DE112011100170T5 - Apparatus for bending three-dimensional surfaces of heavy plate using a high frequency induction heater with precise control of the coil position - Google Patents

Abstract

An apparatus for bending three-dimensional surfaces of heavy plate using a high frequency induction heater with automatic, accurate control of coil position, comprising: a power supply device; a frame for supporting a plurality of components; a heater that performs heating with a high-frequency induction heater on a heavy plate supported on a support surface; a transport means which performs the movement of the heater or the support surface; a heat exchanger for cooling the heater when crossing one side of the heater; a deformation measuring device for measuring a height-oriented deformation on the heavy plate before and after the heating; and a controller that controls the operation of the heater, the conveyor, the heat exchanger, and the deformation measuring means. In the illustrated embodiment, the time and energy consumption for the curvature are considerably reduced, and unlike the gas torch models, no gas is used as the heating source, so that it is more environmentally friendly, and it is possible to improve the accuracy of the curvature, since a deformation measuring device Part of the apparatus is.

Description

BACKGROUND OF THE INVENTION

SCOPE OF THE INVENTION

The present invention relates to an apparatus for bending three-dimensional surfaces of heavy plate using a high-frequency induction heater with accurate coil position control which uses high-frequency induction heating with close control of coil position and which allows accurate three-dimensional curvature of surfaces by providing height-oriented deformation. after heating a heavy plate is measured by means of a device for measuring deformations.

Relevant prior art

The shape of a ship is designed to provide optimum travel performance, taking into account the relationships between shipload, speed and fuel consumption, in order to meet the requirements for ship use and shipowner in a shipyard.

Therefore, the outer hull of the hull is composed of many three-dimensionally curved surfaces. The outer hull of the hull, defined by the design of the hull, is divided into approximately one to three hundred outer panels.

The outer panels are made of heavy plate to extend the life of the vessel and consist of approximately 70% or more of curved surfaces.

In the prior art, the curvature of a heavy plate was carried out with a curving apparatus consisting of a plurality of rollers and presses.

The Korean Laid-Open Publication No. 10-2009-0093657 describes a "system for the design of fuselage panels for ships by means of a calculation method for positioning a multipoint press for the design of a ship's hull plate", whose application is shown schematically in FIG 1 is pictured.

Below, however, the problems are shown, which in the forming of an outer panel 10 for a hull using a multipoint press 20 occur.

One problem is that when curving a surface with the press 20 large deformations occur in the initial stage, and that there are many process variables, such as the forming position and the forming depth, so that the accuracy of curvature depends greatly on the skill of the operator.

In addition, the outer plates are generally different in shape and thickness and are made of heavy plates having a thickness between 10 and 40 mm, which are very difficult to transform into a desired shape in one operation; it is simply difficult to perform a hull curvature only with cold forming, such as multi-point pressing, in the same forming process; therefore, it is necessary to repeat hot working with hot bands for final accurate forming when bending the outer panels of a ship's hull.

The prior art hot working hot forming uses a principle that produces plastic transformations of the plate by tensioning and compressing the plate, while at the same time the predetermined area on the surface of the plate, as in 2 shown in the accompanying drawing, heated intensively with a gas flare and cooled.

A variety of gas flares 40 becomes at a predetermined distance one below the other with downward flames in a line above the plate to be bent 30 arranged.

The hot working still has a problem where the material is formed into an undesirable shape when the temperature of the heavy plate 30 is not closely monitored, causing local a very high heat on the plate 30 and there are many factors which influence the deformation, such as firing direction, speed, firing efficiency, cooling method and the thickness of the sheet; This makes it very difficult to make the plate with the desired curvature.

Although efforts are constantly made for automation, it is not applied in practice because the heating rate is relatively low, several environmentally hostile factors occur, for example, large amounts of CO ₂ gas and a high noise level, and it is difficult Build up database for thermal transformations and the control of the extent of thermal deformation.

The present invention has been developed with the aim of solving these problems and it is an object of the present invention to provide an apparatus for the three-dimensional curvature of a surface of heavy plate using a Provide high-frequency induction heating with automatic and accurate control of a coil position to allow a more precise curvature by measuring a height-oriented deformation after heating in a thermal path using a device for measuring three-dimensional deformations when heating in a thermal path using a high frequency induction heating under automatic more accurate Control of the coil position is performed.

Another object of the present invention is to provide apparatus for the three-dimensional curvature of a surface of heavy plate using a high frequency induction heating with an automatic and accurate control of a bobbin position, which improves the processing and productivity by being equipped with a transporting device which can produce a fast Heating by optimizing the shape and arrangement of the heating coils and by a three-dimensional movement of the heating coils allowed.

PRESENTATION OF THE INVENTION

An apparatus for bending three-dimensional surfaces of heavy plate using a high frequency induction heater with automatic, accurate control of coil position, comprising: a power supply device; a frame for supporting a plurality of components; a heater that performs heating with a high-frequency induction heater on a heavy plate supported on a support surface; a transport device which initiates the movement of the heater or the support surface; a heat exchanger for cooling the heater when crossing one side of the heater; a deformation measuring device for measuring a height-oriented deformation on the heavy plate before and after the heating; and a controller that controls the operation of the heater, the conveyor, the heat exchanger, and the deformation measuring means.

The deformation measuring device is mounted at a predetermined distance from the heater, measures the height data for each position of the plate, and transmits the data to the controller.

The device for deformation measurement is a contact sensor.

The transport means moves the heater in three-dimensional movements with respect to the heavy plate.

The heater comprises: a transformer mounted below the heater and applying a heater to the plate by induction; a control box which receives power from the power supply and controls the output intensity of the high frequency power; and a connector electrically connecting the control box to the transformer.

The transformer comprises: a coil receiving a high frequency current from the control box and generating an induction flux; and a core for receiving the coil.

The coil is formed by bending a rod with a rectangular cross section several times.

The coil is bent so that it is open in one direction.

The core is formed from a variety of laminated silicon steel elements.

The heat exchanger simultaneously cools the transformer and the connector.

The transformer, the control box and the connector are integrally connected to each other.

The connector is formed by bending a metal plate several times and has on one side a channel through which the cooling water supplied by the heat exchanger can flow.

The apparatus also includes a spacer mechanism that limits the distance between the transformer and the plate while the transformer rolls over the plate.

The transport device comprises a vertical transport device, which can move the heating device back and forth in a straight line in the direction of the frame height.

As described in detail above, the apparatus for bending three-dimensional surfaces of heavy plate using a high-frequency induction heating with automatic, accurate control of a coil position allows optimization of the shape and arrangement of coil and core, automatic control of the movement of the coil and a fast and local heating in the direction of the height of the central areas of the thermal paths and the surfaces located near the coil.

In this configuration, since the corners of the coil are not further heated by a weakness in design, it is possible to improve the performance of the entire process of curving a plate by using a local melting or melting process Deformation at the edges of the plate is excluded by eddy currents.

In addition, according to the present invention, it is possible to improve the accuracy by comparing the height information measured by the deformation measuring means for each position of the heavy plate with the information measured after the bending so as to reduce the processing errors.

In addition, it is possible to improve the productivity, since the duration for the curvature process is significantly reduced.

In addition, since no gas is used, the present invention can be classified as a more environmentally friendly processing method without emission of carbon dioxide as compared with the prior art gas flare methods.

BRIEF DESCRIPTION OF THE DRAWING

1 shows the application of an apparatus for curving a heavy plate from the prior art.

2 shows the use of another apparatus for curving a heavy plate from the prior art.

3 FIG. 12 is a perspective view of an apparatus for bending three-dimensional surfaces of heavy plate using a high-frequency induction heater according to the present invention. FIG.

4 FIG. 15 is a frontal view of an apparatus for bending three-dimensional surfaces of heavy plate using a high-frequency induction heater according to the present invention. FIG.

5 FIG. 13 is a perspective view of a heater in the apparatus for bending three-dimensional surfaces of heavy plate using a high-frequency induction heater according to the present invention. FIG.

6 Fig. 12 is a partially enlarged view of a transformer constituting the main part of the heater in the apparatus for bending three-dimensional surfaces of heavy plate using a high-frequency induction heater according to the present invention.

7 is a frontal view of a preferred embodiment of a transformer.

8th is a side view of the preferred embodiment of the transformer.

9 Fig. 12 is a longitudinal sectional view of the embodiment of a spacer mechanism which is a component of the apparatus for bending three-dimensional surfaces of heavy plate using a high-frequency induction heater according to the present invention.

10 FIG. 12 shows the application of an embodiment of a deformation measuring device which is a component of the three-dimensional surface bending apparatus of heavy plate using a high-frequency induction heater according to the present invention.

11 Fig. 12 is a graph showing the result of heat transfer analysis on the curvature of a plate in an apparatus for bending a three-dimensional surface of plate using a high frequency induction heater according to the present invention.

12 FIG. 12 is a schematic diagram showing the positions of heat transfer analysis in the curvature of a plate in an apparatus for bending a three-dimensional surface of heavy plate using a high-frequency induction heater according to the present invention.

13 is a graph showing the result of the heat transfer analysis of the application of a thermal link at the positions of the 12 shows.

14 FIG. 12 is a graph showing the result of FEM analysis of stress and magnitude of Z-direction deformation versus power used by the three-dimensional surface curving apparatus. FIG.

15 Fig. 10 is a photograph showing the cross sections of heavy plates processed by a preferred embodiment of the present invention and the results of the deformation measurement for each position.

16 is an enlargement showing only the cross-sections of the heat paths in the plates.

17 FIG. 15 is a graph showing the measurement data of the height measurements taken before and after the heating with the deformation measuring device, which is a component of the three-dimensional surface bending apparatus of heavy plate using a high-frequency induction heater according to the present invention.

18 is a table showing the deformations before / after heating according to the 17 shows.

19 is a graph showing the data of the table 18 shows.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The configuration of a plate by means of an apparatus for bending three-dimensional surfaces of heavy plate by using a high-frequency induction heater according to the present invention will be described below with reference to FIG 3 and 4 described.

First of all, it should be noted that the terminologies or terms used are not to be understood solely in terms of their general and encyclopedic meanings, but should be construed as meanings and concepts consistent with the spirit of the present invention on the basis of the principle according to which Inventions may suitably define the concept of terminologies with the aim of describing the invention as clearly as possible.

Therefore, the embodiments described herein and the embodiments shown in the drawings are merely preferred embodiments of the present invention and do not include all possible forms of the present invention; therefore, the invention must be understood to have a variety of variations and modifications that may be substituted for the invention within the scope of the actual application.

3 FIG. 15 is a perspective view of an apparatus for bending three-dimensional surfaces of heavy plate using a high-frequency induction heater according to the present invention; and FIG 4 Fig. 15 is a frontal view of an apparatus for bending three-dimensional surfaces of heavy plate using a high-frequency induction heater (hereinafter referred to as a 'roughening apparatus') according to the present invention.

As shown in the figures, the curving apparatus according to the present invention is an apparatus that heats a plate by means of a high-frequency induction heating to produce a curved surface, and that enables the deformations before / after the heating of a plate subjected to a three-dimensional curvature to compare and examine.

For this embodiment, the curvature apparatus includes a power supply device 100 a frame 200 for supporting a plurality of components; a heating device 300 using a high-frequency induction heating on a support surface 210 stored heavy plate P heats up; a transport device 400 indicating the movement of the heater 300 or the bearing surface 210 executing; a heat exchanger 500 for cooling the heater 300 when crossing one side of the heater 300 , a device for deformation measurement 600 for measuring a height-oriented deformation on the heavy plate P before and after the heating; and a controller 700 that the operation of the heater 300 , the transport device 400 , the heat exchanger 500 and the device for deformation measurement 600 controls.

The power supply device 100 which in the embodiment of the present invention, the heater 300 energized to carry out the heating with the high-frequency induction heating, generates a high-frequency current of a maximum of 20 kHz, has an output capacity of 100 kW and provides a maximum heating temperature of 1000 ° C.

The frame 200 is to the left of the power supply 100 appropriate. The frame 200 supports a variety of components and includes the support surface 210 on which the heavy plate P is stored.

Specifically, the bearing surface 210 formed by a plurality of rods, which are mounted at a distance from each other to the heater 300 hang.

The frame 200 is with the transport device 400 fitted. The transport device 400 showing the three-dimensional movements of the heater 300 with respect to the heavy plate P, allows the heater 300 in terms of the frame 200 back and forth, right and left and up and down to move, and it also allows the support surface 210 straight forward and backward.

The transport device 400 includes a lateral transport device 420 that on the frame 200 attached vehicle 220 drives with the heater 300 connected and the load of the heater 300 carries to move straight to the right and left; a horizontal transport device 440 on the bottom of the support surface 210 is stored and this drives in a forward / backward movement; and a vertical transport device ( 460 in 5 ), which the heater 300 in relation to the carrier 220 in an up / down movement drives.

Both the lateral transport device 420 as well as the horizontal transport device 440 Each includes a rail, a guide and a motor to allow straightforward movements in both directions, while the vertical transport means 460 includes a screw and a cam.

The heat exchanger 500 is at the back of the frame 200 appropriate. The heat exchanger 500 which the heater 300 cooled by circulating cooling water, includes a tank for storing the cooling water and a pump to drive the circulation of the cooling water stored in the tank.

The device for deformation measurement 600 is right of the heater 300 appropriate. The device for deformation measurement 600 can measure the deformation by taking all data of the height of the heavy plate P measured before the curvature and sent to the control device 700 be transferred and stored there, and then compared with all height data of the heavy plate P measured after the curvature.

For this process, the device for deformation measurement 600 Measure a deformation in direct contact with the heavy plate P and can also calculate the curvature by measuring the position of the sheet after the curvature.

For this process is the device for deformation measurement 600 preferably equipped with a contact sensor and mounted so that they are together with the heater 300 at a preset distance from the heater 300 emotional.

The control device 700 is to the right of the frame 200 appropriate. The control device 700 controls the operation of the heater 300 , the transport device 400 and the heat exchanger 500 It also controls the heating temperature of the heavy plate P coming from the heater 300 is heated, the operation of the transport device 400 for the movement of the heater 300 or the bearing surface 210 , and the flow rate of cooling water coming from the heat exchanger 500 is circulated.

The heater 300 is on the left side of the controller 700 appropriate. The heater 300 The heavy plate P heats by induction while coming from the power supply device 100 is powered and the detailed configuration of the heater 300 is referred to below with reference to 5 and 6 the accompanying drawings.

5 is a perspective view of a heater 300 in the apparatus for bending three-dimensional surfaces of heavy plate using a Hochfrequenzinduktionsheizung according to the present invention and 6 Fig. 12 is a partially enlarged view of a transformer constituting the main part of the heater in the apparatus for bending three-dimensional surfaces of heavy plate using a high-frequency induction heater according to the present invention.

First, the heater includes 300 , as in 5 represented a transformer 320 the heavy plate P under the heater 300 induction heating, a control box 340 which controls the output intensity of a high-frequency current while being supplied by the power supply device 100 is powered, and a connector 360 that the control box 340 with the transformer 320 combines.

The transformer 320 , the main component of the heater 300 , includes a coil 324 consisting of ferrite formed by bending a laminated silicon steel of rectangular cross section several times while leaving it unidirectional, and a core 322 that in the coil 324 is appropriate.

The connector 360 is over the transformer 320 arranged. The connector 360 is formed by bending a metal plate a plurality of times, thereby obtaining a ⊏-shaped cross section in the central area when viewed from the front, and its lower end is electrically connected to the transformer 320 connected.

In addition, the upper rear end of the connector 360 electrically with the control box 340 connected. Therefore, the connector allows 360 an electrical connection between the control box 340 and the transformer 320 ,

In addition, the connector 360 , the control box 340 and the transformer 320 integrally connected so that they can be moved together. As described above, the carrier becomes 220 for a straightforward float from the frame 200 kept and the carrier 220 carries the load of the control box 340 ,

Because the control box 340 from the carrier 220 is moved, also the connector 360 and the transformer 320 in terms of the frame 200 moved straight to the right and left.

On the surface of the connector 360 is a channel 362 educated. The channel 362 through which the cooling water used to cool the heat exchangers 500 is delivered through the connector 360 is a hollow tube with a variety of bends and on the outer surface of the connector 360 appropriate.

Therefore, the cooling water flowing through the channel 362 flows, the connector 360 cool by absorbing its heat.

The heat exchanger 500 But also cools the heater 300 , That through the heat exchanger 500 flowing cooling water is through a cooling pipe 364 also by the heater 300 directed.

As in 7 and 8th shown is the cooling tube 364 also in connection with the core 322 so the transformer 320 can be cooled by a heat exchange with the cooling water.

The cooling tube 364 can also, as in 5 Shown to be divided into a variety of branches to both the channel 362 as well as with the transformer 320 to communicate.

The distance mechanism 380 is on the outside of the transformer 320 arranged. Four distance mechanisms 380 are at preset distances from each other on the outside of the transformer 320 arranged to the distance between the heavy plate P and the transformer 320 to limit.

9 shows the detailed configuration of the distance mechanism 380 , As shown in the figure, the distance mechanism indicates 380 a coupling part 382 on, on one side of the heater 300 is attached perpendicular to the ground, an elasticity generating part 384 that under the coupling part 382 is mounted and by the selective contact with the heavy plate P generates an elastic restoring force, and a part for height adjustment 388 to the height of the elasticity generating part 384 adjust.

The coupling part 382 is at its lower end to the height adjustment part 388 coupled and the part for height adjustment 388 has an interior, so that the elasticity generating part 384 can move straight up and down (see the right part in 9 ). Also, through the right side of the height adjustment part 388 a tensioner 389 appropriate.

Therefore, it is possible the insertion depth in the part for height adjustment 388 set by the tensioner 389 is rotated so that the outer surface of the elasticity generating part 384 is pressed.

Besides, in the elasticity generating part 384 an elastic element 385 attached and under this elastic element 385 becomes a rotatable ball 386 held. Consequently, the ball is 386 as the lowest component of the distance mechanism 380 in contact with the heavy plate P and allows the elastic element 385 to generate an elastic restoring force while being pushed up by an additional pressure by the contact with the heavy plate P.

Therefore, the ball makes it possible 386 To avoid defects such as a splitting of the heavy plate P by rolling the ball on the heavy plate P when the heavy plate P by means of the horizontal transport device 440 is moved.

The detailed configuration of the deformation measurement device 600 is referred to below with reference to 10 described.

10 FIG. 12 shows the use of an embodiment of a strain measurement device that is a component of the three-dimensional heavy plate surface curvature apparatus using a high frequency induction heater according to the present invention.

The device for deformation measurement 600 makes it possible to adjust the contact with different heavy plates P.

This includes the device for deformation measurement 600 a contact sensor 620 which measures the height data in contact with the heavy plate P, and a holder 640 that the contact sensor 620 carries to keep it in a preset position.

The holder 640 is on the vertical transport device 460 attached to yourself at the same speed and in the same direction as the heater 300 to move, and its length and angle can be adjusted.

The contact sensor 620 is also at the bottom of the holder 640 appropriate. The contact sensor 620 is from the power supply device 100 powered and measures the position data by bringing the lower end into contact with the surface of the heavy plate P.

The contact sensor 620 also transmits the measurement data to the controller 700 and the controller stores or compares the data, measuring a height deformation before / after the curvature.

Experimental results from the use of the curvature apparatus as above are described below with reference to the 11 to 18 described.

First is 11 4 is a graph showing the result of heat transfer analysis on the curvature of a plate in an apparatus for bending a three-dimensional surface of heavy plate using a high-frequency induction heater according to the present invention. In an experiment of the present invention, a heavy plate P made of SS400 having dimensions of 17 mm × 300 mm × 500 mm was used, a ferrite magnetic body was used as a core 322 used and the core was surrounded by a coil of oxygen-free copper in a 'Π' shape.

The core 322 was also formed by stacking a plurality of silicon steel plates.

The speed of the heavy plate was 5 mm / s, a power of 40 kW at 15 kHz was applied and the distance, ie the air gap, between heater 300 and the heavy plate P was kept constant at 5 mm.

An air convection coefficient was 0.02 N / sec / mm / ° C.

On the heavy plate P also a variety of heat paths was defined; the thermal pads were numbered by being positioned at regular intervals so that the deformation before / after the bend can be measured.

With the result of the FEM (Finite Element Method) under the conditions described above, it was possible to estimate that the temperature of the plate increases to the deformation temperature of more austenite (A3) (at least 950 ° C or more) because the heat input becomes intense is directed to the central area of the heavy plate P, where the heat pipe, as in 11 shown, is positioned.

In 13 In addition, the result of the estimated temperature profiles at five different positions of the heavy plate P is shown, wherein the initial corner position corresponding to the step 1 was overheated by 100 ° C or more from the other positions due to the eddy current due to the corner effect.

14 FIG. 12 is a graph showing the result of FEM analysis of the stress and the amount of Z-direction deformation versus the power used by the three-dimensional surface bending apparatus, and showing that the larger the applied one Power is the more the maximum voltage increases and, accordingly, the magnitude of the thermomechanical deformation in the direction of the thickness is proportional to the applied power.

It can be assumed that this is due to the larger heat flux applied to the surface area concerned.

15 Fig. 11 is a photograph showing the cross sections of heavy plates processed by a preferred embodiment of the present invention, and for each position, the results of the deformation measurement and in which it was possible to measure the absolute deformation value in the height direction at each position ,

16 is an enlargement showing only the cross sections of the hot plates in the heavy plates, and in which it can be seen that the more power is applied, the larger becomes the heating affected area.

17 FIG. 15 is a diagram showing the measurement data of the height measurements obtained before and after the heating with the deformation measuring device, which is a component of the three-dimensional surface bending apparatus of heavy plate using a high-frequency induction heater according to the present invention. 18 is a table showing the deformations before and after the heating according to the 17 shows, and 19 is a graph showing the data of the table 18 shows.

Since measured flatness before curvature is relatively uniform in the experimental results, in an experiment in which a power of 40 kW was applied and the speed of the heater 300 was set to 5 mm / s with respect to the heavy plate P, which in 19 shown graphic obtained.

It can be seen that the height positions (in the direction of the (Z-axis) with the progression of the thermal path (in the direction of the Y-axis) at the successive points have each changed in a similar manner.

The scope of the present invention is not limited to the above embodiments, and the present invention can be variously changed by those skilled in the art without departing from the scope of the present invention.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• KR 10-2009-0093657 [0006]

Claims (14)

Apparatus for bending three-dimensional surfaces of heavy plate using high frequency induction heating with accurate control of coil position, comprising: a power supply device; a frame for supporting a plurality of components; a heater that performs heating with a high-frequency induction heater on a heavy plate supported on a support surface; a transport means which performs the movement of the heater or the support surface; a heat exchanger for cooling the heater when crossing one side of the heater; a deformation measuring device for measuring a height-oriented deformation on the heavy plate before and after the heating; and a controller that controls the operation of the heater, the transport, the heat exchanger, and the deformation measurement device. The apparatus according to claim 1, wherein the deformation measuring means is mounted at a predetermined distance from the heater, which measures height data for each position of the plate and transmits the data to the control means. The apparatus of claim 2, wherein the means for measuring strain is a contact sensor. The apparatus according to claim 2 or 3, wherein the transport means moves the heater in three-dimensional movements with respect to the plate. The apparatus according to claim 2 or 3, wherein the heating device comprises the following components: a transformer mounted at the bottom of the heater and applying a heater to the plate by induction; a control box which receives power from the power supply and controls the output intensity of the high frequency power; and a connector that electrically connects the control box to the transformer. The apparatus according to claim 5, the transformer comprising the following components: a coil receiving a high frequency current from the control box and generating an induction flux; and a core for receiving the coil. The apparatus according to claim 6, wherein the coil is formed by bending a rod having a rectangular cross section a plurality of times. The apparatus of claim 7, wherein the coil is bent so as to be open in one direction. The apparatus of claim 8, wherein the core is formed of a plurality of laminated silicon steel elements. The apparatus of claim 5, wherein the heat exchanger simultaneously cools the transformer and the connector. The apparatus according to claim 5, wherein the transformer, the control box and the connector are integrally connected to each other to be moved together. The apparatus according to claim 8, wherein the connector is formed by bending a metal plate several times and has a channel on one side so that the cooling water supplied from the heat exchanger can flow. The apparatus of claim 3, further comprising a spacer mechanism that limits the distance between the transformer and the plate while the transformer rolls over the plate. The apparatus according to claim 3, wherein the transport means comprises a vertical transport means which can reciprocate the heater rectilinearly toward the frame height.

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