Continuous process of roll-forming pre-stamped varying shapes

Abstract

An apparatus includes a press with dies configured to deform a strip of material by drawing material primarily from a width direction, a slitter set to cut the deformed strip to a uniform desired width dimension, and a roll-former with rolls configured to shape linear portions of the deformed and now uniform-width strip into a continuous beam. The apparatus further includes a welder for welding abutting edges of the sheet together to form a permanent tube, a sweep station for imparting a longitudinal shape to the continuous beam, and a cut-off for cutting the continuous beam into segments useful as vehicle bumper beams. A controller controls timing of various components. The beam segments are optimized in specific regions for local strength and minimized weight, and features can be incorporated into the beam segments such as coplanar mounting surfaces.

1 . An apparatus adapted to form a reinforcement beam comprising: 
 a press including dies configured to deform a flat strip of material into a deformed strip with a three-dimensional shape by moving material primarily in a width direction;    a slitter set to cut the deformed strip to a uniform width of desired constant dimension; and    a roll-former with rolls configured to shape linear portions of the deformed and uniform-width strip into a continuous beam.    
   
   
       2 . The apparatus defined in  claim 1 , wherein the rolls are configured to shape opposing edge portions of the strip.  
   
   
       3 . The apparatus defined in  claim 1 , wherein the rolls are configured and arranged to cause the opposing edge portions of the strip to abut.  
   
   
       4 . The apparatus defined in  claim 3 , including a welder configured to weld the opposing edge portions together to form the beam as a permanent continuous tube.  
   
   
       5 . The apparatus defined in  claim 4 , including a cut-off device for cutting the permanent continuous tube into beam segments.  
   
   
       6 . The apparatus defined in  claim 5 , including a controller for controlling the press, the roll-former, the welder, and the cut-off device in a coordinated manner.  
   
   
       7 . The apparatus defined in  claim 1 , including a sweep station configured to impart a longitudinally curved shape to the beam.  
   
   
       8 . The apparatus defined in  claim 1 , wherein the dies are configured to form flat mounting surfaces.  
   
   
       9 . The apparatus defined in  claim 8 , including a cut-off device for cutting the continuous beam into beam segments, wherein the roll-former includes a sweep station for deforming the continuous beam into a longitudinally curved shape, and wherein the mounting surfaces are coplanar in the individual segments.  
   
   
       10 . The apparatus defined in  claim 1 , including a cut-off device for cutting the continuous beam into beam segments, and wherein a transverse cross section taken through ends of the beam segments defines first tubular sections, and a transverse cross section taken through a center region of the beam segments define a second tubular section different in a fore/aft direction than the first tubular section such that the reinforcement beam has a changing cross-sectional geometry along at least some portions of its length.  
   
   
       11 . The apparatus defined in  claim 1 , wherein the rolls are configured to form an open section with different depths along a length of the beam.  
   
   
       12 . An apparatus adapted to form a reinforcement beam comprising: 
 a press including dies configured to deform a continuous strip of material by moving the material primarily in a direction perpendicular to a feed direction defined by a length of the strip; and    a roll-former positioned in-line with the press and having rolls configured and arranged to receive the strip in the feed direction and shape edge portions of the deformed strip into a reinforcement beam.    
   
   
       13 . A method comprising steps of: 
 providing a single elongated sheet defining a plane and including first, second, and third strip portions integrally connected together;    stamping the first strip portion to deform the first strip portion by moving material primarily in a direction perpendicular to the plane; and    roll-forming the second and third strip portions by use of a roll-forming mill into a beam.    
   
   
       14 . The method defined in  claim 13 , wherein the step of stamping includes drawing material primarily from a width direction of the strip and not from a longitudinal direction.  
   
   
       15 . The method defined in  claim 13 , wherein the second and third strip portions extend from opposing sides of the first strip portion, and wherein the step of roll-forming includes forming the edges of the second and third strip portions into abutting contact.  
   
   
       16 . The method defined in  claim 15 , including a step of welding the edges to form a permanent continuous beam.  
   
   
       17 . The method defined in  claim 13 , including a step of sweeping the continuous beam into a longitudinal curvilinear shape.  
   
   
       18 . The method defined in  claim 17 , wherein the step of stamping includes forming mounting surfaces on the first strip portion, the mounting surfaces being configured to engage and be secured to vehicle frame rails.  
   
   
       19 . The method defined in  claim 13 , wherein the step of roll-forming includes forming the beam to have an open section with a varied depth dimension.  
   
   
       20 . A tubular reinforcement beam comprising: 
 a sheet of material formed into a tubular beam having a length with a center section, opposing mounting sections, and intermediate sections connecting outboard ends of the center section to associated ones of the mounting sections;    a first transverse cross section taken through the center section defining a first wall length around its perimeter that is a first length dimension;    a second transverse cross section through an inboard edge of the mounting sections defining a second wall length around its perimeter that is a second length dimension;    a third transverse cross section taken through a middle of the intermediate sections defining a first wall length around its perimeter that is a third length dimension;    the second length dimension being different than the first and third length dimensions and wherein the first, second, and third length dimensions are selected to optimize local beam strength and to minimize weight and wasted material.    
   
   
       21 . The beam defined in  claim 20 , wherein the first, second, and third length dimensions are each different.  
   
   
       22 . A method of forming a reinforcement beam comprising steps of: 
 providing a press including forming dies at a location in-line and upstream of a roll-former having rolls;    operating the dies to deform a continuous strip of material by moving the material primarily in a direction perpendicular to a feed direction defined by a length of the strip; and    operating rolls of a roll-forming mill to receive the strip in the feed direction and shape edge portions of the deformed strip into a reinforcement beam.