
embodied in whole or in part using suitable hardware components,
such as Application Specific Integrated Circuits (ASICs),
Field-Programmable Gate Arrays (FPGAs), state machines, controllers
or other hardware components or devices, or a combination of
hardware, software and firmware components.
[0047] The words used in the specification are words of description
rather than limitation, and it is understood that various changes
may be made without departing from the spirit and scope of the
disclosure. As previously described, the features of various
embodiments may be combined to form further embodiments of the
invention that may not be explicitly described or illustrated.
While various embodiments could have been described as providing
advantages or being preferred over other embodiments or prior art
implementations with respect to one or more desired
characteristics, those of ordinary skill in the art recognize that
one or more features or characteristics may be compromised to
achieve desired overall system attributes, which depend on the
specific application and implementation. These attributes may
include, but are not limited to cost, strength, durability, life
cycle cost, marketability, appearance, packaging, size,
serviceability, weight, manufacturability, ease of assembly, etc.
As such, embodiments described as less desirable than other
embodiments or prior art implementations with respect to one or
more characteristics are not outside the scope of the disclosure
and may be desirable for particular applications.
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