A multi-tubular beam for a vehicle, such as a vehicle structure or a bumper reinforcement, includes an elongated beam formed with a metal sheet. The metal sheet has a central section and outer sections extending along a length of the metal sheet. The outer sections are disposed in opposing directions from the outer edges of the central section to provide adjacent first and second tubular portions. The central section forms a common center wall between the adjacent first and second tubular portions. A first edge portion of the metal sheet is disposed along and in parallel alignment with the center wall. The first edge portion is attached to the center wall at a first weld joint to form the first tubular portion. The first weld joint includes a weld material that extends through a thickness of the center wall and into a thickness of the first edge portion.

A method for joining edges and/or surfaces of a profile in a profiling installation for longitudinally forming a virtually endless material strip into an at least partially closed profile shape. The material strip or profile is formed roll forming tools into a profile which is closed or partially closed, and is fixed in a joining zone, with a longitudinally running joining seam being formed. The profile passes in the joining zone through a joining roller arrangement and/or planar joining arrangement to feed the profile to a joining point and to stabilize the profile there, and/or to ensure that it is dimensionally stable during and after joining. Forces or magnitudes of force components which act on the profile from at least one of the joining rollers and/or a subsection of the planar joining arrangement are detected in the joining zone. A planar joining arrangement and a profiling installation are also provided.

A roof rail including a rail profile including a sheet material. The sheet material includes a cover part and a mounting part. A flange wall includes an edge portion of the cover part and a proximal portion of the mounting part connected to the edge portion, wherein an inner surface of the proximal portion is arranged at an angle. A second flange wall includes a second edge portion of the cover part arranged opposite the edge portion and a second proximal portion of the mounting part connected to the second edge portion, wherein an inner surface of the second proximal portion is arranged at a second angle. The mounting part includes a distal portion, wherein the distal portion is attached to the proximal portion and the second proximal portion and arranged at a mounting distance of at least 1 mm above a plane including lowermost parts of the flange walls.

A galvanized reinforcement beam is continuously formed by uncoiling a roll of galvanized sheet stock in a generally horizontal plane. Protrusions are formed at an upper surface of the sheet stock, which is then roll formed to form a tubular shape with the protrusions abutting a surface of the sheet stock to form venting gaps. The sheet stock is laser welded at the protrusions to continuously form a weld joint, where zinc oxide gas generated from the welding is permitted to escape an interior of the tubular shape through the venting gaps.

A profiling station, a profiling unit formed therefrom and also a profiling installation continuously form a material strip into a profile. The profiling station includes a rack frame, a profiling arrangement with a forming roller and also a first and a second counter roller as well as a drive assembly. A first roller axis and a second roller axis of the counter rollers form between them a buckling angle, wherein the counter rollers define a bending edge for the material strip to be formed. The first counter roller and also the second counter roller are driven by the drive assembly in such a way that the first counter roller has a circumferential speed at its outer circumference and the second counter roller has a circumferential speed at its outer circumference that are equal to one another.

A multi-tubular beam for a vehicle, such as a vehicle structure or a bumper reinforcement, includes an elongated beam formed with a metal sheet. The metal sheet has a central section and outer sections extending along a length of the metal sheet. The outer sections are disposed in opposing directions from the outer edges of the central section to provide adjacent first and second tubular portions. The central section forms a common center wall between the adjacent first and second tubular portions. A first edge portion of the metal sheet is disposed along and in parallel alignment with the center wall. The first edge portion is attached to the center wall at a first weld joint to form the first tubular portion. The first weld joint includes a weld material that extends through a thickness of the center wall and into a thickness of the first edge portion.

A profiling station, a profiling unit formed therefrom and also a profiling installation continuously form a material strip into a profile. The profiling station includes a rack frame, a profiling arrangement with a forming roller and also a first and a second counter roller as well as a drive assembly. A first roller axis and a second roller axis of the counter rollers form between them a buckling angle, wherein the counter rollers define a bending edge for the material strip to be formed. The first counter roller and also the second counter roller are driven by the drive assembly in such a way that the first counter roller has a circumferential speed at its outer circumference and the second counter roller has a circumferential speed at its outer circumference that are equal to one another.

A multi-axis roll-forming system for forming a stepped diameter in a cylinder includes a support that spins about a rotation axis while supporting a workpiece that includes the cylinder. A first actuator translates a first roller perpendicularly to the rotation axis. A second actuator moves a multi-axis roller radially outward, relative to the rotation axis, and upward along the rotation axis. The system may also include a first roller arm to which the multi-axis roller is coupled. The first roller arm is connected to a pivot joint having a pivot axis that is perpendicular to the rotation axis. The second actuator may include a linear-drive actuator that is coupled to the first roller arm and extends along the rotation axis to force the multi-axis roller to pivot about the pivot axis.

A multi-axis roll-forming system for forming a stepped diameter in a cylinder includes a support that spins about a rotation axis while supporting a workpiece that includes the cylinder. A first actuator translates a first roller perpendicularly to the rotation axis. A second actuator moves a multi-axis roller radially outward, relative to the rotation axis, and upward along the rotation axis. The system may also include a first roller arm to which the multi-axis roller is coupled. The first roller arm is connected to a pivot joint having a pivot axis that is perpendicular to the rotation axis. The second actuator may include a linear-drive actuator that is coupled to the first roller arm and extends along the rotation axis to force the multi-axis roller to pivot about the pivot axis.

A multi-axis roll-forming system for forming a stepped diameter in a cylinder. The system includes a support configured to spin about a rotation axis while supporting a workpiece including a cylinder. A first actuator is configured to translate a first roller perpendicular to rotation axis. The first roller includes a truncated conical work surface configured to press against the inward-facing surface of the cylinder to angle it outward according to a slant angle of the truncated conical work surface.