DE102005018549B3 - Production method for metallic guide element involves implementation of milling operation by position-controlled mill-cutting body with cutting disk of large diameter and flow of material inside high-speed milling cutter system - Google Patents

Abstract

Production method involves implementation of milling operation by position-controlled mill-cutting body (34) with cutting disk of large diameter and flow of material inside high-speed milling cutter system (1) automatically via integrated stacking device (18) consisting of manipulators (12,13) and turning stations (53,54). An independent claim is also included for the high-speed milling cutter system.

Description

The The invention relates to a high performance milling machine constructed of machine modules. with integrated stacking device and a milling device for partial removal of decarburized layers and for tolerance narrowing in geometrically defined rolled profile bars. Manipulators serve as a feeder device. With suitable means, the profile bar chamber in the machining direction measured geometrically, in the middle of a worktable with adjustable Profile stop cocked and machined by a milling body.

Such methods and devices are known from the patents DE 196 21 536 C2 and DE 101 40 307 C1 known. In these methods and apparatus for the production of steel profiled bars for linear guide elements by means of a combination of thermoforming and subsequent cold forming, a machining shaping stage is provided between the stages of hot forming and cold forming. This eliminates costly and time-consuming production steps.

The essentially U- or H-shaped guide elements for the Forklift construction diminishes in the case of widely extending stacker scaffolding for high lifting heights the hot rolling according to the prior art of a cold drawing operation for narrowing the chamber dimension tolerance subjected. This causes about a halving of Kammermaßtoleranz across from the rolled section.

The Cold drawing is however for this task is not economically optimal and leads to high product costs. Furthermore, it has been tried, the chamber size using conventional milling Technology constrict. However, this machining technique could be and performance reasons not enforce in mass production.

It Therefore, the invention is based on the object, a device to propose, with the help of guide elements especially for the stacker industry can be provided whose Kammermaßtoleranz across from the cold drawing is halved again. In contrast to cold drawing is additional to remove the adverse decarburized layer in the functional area. At the same time a significant improvement in profitability compared to the Cold drawing can be achieved.

Is solved the task by a Hochleistungsfräsanlage according to claim 1, in which a Stacking device for Profiles with lengths organically integrated up to several meters. The modular design Hochleistungsfräsanlage deliberately removes the decarburized layers of the rolled section bars and reduces them defines their chamber dimensional tolerance. The stacking device allows the autonomous material flow within the high-performance milling machine, so that the use of external, time-consuming handling equipment can be waived.

Furthermore allows the seamless and system-compliant integration of the high-performance milling system into the existing in-house overall material flow system, as follows To sketch: According to the state of the art, the operationally produced profile bars combined into profile coils, wherein the profile bars within a profile federation in geometrically predetermined sequence and situation to each other, according to a so-called stack image, are arranged.

The stacked profile bundles are the basis of an optimized inner and external Material flow. The integrated automated stacking device Ensures the connection to this material flow without additional Handling effort is required.

The for the High-performance milling provided rolled profile bars, preferably to stacked profile coils in normal operation Subsets are summarized in the area of the material template the high performance milling machine positioned for editing.

to Avoiding additional Handling expenses are the profile coils by means of an inlet side Manipulator destacked by the rod. This one is part of two Manipulators and two turning stations existing integrated stacking device the high performance milling machine. The stacking device is used for unstacking, stacking, turning, transporting and positioning the profile bars.

The manipulator conveys the profile bar either directly or indirectly into the milling plane. The direct feed takes place when the geometric profile positioning in the profile collar is identical to that in the milling plane. The indirect bar feed is required when the profile bar must first be turned by 180 ° about its longitudinal axis, since its stacking position deviates by just 180 ° from the fixed milling position. The turning function is performed by the inflow-side turning station. After milling, the profile bars are removed from the milling plane by means of the outlet-side manipulator and stacked into profile collars. This stack corresponds to that of the inlet side Pro filbundes. Since it is necessary for the execution of the desired stacking image to rotate corresponding profiles before their placement in the resulting outlet side profile collar by 180 ° about its longitudinal axis, an outlet side turning station for performing this function is installed.

There U-shaped profile bars have only a single chamber due to their cross-sectional shape, is just a milling operation required with the appropriate manipulations. H-shaped profiled bars, on the other hand, which have two chambers must have two milling go through with the associated manipulations.

The according to the inventive idea, as described, with two manipulators and two associated turning stations equipped stacking device solves this handling task the coordinated use of the stacking device sub-elements after the principle of minimized non-productive times.

Preferably becomes the outlet side turning station next to the horizontal turning axis also equipped with a vertical turning axis to unbalanced Edit H-profiles in a single pass. Consequently is in principle ensured that as a rolling profile of Horizontalfräsanlage submitted stacked profile collar after completion of milling cost as Stacked finished milled profile collar can be removed in the outlet area.

The milling the profile bars takes place in the milling plane the high performance milling machine. While the milling operation the profile bar remains stationary in the profile clamping device with upwards, in the direction of the milling body, pointing Profile Chamber. By means of at least two vertical levels acting disc milling system becomes the entire profile length overlined in a single pass and thus machined.

It is through appropriate monitoring members ensure that the profile bars are in the correct position - with top - facing profile chamber - from the manipulators are entered into the clamping device.

The profile bars be horizontally against a by means of adjustable clamping elements positionable fixed stop clamped. Coordinating with the horizontal Clamping are vertically arranged clamping elements as hold-down effective to the profile bars without play to the straight profile pads of the clamping device.

On this way you can any existing straightness and torsional deviations of the profile bars no negative influence on the milling result to take.

Further the horizontal clamping elements are designed so that chamber scale changing Profile deformations are excluded. The horizontal and vertical Clamping elements are adaptable to the different profile cross sections.

The effective length The tensioning device can be of a single correspondingly long Profile bar taken or by a combination same or different long profile bars be occupied. The latter are in the inlet area of the high-performance milling machine from different, stacked bundles from introduced. monitoring sensors avoid length collisions.

Of the Milling body constructed from several subelements is in its mechanical engineering Stellachsen with respect to the geometric center of the profile chamber dimension and defined in terms of the depth of the chamber measuring range, to the desired profiledimensions after milling to reach. For this purpose, the profile-specific actual dimensions before milling and while the milling process detected by mechanical or optoelectronic sensors. The corresponding measured value processing can be used to generate those manipulated variables be that the milling body by means of Control elements accurate to measure position.

Of the milling is preferably with a positioned on a driven shaft equipped with adjustable milling body, which is equipped at least in two separate planes with cutting bodies.

Besides It is also possible to use a version in which two "half" milling bodies are attached on each associated with a driven shaft, offset from one another are arranged adjustable. These complement each other with their sub-functions to the function of the complete Milling body and have the advantage that the now clearly separated cutting body tipped levels with little effort can be hired.

advantageously, is the milling area equipped with a deburring and Nachformeinrichtung, with the cutter body unit trailing firmly connected. The device has the task possible Burrs at the transition between machined inner flange area and unprocessed horizontal Defined flange width range to remove and a predetermined transition contour between the surfaces train. This device is designed by in her Diameter and shape adapted driven cutters.

to further increase in performance can the high-performance milling with a second milling plane be provided parallel to the existing at close range is arranged. For this purpose, the cutter body slide rotatable in its vertical axis by 180 ° designed. As a result, the milling body can be a milling plane in the Synchronization and the second run in reverse. This design was not shown in the drawing.

Further Functions, features, details and advantages of the inventive Proposal, to be reproduced by means of the drawings embodiments illustrative being represented. It shows

1 : As a top view, the basic structure of the high-performance milling machine with integrated stacking device, with the manipulators and the turning stations.

2 : The clamping and milling body engagement situation in a U-profile with horizontal / vertical clamping elements and distance measuring device for position determination.

3 : The tension and profile chamber measurement situation of a U-profile with horizontal / vertical clamping elements and sensor.

4 : The tension and profile chamber measurement situation of a symmetrical H-profile with horizontal / vertical clamping elements and sensors.

5 : The tension and profile chamber measurement situation of a U-profile with web with horizontal / vertical clamping elements with sensor and distance gauge.

6 : The schematic representation of a) a 2-disc milling body of the milling unit, with a sliding element, b) a 2-disc milling body on two shafts.

7 : The schematic representation of the machining sequences in the high-performance milling machining of a symmetrical H-profile.

8th : The schematic representation of the handling sequence of an asymmetrical H-profile.

To 1 is the high-performance milling machine with integrated stacking device 1 from essentially similar machine modules 62 together, which result in their length addition in about the plant length L. L can to the desired total length of the profiles to be milled 2 . 3 . 4 or profile combinations 22 . 23 . 24 be adjusted.

The operationally stacked profile bundles are in the material template area 14 opened for editing. The incoming manipulator 12 , the part of the stacking device 18 is sensor-based, the profile bars removes rod from the collar or from the bundles and transports them in profile feed direction 21 towards the milling plane 15 , Are the profile bars, according to their stacking image, so positioned in the profile collar that the profile chamber to be machined up, towards the milling body 34 shows, they can go directly to the milling plane 15 be supplied.

If, on the other hand, the profile chamber points downwards, in the direction of the machine bed, then the profile bars must be turned by means of the inflow-side turning device 53 which are also part of the stacking device 18 is to be turned by 180 ° about its longitudinal axis. This indirect feed ensures that these profiled bars are in the correct position, with the profile chamber pointing upwards, into the milling plane 15 be registered. The plane E1-E1 is the reference level for the automatic destacking.

2 makes the profile bar clamping situation in the milling plane 15 the example of a profile bar with a U-shaped cross-section 2 clear. The profile bar is horizontal by the clamping elements 7 and 8th clamped. The vertical clamping elements 9 have the function of hold-downs. The solid profile stop 7 and the movable horizontal clamping elements 8th are relative to their horizontal movements by the arrows 28 characterized; the direction of movement of the swiveled vertical clamping elements 9 is going through 29 displayed. By means of a coordinated clamping movement between 7 . 8th and 9 becomes the profile bar 2 firm and straight against the flat support surface 33 of the table area 11 created.

The width 56 of the profile cross-section 2 , can through the horizontal distance meter 59 with sensor 60 be determined because the position of the dimensionally known clamping element 7 fix is and clamping element 8th at the time of measurement 2 is applied. From the width 56 is mathematically the profile center 57 certainly. However, this width center is only with the center of the profile chamber width before milling 48 identical, if the two legs of the U-profile are equally strong.

To perform the milling operation in Kammermaßbereich the profile of the milling body 34 , whose predetermined machining effective width of the desired profile chamber width after milling 45 corresponds to the profile center 57 positioned and lowered so far towards the profile chamber down to the desired profile chamber depth 49 results. The difference between the profile chamber wide before milling 48 and the profile chamber width after milling 45 corresponds to the abzuspanenden areas F1, F2, as shown by way of example for a U-profile.

By means of in 3 shown, immersed in the U-profile chamber sensor 30 , the profile center can 57 be measured directly. For the same thigh strength, it is identical to the calculated center of the profile. The sensor 30 also allows the detection of the entire profile chamber contour 50 . 58 represented by the curves R1 to R6.

These Contour detection function leaves in the technical design of the optoelectronic sensor also to use to continuously monitor the milling result around on signs of wear react in time to the carbide cutting plates of the cutter body can.

While U-profiles due to their straight profile back over a large area on the support surface 33 must be created, the H-profiles 3 in the area of the milling body 34 opposite chamber when clamping with an adapted profile pad 16 . 4 be provided. The required clamping clearance 32 ensures statically determined clamping conditions.

A similar clamping situation also applies to U-profiles with web 4 where a suitably adapted clamping clearance 31 is provided, 5 ,

With regard to the design of the milling unit 5 can according to 6 Both the variant a) and the embodiment b) are used. In variant a), the two side milling cutters 41 and 42 of the cutter body 34 on a common wave 35 positioned. The fixing elements 44 create the lateral limit of the side milling cutters 41 . 42 ,

About the sliding element 43 can be the machined effective width of the cutter body 34 to adjust. The design b) uses juxtaposed side milling cutters 36 with own driven waves 51 , The advantage of this design is that the machined effective width of this cutter body 34 by means of the two displacement elements 43 due to individual employment is easier to realize.

To ensure cost-effectiveness that goes far beyond conventional milling, the high-performance milling machine is equipped with two design features that are essential for achieving this goal. The first feature is the use of milling bodies 34 large diameter> 600 mm in order to keep the main times of the actual cutting operation low by realizing high feed rates of about 4 to 8 m / min. The second feature is the significant reduction of process auxiliary times, which are mainly due to the profile bar feed, the profile bar positioning in the milling plane 15 and caused by the profiled bar discharge.

The innovative thought of the integrated stack device 18 is the solution for minimizing process overheads. 7 illustrates the sequence of handling operations using the example of a symmetrical H-profile, which is determined by the targeted use of automatic manipulators 12 . 13 and turning stations 53 . 54 distinguished. The optimization of auxiliary time is made clear in accordance with the flowchart solely by the fact that in the totality of all the handling operations that take place, a relatively large profile bar availability in the milling level 15 it can be seen that is the prerequisite for a milling operation.

Thus, sequence a shows that profile bar A with the upstream manipulator 12 from the original area 14 in the milling plane 15 is transported. While the outlet side manipulator 13 the profile bar A after milling the profile chamber from the milling plane 15 removes and to the outlet side turning station 54 transported, creates manipulator 12 in an overall mode of operation, the next profile bar B from the original area already approaches and conveys it in the direction of the milling plane 15 , After milling, profile bar B is manipulator 12 to the upstream turning station 53 transported - sequence b - and there by 180 ° turned around its longitudinal axis, so that now shows the still unprocessed profile chamber upwards.

Previously, profile bar A is through the turning station 54 turned by 180 ° and by manipulator 13 in the milling plane 15 been transported, where the milling operation was carried out in the second chamber of this section bar A. Profile bar A is now finished and is, as sequence c, shows by manipulator 13 for filing 20 transported and stacked. The plane E2-E2, is the reference plane for the automatic stacking of the finished profile bars.

Profile bar B completed in sequence d, the plant pass after its second chamber milled and he with manipulator 13 was transported in the direction of filing. With sequence e, meaning a, a new cycle of profile processing begins with the profiles C = A and D = B.

While after 7 the milling of a symmetrical H-profile handling technology by the combination of two manipulators 12 . 13 and two turning stations 53 . 54 with horizontal turning axles 38 . 39 This can not be easily achieved with asymmetrical H-profiles.

However, in order to be able to mill this profile group in a single pass through the high-performance milling machine in both chambers K1 and K2, the turning point is proposed in a further embodiment of the inventive idea 53 . 54 in addition to their horizontal turning axes 38 . 39 each with vertical turning axles 27 to provide the turning of the profiled bars about the vertical axis 27 , allowed in mechanical engineering space.

In 8a is the starting position of the asymmetrical H-profile cross-section 63 shown. The profile flange, which is connected by bevels with the web, carries for its identification the geometric reference point P; the second flange with a radius transition bears no marking. The profile chamber K1 points upwards in the direction of the milling body 34 , If the profile cross section by 180 ° about its horizontal axis, axis 38 . 39 , turned, the situation after b. Profile chamber K2 is indeed upwards, in the direction of the milling body 34 oriented, but the flanges of the profile cross-section 63 are reversed, so no milling operation is possible. Only when the profile bar additionally by 180 ° about its vertical axis 27 is turned - representation c - he can take the position, which allows a milling of the second chamber K2 due to geometric agreement: the chamber K2 is in the direction of the cutter body 34 Oriented and bevel and radius transitions are on the correct profile cross-sectional side 63 ,

1

Hochleistungsfräsanlage with integrated stacking device

2

Section bar Cross-section U-shaped

3

Profile bar, Cross-section H-shaped

4

Profile bar, Cross-section U-shaped with web

5

Milling unit with milling body, slide, gearbox, motor, to 11

6

Profile bar tensioner, too 11

7

Horizontal clamping element / fixed profile stop, too 6

8th

Horizontal clamping elements / movable, too 6

9

Vertical clamping elements, hold-down, too 6

10

Profile bar in clamping position, too 6

11

Milling and profile bar handling table, too 1

12

Manipulator, on the inlet side, too 18

13

Manipulator, outlet side, too 18

14

Template area for stacked profile coils, too 11

15

Milling plane, profile chamber, too 11

16

Profile document, too 3

17

Profile document, too 4

18

Stacking device consisting of 12 . 13 . 53 . 54

19

Milling direction, too 5

20

Storage area, for milled stacked profile coils, too 11

21

Profile feed direction, too 11

22

Profile bar length combination, to 2 . 3 . 4

23

Profile bar length combination, to 2 . 3 . 4

24

Profile bar length combination, to 2 . 3 . 4

25

Deburring and Nachformeinrichtung, too 5

26

Horizontal profile bar axis, too 2

27

Vertical profile bar axis, too 2 . 3 . 4

28

Displacement direction, horizontal clamping elements, too 7 . 8th

29

Displacement direction, vertical clamping elements, too 9

30

Sensor, too 5

31

Clamping clearance, too 4

32

Clamping clearance, too 3

33

Bearing surface, even, too 2 . 11

34

Milling body, too 5

35

Drive shaft, too 34

36

Disc milling cutter, too 34

37

End position of milling body, too 5

38

Horizontal profile bar axis, too 3

39

Horizontal profile bar axis, too 4

40

Milling body drive, too 5

41

Disc milling cutter / firm, too 34

42

Disc milling cutter / displaceable, too 34

43

Sliding element, too 34

44

Fixing element, too 34

45

Profile chamber width, after milling, too 2 . 3 . 4

46

Sensor, horizontal, too 30

47

Probe, vertical, too 30

48

Profile chamber, before milling, too 2 . 3 . 4

49

Profile chamber depth, too 2 . 3 . 4

50

Milling area of the profile chamber, too 2 . 4

51

Drive shaft (double shaft), too 34

52

Profile upright, too 11

53

Turning station, on the inlet side, too 18

54

Turning station, outlet side, closed 18

55

Milling area of the profile chambers, too 3

56

Profile width, too 2 . 3 . 4

57

Profile center, too 2 . 3 . 4

58

Horizontal profile chamber level, too 2 . 3 . 4

59

Horizontal distance meter, too 8th

60

Sensor, horizontal, too 59

61

Toolpath payload, too 11

62

Machine modules, too 1

63

Profile bar, Cross-section H-shaped, asymmetrical

E1-E1, E2 E2

Reference planes, too 1

F1, F2

Abzuspanende Areas, chip removal

R1-R6

Curve / profile chamber

K1, K2

Profile chambers, too 63

P

Geometric reference point, too 63

L

Length of milling and profile handling table, too 11

Claims (14)

High-performance milling machine for rolled steel profile bars for the partial removal of decarburized layers and for narrowing the tolerance of the chamber measuring area , characterized in that the milling operation by a position-controlled milling body ( 34 ) with large diameter milling discs ( 36 . 41 . 42 ) and the material flow within the modular high performance milling machine ( 1 ), autonomously by manipulators ( 12 . 13 ) and turning stations ( 53 . 54 ) existing integrated stacking device ( 18 ) he follows. High-performance milling machine according to claim 1, characterized in that the profile bars to be milled are presented to the installation in the form of stacked profile coils ( 14 ) and the incoming manipulator ( 12 ) sensor supports a long profile bar or at the same time removes several short profile bars from the respective stacked profile collar and moves them in the direction of the milling plane ( 15 ). High-performance milling machine according to claim 1 or 2, characterized in that the required turning movements of the profiled bars about their horizontal and vertical axis for the purpose of milling-adequate positioning in the milling plane ( 15 ) automatically from the upstream and downstream turning station ( 53 . 54 ). High-performance milling machine according to one of claims 1 to 3, characterized in that the finished milled profile bars by the outlet side manipulator ( 13 ) in the storage area ( 20 ) are stacked again to a profile collar sensor assisted. Hochleistungsfräsanlage according to one of the claims 1 to 4, characterized in that all the destacking, handling, Turning and stacking functions for all profile bars run programmatically and automatically. Hochleistungsfräsanlage according to one of the claims 1 to 5, characterized in that in addition to the automatic mode Also, a functional sequence with individual profile bars is possible, the high-performance milling presented at level E1-E1. High-performance milling machine according to one of claims 1 to 6, characterized in that the manipulators ( 12 . 13 ) of the milling plane ( 15 ) supplied profile bars by the interaction of horizontal ( 7 . 8th ) and vertical clamping elements ( 9 ) are clamped in milling-ready stationary position and the thereby assumed contour-related actual position of the profile bars by the horizontal distance meter ( 59 ) and the sensor ( 30 ) is detected. Hochleistungsfräsanlage according to one of claims 1 to 7, characterized in that the measured contour-related actual position of the profile bars for employment of the milling body ( 34 ) is used such that the horizontal and vertical chip removal in the course of the milling operation leads to the desired desired dimensions in the profile chamber. High-performance milling installation according to one of claims 1 to 8, characterized in that the milling body used ( 34 ) has a diameter of> 600 mm in order to achieve a high feed rate when milling the profile bars can. High-performance milling installation according to one of claims 1 to 9, characterized in that the milling body ( 34 ) with a trailing deburring and deforming device ( 25 ) is provided. High-performance milling installation according to one of claims 1 to 10, characterized in that the milling body ( 34 ) from mutually engageable side milling cutters ( 36 . 41 . 42 ), either on a common drive shaft ( 35 ) or on separate drive shafts ( 51 ) are positioned. High-performance milling installation according to one of claims 1 to 11, characterized in that the desired profile chamber width ( 45 ) is achieved in a single milling pass. High-performance milling installation according to one of claims 1 to 12, characterized in that parallel to the existing milling plane ( 15 ), a second milling plane ( 15 ) for processing the profile bars in the forward and reverse with the milling body ( 34 ) is arranged. High-performance milling installation according to one of claims 1 to 13, characterized in that the milling body ( 34 ) can be swiveled through 180 ° horizontally is guided.