Patent Application
20250121420
The present invention relates to the technical field of rollforming profiles, specifically, to a method for manufacturing a rollforming frame, and the rollforming frame.
In the current processing method for the main structure of a battery pack frame, joints of left and right longitudinal beams and front and rear transverse beams (four parts) are peripherally butt-welded to form a prefabricated frame, then the prefabricated frame is welded with a bottom steel plate, and finally a battery pack tray is formed. The above processing method has the following defects: a, there are many types of materials, including five types of materials; b, there is a long machining process including frame material rolling, welding, frame butt-welding, steel plate and frame butt-welding, and laser hole-cutting, resulting in low production efficiency; c, there is high difficulty in quality control and welding due to a large amount of deformation after welding and low dimensional accuracy, and a subsequent laser cutting process is needed to ensure the mounting accuracy of riveting holes; and d, there are high costs for equipment investment, machining, labor, etc.
In view of the defects in the prior art, the present invention aims to provide a method for manufacturing a rollforming frame, and the rollforming frame.
A method for manufacturing a rollforming frame provided according to an embodiment of the present invention includes the following steps:
Preferably, in the step 1, a first bend structure is formed between the first vertical wall and the bottom plate, and a second bend structure is formed between the first horizontal wall and the first vertical wall;
in the step 2, a third bend structure and a fourth bend structure are formed in the stepped bent structure;
in the step 3, two ends of the second horizontal wall are connected to the stepped bent structure and the second vertical wall respectively, a fifth bend structure is formed between the second horizontal wall and the second vertical wall, and a sixth bend structure is formed between the second vertical wall and the third horizontal wall;
in the step 4, a seventh bend structure is formed between the third vertical wall and the fourth horizontal wall, and two ends of the fourth horizontal wall are connected to the stepped bent structure and the third vertical wall respectively;
an eighth bend structure is formed between the fourth vertical wall and the fifth horizontal wall, and two ends of the fourth vertical wall are connected to the fifth horizontal wall and the second vertical wall respectively;
in the step 6, a ninth bend structure is formed between the connecting edge and the sixth horizontal wall; and
in the step 7, a tenth bend structure is formed between the fifth vertical wall and the seventh horizontal wall, and two ends of the fifth vertical wall are connected to the connecting edge and the seventh horizontal wall respectively.
Preferably, the step 1 specifically includes the following steps:
Further, in the step 1.1, the angle of the first corner structure is 177°;
in the step 1.2, the angle of the first corner structure is 170°, and the angle of the second corner structure is 172°; and
the step 1.3 specifically includes the following steps:
step 1.3.1: rolling and bending the first vertical wall and the first horizontal wall, such that the angle of the first corner structure is 160°, and the angle of the second corner structure is 162°;
step 1.3.2: rolling and bending the first vertical wall and the first horizontal wall, such that the angle of the first corner structure is 145°, and the angle of the second corner structure is 148°;
step 1.3.3: rolling and bending the first vertical wall and the first horizontal wall, such that the angle of the first corner structure is 130°, and the angle of the second corner structure is 132°;
step 1.3.4: rolling and bending the first vertical wall and the first horizontal wall, such that the angle of the first corner structure is 115°, and the angle of the second corner structure is 118°;
step 1.3.5: rolling and bending the first vertical wall and the first horizontal wall, such that the angle of the first corner structure is 100°, and the angle of the second corner structure is 103°;
step 1.3.6: rolling and bending the first vertical wall and the first horizontal wall, such that the angle of the first corner structure is 90°, the first bend structure is formed, and the angle of the second corner structure is 93°; and
step 1.3.7: rolling and bending the first horizontal wall, such that the angle of the second corner structure is 90°, and the second bend structure is formed.
Further, the step 2 specifically includes the following steps:
Further, in the step 2.1, the angle of the third corner structure is 3°;
in the step 2.2, the angle of the third corner structure is 15° and the angle of the fourth corner structure is 13°; and
the step 2.3 specifically includes the following steps:
step 2.3.1: rolling and bending the fourth side edge structure and the stepped inclined surface structure, such that the angle of the third corner structure is 30° and the angle of the fourth corner structure is 28°;
step 2.3.2: rolling and bending the fourth side edge structure and the stepped inclined surface structure, such that the angle of the third corner structure is 45° and the angle of the fourth corner structure is 42°;
step 2.3.3: rolling and bending the fourth side edge structure and the stepped inclined surface structure, such that the angle of the third corner structure is 54°, the third bend structure is formed, and the angle of the fourth corner structure is 52°; and
step 2.3.4: rolling and bending the fourth side edge structure, such that the angle of the fourth corner structure is 54° and the fourth bend structure is formed.
Further, the step 3 specifically includes the following steps:
Further, in the step 3.1, the angle of the fifth corner structure is 176°;
in the step 3.2, the angle of the fifth corner structure is 165° and the angle of the sixth corner structure is 170°; and
the step 3.3 specifically includes the following steps:
step 3.3.1: rolling and bending the second vertical wall and the third horizontal wall, such that the angle of the fifth corner structure is 150°, and the angle of the sixth corner structure is 155°;
step 3.3.2: rolling and bending the second vertical wall and the third horizontal wall, such that the angle of the fifth corner structure is 135°, and the angle of the sixth corner structure is 140°;
step 3.3.3: rolling and bending the second vertical wall and the third horizontal wall, such that the angle of the fifth corner structure is 120°, and the angle of the sixth corner structure is 125°;
step 3.3.4: rolling and bending the second vertical wall and the third horizontal wall, such that the angle of the fifth corner structure is 105°, and the angle of the sixth corner structure is 110°;
step 3.3.5: rolling and bending the second vertical wall and the third horizontal wall, such that the angle of the fifth corner structure is 90°, the fifth bend structure is formed, and the angle of the sixth corner structure is 95°; and
step 3.3.6: rolling and bending the third horizontal wall, such that the angle of the sixth corner structure is 90° and the sixth bend structure is formed.
Further, the step 4 specifically includes the following steps:
Further, in the step 4.1, the angle of the seventh corner structure when formed is 175°;
in the step 4.2, the angle of the seventh corner structure is 170°;
in the step 4.3, the angle of the seventh corner structure is 160°, and the angle of the eighth corner structure is 170°; and
the step 4.4 specifically includes the following steps:
step 4.4.1: rolling and bending the fifth horizontal wall and the third vertical wall, such that the angle of the seventh corner structure is 150°, and the angle of the eighth corner structure is 160°;
step 4.4.2: rolling and bending the fifth horizontal wall and the third vertical wall, such that the angle of the seventh corner structure is 140°, and the angle of the eighth corner structure is 150°;
step 4.4.3: rolling and bending the fifth horizontal wall and the third vertical wall, such that the angle of the seventh corner structure is 130°, and the angle of the eighth corner structure is 140°;
step 4.4.4: rolling and bending the fifth horizontal wall and the third vertical wall, such that the angle of the seventh corner structure is 120°, and the angle of the eighth corner structure is 130°;
step 4.4.5: rolling and bending the fifth horizontal wall and the third vertical wall, such that the angle of the seventh corner structure is 110°, and the angle of the eighth corner structure is 120°;
step 4.4.6: rolling and bending the fifth horizontal wall and the third vertical wall, such that the angle of the seventh corner structure is 100°, and the angle of the eighth corner structure is 110°;
step 4.4.7: rolling and bending the fifth horizontal wall and the third vertical wall, such that the angle of the seventh corner structure is 90°, the seventh bend structure is formed, and the angle of the eighth corner structure is 100°; and
step 4.4.8: rolling and bending the fifth horizontal wall, such that the angle of the eighth corner structure is 90°, and the eighth bend structure is formed.
Further, the step 6 specifically includes the following steps:
Further, in the step 6.1, the angle of the ninth corner structure is 180°; and the step 6.2 specifically includes the following steps:
Further, the step 7 specifically includes the following steps:
Further, in the step 7.1, the angle of the tenth corner structure is 163°; and
the step 7.2 specifically includes the following steps:
step 7.2.1: rolling and bending the fifth vertical wall, such that the angle of the tenth corner structure is 145°;
step 7.2.2: rolling and bending the fifth vertical wall, such that the angle of the tenth corner structure is 130°;
step 7.2.3: rolling and bending the fifth vertical wall, such that the angle of the tenth corner structure is 115°;
step 7.2.4: rolling and bending the fifth vertical wall, such that the angle of the tenth corner structure is 100°; and
step 7.2.5: rolling and bending the fifth vertical wall, such that the angle of the tenth corner structure is 90°, and the tenth bend structure is formed.
Further, in the step 8, a left longitudinal beam portion and a right longitudinal beam portion are formed at the two opposite ends of the bottom plate; and
the method for manufacturing a rollforming frame further includes the following steps:
step 9: cutting the left longitudinal beam portion and the right longitudinal beam portion that are located at four corners of the bottom plate to form a front longitudinal beam plate and a rear longitudinal beam plate at another two opposite ends of the bottom plate;
step 10: separately bending the front longitudinal beam plate and the rear longitudinal beam plate to form a sixth vertical wall and an eighth horizontal wall, where an eleventh bend structure is formed between the sixth vertical wall and the eighth horizontal wall;
step 11: bending the eighth horizontal wall to form a seventh vertical wall and a ninth horizontal wall, where a twelfth bend structure is formed between the seventh vertical wall and the ninth horizontal wall;
step 12: bending the seventh vertical wall to form an eighth vertical wall and a tenth horizontal wall, where a thirteenth bend structure is formed between the eighth vertical wall and the tenth horizontal wall;
step 13: bending the ninth horizontal wall, such that the sixth vertical wall abuts against the bottom plate, a fourteenth bend structure is formed between the ninth horizontal wall and the bottom plate, and a front longitudinal beam portion and a rear longitudinal beam portion are formed at the another two opposite ends of the bottom plate; and
step 14: welding a joint of the front longitudinal beam portion and the left longitudinal beam portion, welding a joint of the front longitudinal beam portion and the right longitudinal beam portion, welding a joint of the rear longitudinal beam portion and the left longitudinal beam portion, welding a joint of the rear longitudinal beam portion and the right longitudinal beam portion, and welding a joint of the sixth vertical wall and the bottom plate.
The present invention further provides a rollforming frame manufactured using the above method for manufacturing a rollforming frame.
Further, the rollforming frame includes a bottom plate, a left longitudinal beam portion, and a right longitudinal beam portion, where the left longitudinal beam portion and the right longitudinal beam portion are disposed at two opposite ends of the bottom plate respectively;
each of the left longitudinal beam portion and the right longitudinal beam portion includes the first vertical wall, the fourth horizontal wall, the third vertical wall, the second vertical wall, the fourth vertical wall, the seventh horizontal wall, the fifth vertical wall, and the connecting edge that are sequentially connected;
the fourth horizontal wall, the third vertical wall, and the second vertical wall form a first notch structure, and the second vertical wall, the fourth vertical wall, and the seventh horizontal wall form a second notch structure;
the first vertical wall is connected to an opening end of the first notch structure, and the fourth vertical wall is connected to the first vertical wall; and
the fifth vertical wall is connected to an opening end of the second notch structure, and the connecting edge is connected to one end of the second vertical wall adjacent to the third vertical wall.
Other features, objectives and advantages of the present invention will become more apparent upon reading the detailed description of the non-restrictive embodiments with reference to the following drawings, in which:
In the drawings:
The present invention is described in detail below with reference to specific embodiments. The following embodiments will assist those skilled in the art in further understanding the present invention, but do not limit the present invention in any form. It should be pointed out that several changes and improvements may also be made by those of ordinary skill in the art without departing from the conception of the present invention. All the changes and improvements fall within the scope of protection of the present invention.
As shown in
step 1: separately rolling and bending two opposite ends of a to-be-machined plate to separately form a first vertical wall 1 and a first horizontal wall 2 connected to each other at the two opposite ends of the to-be-machined plate, where a bottom plate 3 is formed between the two first vertical walls 1; a first bend structure 27 is formed between the first vertical wall 1 and the bottom plate 3, and a second bend structure 28 is formed between the first horizontal wall 2 and the first vertical wall 1; and the step 1 specifically includes the following steps:
step 1.1: separately rolling and bending the two opposite ends of the to-be-machined plate to form a first side edge structure 20 and a second side edge structure 21 at the two opposite ends of the to-be-machined plate respectively, where the bottom plate 3 is formed between the first side edge structure 20 and the second side edge structure 21, a first corner structure is formed between the first side edge structure 20 and the bottom plate 3, and a first corner structure 53 is formed between the second side edge structure 21 and the bottom plate 3;
step 1.2: separately rolling and bending the first side edge structure 20 and the second side edge structure 21 to form the first vertical wall 1 and the first horizontal wall 2, where a second corner structure 54 is formed between the first vertical wall 1 and the first horizontal wall 2; and
step 1.3: rolling and bending the first vertical wall 1 and the first horizontal wall 2 for multiple times, gradually reducing an angle of the first corner structure 53 to form the first bend structure 27, and gradually reducing an angle of the second corner structure 54 to form the second bend structure 28,
where in the step 1.1, the angle of the first corner structure 53 is 177°;
in the step 1.2, the angle of the first corner structure 53 is 170°, and the angle of the second corner structure 54 is 172°; and
the step 1.3 specifically includes the following steps:
step 1.3.1: rolling and bending the first vertical wall 1 and the first horizontal wall 2, such that the angle of the first corner structure 53 is 160°, and the angle of the second corner structure 54 is 162°;
step 1.3.2: rolling and bending the first vertical wall 1 and the first horizontal wall 2, such that the angle of the first corner structure 53 is 145°, and the angle of the second corner structure 54 is 148°;
step 1.3.3: rolling and bending the first vertical wall 1 and the first horizontal wall 2, such that the angle of the first corner structure 53 is 130°, and the angle of the second corner structure 54 is 132°;
step 1.3.4: rolling and bending the first vertical wall 1 and the first horizontal wall 2, such that the angle of the first corner structure 53 is 115°, and the angle of the second corner structure 54 is 118°;
step 1.3.5: rolling and bending the first vertical wall 1 and the first horizontal wall 2, such that the angle of the first corner structure 53 is 100°, and the angle of the second corner structure 54 is 103°;
step 1.3.6: rolling and bending the first vertical wall 1 and the first horizontal wall 2, such that the angle of the first corner structure 53 is 90°, the first bend structure 27 is formed, and the angle of the second corner structure 54 is 93°; and
step 1.3.7: rolling and bending the first horizontal wall 2, such that the angle of the second corner structure 54 is 90°, and the second bend structure 28 is formed;
step 2: rolling and bending one end of the first horizontal wall 2 adjacent to the first vertical wall 1 to form a stepped bent structure 4, where a third bend structure 29 and a fourth bend structure 30 are formed in the stepped bent structure 4; and the step 2 specifically includes the following steps:
step 2.1: rolling and bending one end of the first horizontal wall 2 adjacent to the first vertical wall 1 to form a stepped planar structure 22 and a third side edge structure 23, where a third corner structure 55 is formed between the stepped planar structure 22 and the third side edge structure 23;
step 2.2: rolling and bending the third side edge structure 23 to form a stepped inclined surface structure 24 and a fourth side edge structure 25, where the third corner structure 55 is formed between the stepped planar structure 22 and the stepped inclined surface structure 24, and a fourth corner structure 56 is formed between the stepped inclined surface structure 24 and the fourth side edge structure 25; and
step 2.3: rolling and bending the fourth side edge structure 25 and the stepped inclined surface structure 24 for multiple times, gradually increasing an angle of the third corner structure 55 to form the third bend structure 29, and gradually increasing an angle of the fourth corner structure 56 to form the fourth bend structure 30, where in the step 2.1, the angle of the third corner structure 55 is 3°;
in the step 2.2, the angle of the third corner structure 55 is 15° and the angle of the fourth corner structure 56 is 13°; and
the step 2.3 specifically includes the following steps:
step 2.3.1: rolling and bending the fourth side edge structure 25 and the stepped inclined surface structure 24, such that the angle of the third corner structure 55 is 30° and the angle of the fourth corner structure 56 is 28°;
step 2.3.2: rolling and bending the fourth side edge structure 25 and the stepped inclined surface structure 24, such that the angle of the third corner structure 55 is 45° and the angle of the fourth corner structure 56 is 42°;
step 2.3.3: rolling and bending the fourth side edge structure 25 and the stepped inclined surface structure 24, such that the angle of the third corner structure 55 is 54°, the third bend structure 29 is formed, and the angle of the fourth corner structure 56 is 52°; and
step 2.3.4: rolling and bending the fourth side edge structure 25, such that the angle of the fourth corner structure 56 is 54° and the fourth bend structure 30 is formed;
step 3: rolling and bending the first horizontal wall 2 to form a second vertical wall 5, a second horizontal wall 6, and a third horizontal wall 7 that are connected, where two ends of the second horizontal wall 6 are connected to the stepped bent structure 4 and the second vertical wall 5 respectively, a fifth bend structure 31 is formed between the second horizontal wall 6 and the second vertical wall 5, and a sixth bend structure 32 is formed between the second vertical wall 5 and the third horizontal wall 7; and the step 3 specifically includes the following steps:
step 3.1: rolling and bending the first horizontal wall 2 to form the second horizontal wall 6 and a fifth side edge structure 26, where a fifth corner structure 57 is formed between the second horizontal wall 6 and the fifth side edge structure 26;
step 3.2: rolling and bending the fifth side edge structure 26 to form the second vertical wall 5 and the third horizontal wall 7, where the fifth corner structure 57 is formed between the second horizontal wall 6 and the second vertical wall 5, and a sixth corner structure 58 is formed between the second vertical wall 5 and the third horizontal wall 7; and
step 3.3: rolling and bending the second vertical wall 5 and the third horizontal wall 7 for multiple times, gradually reducing an angle of the fifth corner structure 57 to form the fifth bend structure 31, and gradually reducing an angle of the sixth corner structure 58 to form the sixth bend structure 32, where in the step 3.1, the angle of the fifth corner structure 57 is 176°;
in the step 3.2, the angle of the fifth corner structure 57 is 165° and the angle of the sixth corner structure 58 is 170°; and
the step 3.3 specifically includes the following steps:
step 3.3.1: rolling and bending the second vertical wall 5 and the third horizontal wall 7, such that the angle of the fifth corner structure 57 is 150°, and the angle of the sixth corner structure 58 is 155°;
step 3.3.2: rolling and bending the second vertical wall 5 and the third horizontal wall 7, such that the angle of the fifth corner structure 57 is 135°, and the angle of the sixth corner structure 58 is 140°;
step 3.3.3: rolling and bending the second vertical wall 5 and the third horizontal wall 7, such that the angle of the fifth corner structure 57 is 120°, and the angle of the sixth corner structure 58 is 125°;
step 3.3.4: rolling and bending the second vertical wall 5 and the third horizontal wall 7, such that the angle of the fifth corner structure 57 is 105°, and the angle of the sixth corner structure 58 is 110°;
step 3.3.5: rolling and bending the second vertical wall 5 and the third horizontal wall 7, such that the angle of the fifth corner structure 57 is 90°, the fifth bend structure 31 is formed, and the angle of the sixth corner structure 58 is 95°; and
step 3.3.6: rolling and bending the third horizontal wall 7, such that the angle of the sixth corner structure 58 is 90°, and the angle of the sixth bend structure 32 is formed;
step 4: rolling and bending the second horizontal wall 6 to form a third vertical wall 8 and a fourth horizontal wall 9 connected to each other; and rolling and bending the third horizontal wall 7 to form a fourth vertical wall 10 and a fifth horizontal wall 11 connected to each other, where the fourth vertical wall 10 abuts against the first vertical wall 1; a seventh bend structure 33 is formed between the third vertical wall 8 and the fourth horizontal wall 9, and two ends of the fourth horizontal wall 9 are connected to the stepped bent structure 4 and the third vertical wall 8 respectively; an eighth bend structure 34 is formed between the fourth vertical wall 10 and the fifth horizontal wall 11, and two ends of the fourth vertical wall 10 are connected to the fifth horizontal wall 11 and the second vertical wall 5 respectively; and the step 4 specifically includes the following steps:
step 4.1: rolling and bending the second horizontal wall 6 to form the third vertical wall 8 and the fourth horizontal wall 9, where a seventh corner structure 59 is formed between the third vertical wall 8 and the fourth horizontal wall 9;
step 4.2: rolling and bending the third vertical wall 8, and reducing an angle of the seventh corner structure 59 for the first time;
step 4.3: rolling the third horizontal wall 7 to form the fourth vertical wall 10 and the fifth horizontal wall 11, where an eighth corner structure 60 is formed between the fourth vertical wall 10 and the fifth horizontal wall 11; and rolling and bending the third vertical wall 8, and reducing the angle of the seventh corner structure 59 for the second time; and
step 4.4: rolling and bending the fifth horizontal wall 11 and the third vertical wall 8 for multiple times, gradually reducing the angle of the seventh corner structure 59 to form the seventh bend structure 33, and gradually reducing an angle of the eighth corner structure 60 to form the eighth bend structure 34, where in the step 4.1, the angle of the seventh corner structure 59 is 175°;
in the step 4.2, the angle of the seventh corner structure 59 is 170°;
in the step 4.3, the angle of the seventh corner structure 59 is 160°, and the angle of the eighth corner structure 60 is 170°; and
the step 4.4 specifically includes the following steps:
step 4.4.1: rolling and bending the fifth horizontal wall 11 and the third vertical wall 8, such that the angle of the seventh corner structure 59 is 150°, and the angle of the eighth corner structure 60 is 160°;
step 4.4.2: rolling and bending the fifth horizontal wall 11 and the third vertical wall 8, such that the angle of the seventh corner structure 59 is 140°, and the angle of the eighth corner structure 60 is 150°;
step 4.4.3: rolling and bending the fifth horizontal wall 11 and the third vertical wall 8, such that the angle of the seventh corner structure 59 is 130°, and the angle of the eighth corner structure 60 is 140°;
step 4.4.4: rolling and bending the fifth horizontal wall 11 and the third vertical wall 8, such that the angle of the seventh corner structure 59 is 120°, and the angle of the eighth corner structure 60 is 130°;
step 4.4.5: rolling and bending the fifth horizontal wall 11 and the third vertical wall 8, such that the angle of the seventh corner structure 59 is 110°, and the angle of the eighth corner structure 60 is 120°;
step 4.4.6: rolling and bending the fifth horizontal wall 11 and the third vertical wall 8, such that the angle of the seventh corner structure 59 is 100°, and the angle of the eighth corner structure 60 is 110°;
step 4.4.7: rolling and bending the fifth horizontal wall 11 and the third vertical wall 8, such that the angle of the seventh corner structure 59 is 90°, the seventh bend structure 33 is formed, and the angle of the eighth corner structure 60 is 100°; and
step 4.4.8: rolling and bending the fifth horizontal wall 11, such that the angle of the eighth corner structure 60 is 90°, and the eighth bend structure 34 is formed;
step 5: performing laser welding on a joint of the fourth vertical wall 10 and the first vertical wall 1, where the second vertical wall 5, the third vertical wall 8, the fourth horizontal wall 9, and the first vertical wall 1 form a first cavity 12 and a second cavity 13;
step 6: rolling and bending one end of the fifth horizontal wall 11 away from the fourth vertical wall 10 to form a connecting edge 14 and a sixth horizontal wall 15 connected to each other, where a ninth corner structure 35 is formed between the connecting edge 14 and the sixth horizontal wall 15; and the step 6 specifically includes the following steps:
step 6.1: rolling and bending one end of the fifth horizontal wall 11 away from the fourth vertical wall 10 to form the connecting edge 14 and the sixth horizontal wall 15, where a ninth corner structure 61 is formed between the connecting edge 14 and the sixth horizontal wall 15; and
step 6.2: rolling and bending the connecting edge 14 for multiple times, and gradually reducing an angle of the ninth corner structure 61 to form the ninth bend structure 35,
where in the step 6.1, the angle of the ninth corner structure 61 is 180°; and
the step 6.2 specifically includes the following steps:
where in the step 7.1, the angle of the tenth corner structure 62 is 163°; and
the step 7.2 specifically includes the following steps:
The method for manufacturing a rollforming frame further includes the following steps:
This embodiment further provides a rollforming frame manufactured using the above method for manufacturing a rollforming frame.
The rollforming frame provided in this embodiment includes a bottom plate 3, a left longitudinal beam portion 49, and a right longitudinal beam portion 50, where the left longitudinal beam portion 49 and the right longitudinal beam portion 50 are disposed at two opposite ends of the bottom plate 3 respectively; each of the left longitudinal beam portion 49 and the right longitudinal beam portion 50 includes the first vertical wall 1, the fourth horizontal wall 9, the third vertical wall 8, the second vertical wall 5, the fourth vertical wall 10, the seventh horizontal wall 17, the fifth vertical wall 16, and the connecting edge 14 that are sequentially connected, the fourth horizontal wall 9, the third vertical wall 8, and the second vertical wall 5 form a first notch structure, the second vertical wall 5, the fourth vertical wall 10, and the seventh horizontal wall 17 form a second notch structure, the first vertical wall 1 is connected to an opening end of the first notch structure, the fourth vertical wall 10 is connected to the first vertical wall 1, the fifth vertical wall 16 is connected to an opening end of the second notch structure, and the connecting edge 14 is connected to one end of the second vertical wall 5 adjacent to the third vertical wall 8.
In this embodiment, a high-strength steel strip is used as a raw material, each of two sides of the steel strip is designed to be provided with a special-shaped cavity in a rectangular shape with a vertical line in the middle, the middle of the cavity is provided with a bottom structure that is a steel plate, and the cavities in the two sides and the bottom structures are integrally formed, where the cavity is laser-welded and a machining technology is roll forming.
On the basis of the above integrally rolled profile, the steel plates at front and rear ends are machined using a bending technology to form predetermined cavities, then a joint is welded, and finally an integrally formed frame is formed.
Those skilled in the art can understand this embodiment as a more specific description of Embodiment 1.
This embodiment provides a method for manufacturing a rollforming frame. High-strength steel with the strength of 600 MPa or above is used as a material to achieve light weight of the material.
According to the manufacturing method in this embodiment, a steel strip passes through a roll forming mold; then, a plurality of cavities are formed on a left side and a right side of the steel strip by rolling respectively; the cavities are connected as a whole by the steel strip to serve as a bottom plate of a battery frame, where the left and right cavities are longitudinal beams, configured to support the frame and prevent collision; front and rear steel strips are formed into front and rear single-cavity transverse beams through a bending technology; and finally welding is performed to form the integrally rolled battery frame.
The manufacturing method in this embodiment includes the following steps.
In 1st to 9th passes,
two vertical walls are gradually formed by a roller, two horizontal plates are distributed in a left-right manner, a lower steel strip is formed into a bottom plate, two sides of the bottom plate are connected, and finally a “hat” shape is formed;
left and right bends 1 # are formed, and optimal angles for the 1st to 8th passes are 177°, 170°, 160°, 145°, 130°, 115°, 100°, and 90° in sequence; and
left and right bends 2 # are formed, and optimal angles for the 2nd to 9th passes are 172°, 162°, 148°, 132°, 118°, 103°, 93°, and 90° in sequence.
In 10th to 15th passes, the left and right horizontal plates are gradually rollformed by the roller, and finally a stepped structure is formed;
left and right bends 3 # are formed, and optimal angles for the 10th to 14th passes are 3°, 15°, 30°, 45°, and 54° in sequence;
left and right bends 4 # are formed, and optimal angles for the 11st to 15th passes are 13°, 28°, 42°, 52°, and 54° in sequence; and
a step can be formed after bending by the roller, has the optimal height of 2 mm, and is configured to mount a sealing strip and/or a sealing adhesive.
In 16th to 23rd passes,
the left and right horizontal plates continue being rollforming by the roller, and finally left and right second vertical walls and second horizontal walls are formed;
left and right bends 5 # are formed, and optimal angles for the 16th to 22nd passes are 176°, 165°, 150°, 135°, 120°, 105°, and 90° in sequence; and
left and right bends 6 # are formed, and optimal angles for the 17th to 23rd passes are 170°, 155°, 140°, 125°, 110°, 95°, and 90° in sequence.
In 24th to 34th passes,
horizontal edges between the step and the second vertical walls are gradually rollformed and bent by the roller, and the second horizontal edges continue being rollformed and bent, where the second horizontal edges are bent by 90° and then are in contact with first vertical walls to form a first cavity and a second cavity;
left and right bends 7 # are formed, and optimal angles for the 24th to 33rd passes are 175°, 170°, 160°, 150°, 140°, 130°, 120°, 110°, 100°, and 90° in sequence; and
left and right bends 8 # are formed, and optimal angles for the 26th to 34th passes are 170°, 160°, 150°, 140°, 130°, 120°, 110°, 100°, and 90° in sequence.
In a 35th pass of welding, contact parts between the left and right second horizontal edges and the left and right first vertical walls are gradually laser-welded by the roller to form a first cavity and a second cavity that are closed, and steel plates are formed as a whole, thereby ensuring the structural stability, strength and stiffness.
In 36th to 39th passes,
the left and right second horizontal edges continue being gradually rollformed and bent by the roller, and a small weld edge is formed; and
left and right bends 9 # are formed, and optimal angles for the 36th to 39th passes are 180°, 150°, 120°, and 90° in sequence.
In 40th to 45th passes, the left and right second horizontal edges and the small weld edge continue to be gradually rollformed and bent by the roller, and a bend 10 # is formed; and
left and right bends 10 # are formed, and optimal angles for the 40th to 45th passes are 163°, 145°, 130°, 115°, 100°, and 90° in sequence.
In a 46th pass of welding,
contact parts between the left and right second horizontal edges and left and right small weld edges are gradually laser-welded by the roller to form a third cavity and a fourth cavity that are closed, steel plates are formed as a whole, and forming of a total of four cavities is completed, thereby ensuring the structural stability, strength and stiffness.
The periphery of the frame is welded using a welding technology to form a whole, thereby ensuring the structural integrity, stability and performance requirements of the entire frame.
In the technological process, the offline butt-welding step is canceled, which reduces equipment investment and labor input, significantly reduces equipment investment, factory investment, and machining costs, and creates huge economic benefits.
According to the present invention, an advanced roll forming technology is used for online integral forming, during which there are good product quality and high production stability and efficiency.
In the description of this application, it is to be understood that the orientations or positional relationships indicated by the terms “upper”, “lower”, “front”, “rear”, “left”, “right”, “vertical”, “horizontal”, “top”, “bottom”, “inside”, “outside”, etc. are based on the orientations or positional relationships shown in the accompanying drawings, only for the convenience of describing the present application and simplifying the description rather than indicating or implying that the apparatus or element referred to must have a particular orientation or be constructed and operated in a particular orientation, and therefore cannot be construed as limitations to the present application.
Compared with the prior art, the present invention has the following beneficial effects:
The specific embodiments of the present invention are described above. It is to be understood that the present invention is not limited to the specific embodiments described above, and various changes or modifications may be made by those skilled in the art within the scope of the claims without affecting the spirit of the present invention. The embodiments in this application and the features in the embodiments may be arbitrarily combined with each other under no conflict.
| Number | Date | Country | Kind |
|---|---|---|---|
| 202310579604.5 | May 2023 | CN | national |
This application is a continuation application of International Application No. PCT/CN2023/100557, filed on Jun. 16, 2023, which is based upon and claims priority to Chinese Patent Application No. 202310579604.5, filed on May 22, 2023, the entire contents of which are incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/CN2023/100557 | Jun 2023 | WO |
| Child | 19002812 | US |
