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EP-4534238-B1 - PREPARATION METHOD FOR ROLL FORMING FRAME AND ROLL FORMING FRAME

EP4534238B1EP 4534238 B1EP4534238 B1EP 4534238B1EP-4534238-B1

Inventors

  • LI, DANYANG
  • ZHANG, HUI

Dates

Publication Date
20260513
Application Date
20230616

Claims (16)

  1. A method for manufacturing a rollforming frame, comprising the following steps: 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, wherein a bottom plate (3) is formed between two first vertical walls (1); step 2: for each of the two opposite ends of the bottom plate (3), rolling and bending an end of the first horizontal wall (2) adjacent to the first vertical wall (1) to form a stepped bent structure (4); step 3: for each of the two opposite ends of the bottom plate (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; step 4: for each of the two opposite ends of the bottom plate (3), 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, wherein the fourth vertical wall (10) abuts against the first vertical wall (1); step 5: for each of the two opposite ends of the bottom plate (3), performing laser welding on a joint of the fourth vertical wall (10) and the first vertical wall (1), wherein 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), respectively, at the two opposite ends of the bottom plate (3); step 6: for each of the two opposite ends of the bottom plate (3), rolling and bending an 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; step 7: for each of the two opposite ends of the bottom plate (3), rolling and bending the sixth horizontal wall (15) to form a fifth vertical wall (16) and a seventh horizontal wall (17) connected to each other, wherein the connecting edge (14) abuts against the second vertical wall (5); and step 8: for each of the two opposite ends of the bottom plate (3), performing laser welding on a joint of the connecting edge (14) and the second vertical wall (5), wherein the fourth vertical wall (10), the fifth vertical wall (16), the seventh horizontal wall (17), and the second vertical wall (5) form a third cavity (18) and a fourth cavity (19), respectively, at the two opposite ends of the bottom plate (3).
  2. The method for manufacturing the rollforming frame according to claim 1, wherein in the step 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); in the step 2, a third bend structure (29) and a fourth bend structure (30) are formed in the stepped bent structure (4); in the step 3, 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); in the step 4, 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; in the step 6, a ninth bend structure (35) is formed between the connecting edge (14) and the sixth horizontal wall (15); and in the step 7, a tenth bend structure (36) is formed between the fifth vertical wall (16) and the seventh horizontal wall (17), and two ends of the fifth vertical wall (16) are connected to the connecting edge (14) and the seventh horizontal wall (17) respectively.
  3. The method for manufacturing the rollforming frame according to claim 2, wherein the step 1 specifically comprises 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, wherein the bottom plate (3) is formed between the first side edge structure (20) and the second side edge structure (21), a first corner structure (53) is formed between the first side edge structure (20) and the bottom plate (3), and the 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), wherein 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).
  4. The method for manufacturing the rollforming frame according to claim 3, wherein 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 comprises 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.
  5. The method for manufacturing the rollforming frame according to claim 2, wherein the step 2 specifically comprises the following steps: step 2.1: rolling and bending the 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), wherein 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), wherein 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).
  6. The method for manufacturing the rollforming frame according to claim 5, wherein 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 comprises 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.
  7. The method for manufacturing the rollforming frame according to claim 2, wherein the step 3 specifically comprises 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), wherein 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), wherein 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).
  8. The method for manufacturing the rollforming frame according to claim 7, wherein 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 comprises 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 sixth bend structure (32) is formed.
  9. The method for manufacturing the rollforming frame according to claim 2, wherein the step 4 specifically comprises 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), wherein 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 a first time; step 4.3: rolling the third horizontal wall (7) to form the fourth vertical wall (10) and the fifth horizontal wall (11), wherein 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 a 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).
  10. The method for manufacturing the rollforming frame according to claim 9, wherein in the step 4.1, the angle of the seventh corner structure (59) when formed 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 comprises 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.
  11. The method for manufacturing the rollforming frame according to claim 2, wherein the step 6 specifically comprises the following steps: step 6.1: rolling and bending the 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), wherein 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).
  12. The method for manufacturing the rollforming frame according to claim 11, wherein in the step 6.1, the angle of the ninth corner structure (61) is 180°; and the step 6.2 specifically comprises the following steps: step 6.2.1: rolling and bending the connecting edge (14), such that the angle of the ninth corner structure (61) is 150°; step 6.2.2: rolling and bending the connecting edge (14), such that the angle of the ninth corner structure (61) is 120°; and step 6.2.3: rolling and bending the connecting edge (14), such that the angle of the ninth corner structure (61) is 90°, and the ninth bend structure (35) is formed.
  13. The method for manufacturing the rollforming frame according to claim 2, wherein the step 7 specifically comprises the following steps: step 7.1: rolling and bending the sixth horizontal wall (15) to form the fifth vertical wall (16) and the seventh horizontal wall (17), wherein a tenth corner structure (62) is formed between the fifth vertical wall (16) and the seventh horizontal wall (17); and step 7.2: rolling and bending the fifth vertical wall (16) for multiple times, and gradually reducing an angle of the tenth corner structure (62) to form the tenth bend structure (36).
  14. The method for manufacturing the rollforming frame according to claim 13, wherein in the step 7.1, the angle of the tenth corner structure (62) is 163°; and the step 7.2 specifically comprises the following steps: step 7.2.1: rolling and bending the fifth vertical wall (16), such that the angle of the tenth corner structure (62) is 145°; step 7.2.2: rolling and bending the fifth vertical wall (16), such that the angle of the tenth corner structure (62) is 130°; step 7.2.3: rolling and bending the fifth vertical wall (16), such that the angle of the tenth corner structure (62) is 115°; step 7.2.4: rolling and bending the fifth vertical wall (16), such that the angle of the tenth corner structure (62) is 100°; and step 7.2.5: rolling and bending the fifth vertical wall (16), such that the angle of the tenth corner structure (62) is 90°, and the tenth bend structure (36) is formed.
  15. The method for manufacturing the rollforming frame according to claim 2, wherein in the step 8, a left longitudinal beam portion (49) and a right longitudinal beam portion (50) are formed at two opposite ends of the bottom plate (3); and the method for manufacturing the rollforming frame further comprises the following steps: step 9: cutting the left longitudinal beam portion (49) and the right longitudinal beam portion (50) located at four corners of the bottom plate (3) to form a front longitudinal beam plate (37) and a rear longitudinal beam plate (38) at another two opposite ends of the bottom plate (3); step 10: for each of the another two opposite ends of the bottom plate (3), separately bending the front longitudinal beam plate (37) and the rear longitudinal beam plate (38) to form a sixth vertical wall (39) and an eighth horizontal wall (40), wherein an eleventh bend structure (41) is formed between the sixth vertical wall (39) and the eighth horizontal wall (40); step 11: for each of the another two opposite ends of the bottom plate (3), bending the eighth horizontal wall (40) to form a seventh vertical wall (42) and a ninth horizontal wall (43), wherein a twelfth bend structure (44) is formed between the seventh vertical wall (42) and the ninth horizontal wall (43); step 12: for each of the another two opposite ends of the bottom plate (3), bending the seventh vertical wall (42) to form an eighth vertical wall (45) and a tenth horizontal wall (46), wherein a thirteenth bend structure (47) is formed between the eighth vertical wall (45) and the tenth horizontal wall (46); step 13: for each of the another two opposite ends of the bottom plate (3), bending the ninth horizontal wall (43), such that the sixth vertical wall (39) abuts against the bottom plate (3), a fourteenth bend structure (48) is formed between the ninth horizontal wall (43) and the bottom plate (3), and a front longitudinal beam portion (51) and a rear longitudinal beam portion (52) are respectively formed at the another two opposite ends of the bottom plate (3); and step 14: welding a joint of the front longitudinal beam portion (51) and the left longitudinal beam portion (49), welding a joint of the front longitudinal beam portion (51) and the right longitudinal beam portion (50), welding a joint of the rear longitudinal beam portion (52) and the left longitudinal beam portion (49), welding a joint of the rear longitudinal beam portion (52) and the right longitudinal beam portion (50), and welding a joint of the sixth vertical wall (39) and the bottom plate (3).
  16. A rollforming frame, manufactured using the method for manufacturing the rollforming frame according to any one of claims 1 to 15, comprising a bottom plate (3), a left longitudinal beam portion (49), and a right longitudinal beam portion (50), wherein 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) comprises 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, and 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, and the fourth vertical wall (10) is connected to the first vertical wall (1); and the fifth vertical wall (16) is connected to an opening end of the second notch structure, and the connecting edge (14) is connected to an end of the second vertical wall (5) adjacent to the third vertical wall (8).

Description

TECHNICAL FIELD The present invention relates to the technical field of rollforming profiles, specifically, to a method for manufacturing a rollforming frame, and the rollforming frame. BACKGROUND 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. CN 216288746U discloses a a battery tray, comprising a closed frame and a support part arranged at the bottom of the frame; the top of the frame is provided with an upper cover; the upper cover, the frame and the support part form a closed cavity for accommodating batteries. The cavity is provided with a reinforcing beam, both ends of the reinforcing beam are connected with the frame, and the reinforcing beam divides the first channel surrounded by the closed frame into a second channel and a third channel, and it is characterized in that the support part includes a maintenance cover Plate and bottom plate, the maintenance cover plate is detachably arranged at the bottom of the second channel, the bottom plate is arranged at the bottom of the third channel, the inner wall of the second channel is provided with a plurality of first brackets, and the battery elements in the second channel are installed on the first on the stand. CN 111916603A discloses a rolled section bar and a preparation method thereof, a battery pack framework and a battery pack, wherein the rolled section bar comprises a rolled section bar body which is prepared by rolling and bending a steel belt for multiple times, the rolled section bar body comprises a first part, a second part and reinforcing ribs, the reinforcing ribs in the middle part enable the rolled section bar to be effectively further thinned and reduced in weight under the condition that the strength and the rigidity are not reduced, the rolled section bar provided by the invention can be used for enclosing to form the battery pack framework, an L-shaped pipe structure formed by enclosing the second part and the reinforcing ribs can realize the bottom supporting function of a battery pack. However, these prior arts fail to overcome the defects mentioned above. SUMMARY 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: step 1: separately rolling and bending two opposite ends of a to-be-machined plate to separately form a first vertical wall and a first horizontal wall connected to each other at the two opposite ends of the to-be-machined plate, where a bottom plate is formed between the two first vertical walls;step 2: for each of the two opposite ends of the bottom plate, rolling and bending one end of the first horizontal wall adjacent to the first vertical wall to form a stepped bent structure;step 3: for each of the two opposite ends of the bottom plate, rolling and bending the first horizontal wall to form a second vertical wall, a second horizontal wall, and a third horizontal wall that are connected;step 4: for each of the two opposite ends of the bottom plate, rolling and bending the second horizontal wall to form a third vertical wall and a fourth horizontal wall connected to each other; and rolling and bending the third horizontal wall to form a fourth vertical wall and a fifth horizontal wall connected to each other, where the fourth vertical wall abuts against the first vertical wall;step 5: for each of the two opposite ends of the bottom plate, performing laser welding on a joint of the fourth vertical wall and the first vertical wall, where the second vertical wall, the third vertical wall, the fourth horizontal wall, and the first vertical wall form a first cavity and a second cavity, respectively, at the two opposite ends of the bottom plate;step 6: for each of the two opposite ends of the bottom plate, rolling and bending one end of the fifth horizontal wall away from the fourth vertical wall to form a connecting edge and a sixth horizontal wall connected to e