EP1371430B1 - Method and apparatus for the manufacturing of a hollow profile - Google Patents

Method and apparatus for the manufacturing of a hollow profile Download PDF

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Publication number
EP1371430B1
EP1371430B1 EP03010747A EP03010747A EP1371430B1 EP 1371430 B1 EP1371430 B1 EP 1371430B1 EP 03010747 A EP03010747 A EP 03010747A EP 03010747 A EP03010747 A EP 03010747A EP 1371430 B1 EP1371430 B1 EP 1371430B1
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EP
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Prior art keywords
metal strip
welding
profile
open profile
open
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EP03010747A
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German (de)
French (fr)
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EP1371430A3 (en
EP1371430A2 (en
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Dreistern Werk Maschinenbau GmbH and Co KG
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Dreistern Werk Maschinenbau GmbH and Co KG
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21DWORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D47/00Making rigid structural elements or units, e.g. honeycomb structures
    • B21D47/01Making rigid structural elements or units, e.g. honeycomb structures beams or pillars
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21CMANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C37/00Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape
    • B21C37/06Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape of tubes or metal hoses; Combined procedures for making tubes, e.g. for making multi-wall tubes
    • B21C37/08Making tubes with welded or soldered seams
    • B21C37/0803Making tubes with welded or soldered seams the tubes having a special shape, e.g. polygonal tubes
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21CMANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C37/00Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape
    • B21C37/06Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape of tubes or metal hoses; Combined procedures for making tubes, e.g. for making multi-wall tubes
    • B21C37/08Making tubes with welded or soldered seams
    • B21C37/083Supply, or operations combined with supply, of strip material

Definitions

  • the invention relates to a method and an apparatus for producing a hollow profile with a varying over the length of its cross section according to the preambles of claims 1 and 12.
  • hollow profiles with a constant cross-section are not produced in a continuous process. Rather, initially produced seamless or welded welded round or square tubes in the desired length. These are then converted in the hydroforming process into hollow profiles whose cross section does not remain constant, but changes along the longitudinal axis of the hollow profile.
  • the process step of hydroforming is significantly involved in the production costs, since the handling of workpieces that are formed piece by piece, even using industrial robots is quite expensive.
  • the present invention is therefore based on the object to propose a method and an apparatus for producing a hollow profile with a varying over the length of its cross section, with or with the production of such hollow sections faster and more efficient, and thus cheaper.
  • the invention is thus based on the finding that hollow profiles with varying cross-section can also be produced continuously, specifically with a profiling machine comprising a plurality of forming stations with roll forming tools arranged in line one behind the other as well as a welding station.
  • the principle of such a profiling machine is known per se, for example, from DE 198 34 400 C1 of the Applicant.
  • the profiling machine described therein has a plurality of forming stations, in each of which pairwise cooperating roll forming tools are driven for stepwise forming of a metal strip in a continuous forming process or are mounted in freewheeling manner in racks.
  • the metal strip formed into a hollow profile then subsequently passes through a welding station arranged in line, in which the bent-together edges of the metal strip are butt welded together.
  • This known profiling machine is very efficient due to the continuous production process and enables the cost-effective mass production of hollow profiles.
  • Another profiling machine is known per se from US-A-4,558,577.
  • open profiles having a longitudinally varying width are made by roll forming from a metal strip of varying width in the longitudinal direction.
  • This device comprises roll forming tools, the position and inclination of which can be changed during the forming process in order to be able to continuously shape the open profiles of varying width and still remaining sidewall heights.
  • a hollow profile with a cross section varying over its length can be produced on a correspondingly adapted profiling machine with roll forming tools, namely by first including a first metal strip a width varying over its length in the roll forming tools is formed into an open profile, then a second metal strip is placed on the edges bounding the open side of the open profile, and finally the second metal strip with the open profile into a hollow profile is welded.
  • the hollow profile is thus not made of a single metal strip, but of two metal strips, wherein at least the first metal strip according to the desired cross-sectional profile of the finished hollow profile varies in width, that is not provided as usual with parallel edges.
  • the forming of the first metal strip is not completely up to a hollow profile, which in general will not be possible due to its varying width, but by welding a second metal strip to the "gap" of the open profile produced by roll forming.
  • the roll forming and the welding takes place in a continuous process by the method steps according to the invention are carried out in line one behind the other.
  • the first metal strip used does not necessarily have symmetrical edges on both sides; It is for example possible to provide only one side of the metal strip with an edge different from a straight line, so that the desired varying cross-sectional profile can be produced by welding the second metal strip onto this "varying" edge. In most cases, however, it will be useful to mold a more or less U-shaped profile with side walls that vary symmetrically in height, onto which the second metal strip is welded as a cover plate. This results in a hollow profile with the desired cross-sectional profile.
  • the invention makes the efficiency and production speed of a profiling machine with roll forming tools also usable for the production of a hollow profile with varying cross section for the first time.
  • the resulting in particular in a mass production cost advantages are obvious.
  • the welding is preferably carried out with a laser welding system, which allows a pinpoint welding with high local variability of the site of action.
  • the laser radiation is preferably directed substantially perpendicular to the longitudinal axis of the open profile on the contact areas between the open profile and the second metal strip. As a result, the laser radiation with relatively low intensity can nevertheless act on the entire contact area to be welded.
  • the welding device is designed such that its site of action is variable in position; because only then, the welding head or welding heads can be tracked a more or less wavy course of the edges to be welded during continuous transport of the profile through the welding station, thereby eliminating costly mechanisms that would ensure that the weld to be produced always exactly on the appropriate welding head is passed straight ahead.
  • the corresponding configuration of the welding station with a welding device variable in position with regard to its point of action also comprises a scanning device for detecting the current position of at least one of the contact points between the open profile and the second metal strip.
  • This scanning device may in particular be designed electronically, optically or mechanically, wherein it expediently controls the welding device in such a way that its point of action is always directed precisely to the edges to be welded, irrespective of their changing instantaneous position in the welding station during transport of the hollow profile.
  • each weld can be produced a scanning device;
  • a scanning device for example, in the case of U-shaped profiles with upwardly undulating side cheeks which conform to their shape on the right and left, it is also possible to use only one scanning device for both welds to be produced, even if in this case preferably two welding heads, the right and left of the Hollow sections are arranged to be used.
  • a mechanical scanning device for controlling the movement of the welding device It may be provided in particular to use a roller which rolls on the laid on the open profile second metal strip and thereby the current profile of the edge to be welded recognizes and passes on to the welding device.
  • the relative speed between the edges to be welded and the welding device can be detected, this size is preferably used to control the welding performance.
  • the relative velocity between the edge to be welded and the welding device becomes greater when that edge is not straight through the welding station but deviates from the longitudinal axis of the hollow profile so that the welding head or heads are perpendicular to the advancing direction of the profile Have to move.
  • the second metal strip is preferably placed on the open profile by means of a guide roller device, so that it can be placed flush on the more or less wavy course of the edges or edges of the open profile to be welded.
  • a guide roller device can simultaneously serve as a scanning device, with or without control of the welding power.
  • a spring-loaded guide roller device can be provided, which controls the adjustment of an adjustable perpendicular to the longitudinal axis of the profile welding device. This is particularly simple when one or more welding heads of the welding device are mounted directly on the guide roller device. This leads to a particularly simple and compact welding station for hollow sections with varying cross sections.
  • the second metal band can also be provided with punched holes and / or bends before being placed on the open profile.
  • Figure 1 shows a schematic side view of the structure of an embodiment of the device according to the invention: A first, varying in width metal strip 1 and a second, provided in the usual way with parallel longitudinal edges metal strip 2 of a first unwinding reel 3 and a second unwinding reel 4 for continuous production process.
  • the first metal strip 1 passes through a forming system 5 with five frames 6 shown here, in each of which a cooperating pair of driven or free-running roll forming tools 9 effect a stepwise forming of the first metal strip 1 into an open profile 7.
  • the second metal strip 2 is guided past the roll forming tools 9 and transported together with the molded open profile 7 through a welding station 8. There, as described in more detail below, the second metal strip 2 is placed flush on the open side of the profile 7 and welded thereto.
  • the method according to the invention is thus a continuous method with which a cost-effective and rapid mass production of profiles with a varying cross-section is possible.
  • FIG. 2 shows a purely schematic representation of the main functional elements of the welding station 8.
  • the open profile 7, which as a U-shaped profile with a flat, bounded by parallel edges edges base 13 and two side walls 14 is formed, the upper boundary edges 15 have a right and left identical wavy course is continuously guided by a driven, mounted in a frame 16 guide roller 17 through the welding station, the second metal strip 2 is placed flush on the edges 15 and positioned by means of a guide roller device 18 for welding.
  • the guide roller device 18 is not driven and is biased by two springs 19 against the second metal strip 2, so that it provides in cooperation with the guide roller 17 for a clean concern of the second metal strip 2 on the edges 15 of the open profile 7.
  • the contact surface between the profile 7 and the second metal strip 2 is thus defined by the lower surface of the second metal strip 2, so that the instantaneous position of the front rollers 20 of the guide roller device each represent the exact location of the weld to be produced.
  • These rollers 20 also take the current overall speed of the second metal strip 2 and thus the edge 15 of the profile 7, which is composed of the feed rate of the profile 7 and the perpendicular to the longitudinal axis of the profile 7 extending movement of the guide roller device 18.
  • the rotational speed of the rollers 20 is used to control the welding power.
  • a first and a second welding head 21, 22 are fixed to the axis of the rollers 20, which each focus a laser beam on the contact area between the edge 15 of the profile 7 and the metal strip 2.
  • the arrangement of the welding heads 21, 22, the guide roller device 18 automatically transmits the varying contour of the profile 7 on the welding heads 21, 22, so that they are tracked very exactly the edge 15 of the profile 7.
  • the hollow profile 11 with varying cross section leaving the welding station 8 shown in FIG. 2 can be seen again in FIG. It is a part of the hollow section 11 which is cut to length by the cutting machine 10 and consists of a U-profile 7 with wave-shaped side cheeks 14 and a shroud 23 which is laid onto the side cheeks and welded thereto.
  • the geometry shown in Figure 3 can be made quite easily by the first metal strip either already has a prefabricated, varying width, or stamped in a arranged in line to the coil pre-punching one of the different end heights of the U-profile 7 corresponding contour of the tape longitudinal edges gets.
  • the forming 5 ensures the deformation of the first metal strip 1 to the U-profile 7, wherein the lateral band guide can be ensured by means of sprung mounted side rollers.
  • the continuously supplied during the process shroud 23 in the form of a second metal strip 2 is welded in the welding station 8 on the undulating edges 15 of the side walls 14, wherein the welding power was chosen lower on the purely horizontal sections of the hollow section shown here, as to the Ramp-shaped sections, which naturally have a higher relative speed to the welding device in the continuous flow process, as the horizontal sections.

Description

Die Erfindung betrifft ein Verfahren und eine Vorrichtung zum Herstellen eines Hohlprofils mit einem über dessen Länge variierenden Querschnitt nach den Oberbegriffen der Ansprüche 1 und 12.The invention relates to a method and an apparatus for producing a hollow profile with a varying over the length of its cross section according to the preambles of claims 1 and 12.

Im Gegensatz zu Hohlprofilen mit gleichbleibendem Querschnitt werden Hohlprofile der eingangs genannten Art nicht in einem kontinuierlichen Arbeitsprozess hergestellt. Vielmehr werden zunächst nahtlos oder auch geschweißt gefertigte Rund- oder Viereckrohre in gewünschter Länge hergestellt. Diese werden dann im Innenhochdruck-Umformverfahren in Hohlprofile umgeformt, deren Querschnitt nicht konstant bleibt, sondern sich entlang der Längsachse des Hohlprofils ändert.In contrast to hollow profiles with a constant cross-section hollow sections of the type mentioned are not produced in a continuous process. Rather, initially produced seamless or welded welded round or square tubes in the desired length. These are then converted in the hydroforming process into hollow profiles whose cross section does not remain constant, but changes along the longitudinal axis of the hollow profile.

Dieses Herstellungsverfahren nach dem Stand der Technik für Hohlprofile der eingangs genannten Art ist also kein kontinuierliches Verfahren, sondern die Werkstücke müssen stückweise in ihre endgültige Form umgeformt werden.This manufacturing method according to the prior art for hollow sections of the type mentioned is therefore not a continuous process, but the workpieces must be piecewise transformed into their final shape.

Dementsprechend ist der Verfahrensschritt des Innenhochdruck-Umformens maßgeblich mit an den Produktionskosten beteiligt, da das Handling von Werkstücken, die Stück für Stück umgeformt werden, auch unter Einsatz von Industrierobotern recht aufwendig ist.Accordingly, the process step of hydroforming is significantly involved in the production costs, since the handling of workpieces that are formed piece by piece, even using industrial robots is quite expensive.

Der vorliegenden Erfindung liegt daher die Aufgabe zugrunde, ein Verfahren und eine Vorrichtung zur Herstellung eines Hohlprofils mit einem über dessen Länge variierenden Querschnitt vorzuschlagen, mit dem bzw. mit der die Produktion von solchen Hohlprofilen schneller und effizienter, und damit kostengünstiger wird.The present invention is therefore based on the object to propose a method and an apparatus for producing a hollow profile with a varying over the length of its cross section, with or with the production of such hollow sections faster and more efficient, and thus cheaper.

Diese Aufgabe ist mit einem Verfahren nach dem beigefügten Patentanspruch 1 und mit einer Vorrichtung nach dem beigefügten Patentanspruch 12 gelöst.This object is achieved by a method according to the appended claim 1 and with a device according to the appended claim 12.

Die Erfindung beruht also auf der Erkenntnis, dass auch Hohlprofile mit variierendem Querschnitt kontinuierlich hergestellt werden können, und zwar mit einer Profiliermaschine, die mehrere, in Linie hintereinander angeordnete Umformstationen mit Rollformwerkzeugen sowie eine Schweißstation umfasst.The invention is thus based on the finding that hollow profiles with varying cross-section can also be produced continuously, specifically with a profiling machine comprising a plurality of forming stations with roll forming tools arranged in line one behind the other as well as a welding station.

Das Prinzip einer solchen Profiliermaschine ist an sich beispielsweise aus der DE 198 34 400 C1 der Anmelderin bekannt. Die dort beschriebene Profiliermaschine weist eine Mehrzahl von Umformstationen auf, in denen jeweils paarweise zusammenwirkende Rollformwerkzeuge zum stufenweisen Umformen eines Metallbandes in einem kontinuierlichen Umformprozess angetrieben oder freilaufend in Gestellen gelagert sind. Das zu einem Hohlprofil umgeformte Metallband durchläuft dann anschließend eine in Linie angeordnete Schweißstation, in der die zusammengebogenen Ränder des Metallbands stumpf miteinander verschweißt werden. Diese an sich bekannte Profiliermaschine ist durch den kontinuierlichen Herstellungsprozess sehr effizient und ermöglicht die kostengünstige Massenherstellung von Hohlprofilen. Allerdings erfordert eine Änderung des Profilquerschnittes eine komplette Umrüstung der Maschine auch dann, wenn die Rollformwerkzeuge in ihren Gestellen verstellbar sind. Ein kontinuierliches Herstellen eines Hohlprofils mit variierendem Querschnitt, wie nach der Erfindung vorgesehen, war im Stand der Technik mit Profiliermaschinen, wie sie aus der DE 198 34 400 C1 bekannt sind, jedenfalls ausgeschlossen.The principle of such a profiling machine is known per se, for example, from DE 198 34 400 C1 of the Applicant. The profiling machine described therein has a plurality of forming stations, in each of which pairwise cooperating roll forming tools are driven for stepwise forming of a metal strip in a continuous forming process or are mounted in freewheeling manner in racks. The metal strip formed into a hollow profile then subsequently passes through a welding station arranged in line, in which the bent-together edges of the metal strip are butt welded together. This known profiling machine is very efficient due to the continuous production process and enables the cost-effective mass production of hollow profiles. However, a change of the profile cross-section requires a complete conversion of the machine, even if the roll forming tools are adjustable in their racks. A continuous production of a hollow profile with varying cross-section, as provided according to the invention, was at least excluded in the prior art with profiling machines, as they are known from DE 198 34 400 C1.

Eine weitere Profiliermaschine ist an sich aus dar US-A-4,558,577 bekannt. Dort werden offene profile, die eine in Längsrichtung variierende Breite besitzen, durch Rollumformen aus einem Metallband mit in Längsrichtung variierender Breite hergestellt. Diese Vorrichtung umfasst Rollformwerkzeuge, deren Position und Neigung während des Umformvorgangs verändert werden können, um die offenen Profile mit variierender Breite und dennoch konstant bleibenden Seitenwandhöhen kontinuierlich formen zu können.Another profiling machine is known per se from US-A-4,558,577. There, open profiles having a longitudinally varying width are made by roll forming from a metal strip of varying width in the longitudinal direction. This device comprises roll forming tools, the position and inclination of which can be changed during the forming process in order to be able to continuously shape the open profiles of varying width and still remaining sidewall heights.

Wie bereits erwähnt, geht die vorliegende Erfindung entgegen der bisherigen Möglichkeiten vom zentralen Gedanken aus, dass unter bestimmten Voraussetzungen auch ein Hohlprofil mit einem über dessen Länge variierenden Querschnitt auf einer entsprechend angepassten Profiliermaschine mit Rollformwerkzeugen hergestellt werden kann, und zwar indem zunächst ein erstes Metallband mit einer über dessen Länge variierenden Breite in den Rollformwerkzeugen zu einem offenen Profil umgeformt wird, danach ein zweites Metallband auf die die offene Seite des offenen Profils begrenzenden Kanten aufgelegt wird, und schließlich das zweite Metallband mit dem offenen Profil zu einem Hohlprofil verschweißt wird. Das Hohlprofil wird also nicht aus einem einzigen Metallband, sondern aus zwei Metallbändern hergestellt, wobei zumindest das erste Metallband entsprechend dem gewünschten Querschnittverlauf des fertigen Hohlprofils in seiner Breite variiert, also nicht wie üblich mit parallel verlaufenden Kanten versehen ist. Das Umformen des ersten Metallbandes erfolgt nicht vollständig bis zu einem Hohlprofil, was aufgrund von dessen variierender Breite im allgemeinen auch nicht möglich sein wird, sondern durch Aufschweißen eines zweiten Metallbandes auf die "Lücke" des durch Rollumformung hergestellten offenen Profils. Zweckmäßigerweise erfolgt das Rollumformen und das Verschweißen in einem kontinuierlichen Prozess, indem die erfindungsgemäßen Verfahrensschritte in Linie hintereinander durchgeführt werden.As already mentioned, contrary to the previous possibilities, the present invention is based on the central idea that, under certain conditions, a hollow profile with a cross section varying over its length can be produced on a correspondingly adapted profiling machine with roll forming tools, namely by first including a first metal strip a width varying over its length in the roll forming tools is formed into an open profile, then a second metal strip is placed on the edges bounding the open side of the open profile, and finally the second metal strip with the open profile into a hollow profile is welded. The hollow profile is thus not made of a single metal strip, but of two metal strips, wherein at least the first metal strip according to the desired cross-sectional profile of the finished hollow profile varies in width, that is not provided as usual with parallel edges. The forming of the first metal strip is not completely up to a hollow profile, which in general will not be possible due to its varying width, but by welding a second metal strip to the "gap" of the open profile produced by roll forming. Advantageously, the roll forming and the welding takes place in a continuous process by the method steps according to the invention are carried out in line one behind the other.

Das verwendete erste Metallband muss nicht unbedingt beidseitig symmetrisch verlaufende Kanten aufweisen; es ist beispielsweise möglich, nur eine Seite des Metallbandes mit einer von einer Geraden verschiedenen Kante zu versehen, so dass durch das Aufschweißen des zweiten Metallbandes auf diese "variierende" Kante der gewünschte variierende Querschnittverlauf herstellbar ist. Meist wird es jedoch sinnvoll sein, ein mehr oder weniger U-förmiges Profil mit symmetrisch in ihrer Höhe variierenden Seitenwangen einzuformen, auf das als Deckblech das zweite Metallband aufgeschweißt wird. Hierdurch ergibt sich dann ein Hohlprofil mit dem erwünschten Querschnittverlauf.The first metal strip used does not necessarily have symmetrical edges on both sides; It is for example possible to provide only one side of the metal strip with an edge different from a straight line, so that the desired varying cross-sectional profile can be produced by welding the second metal strip onto this "varying" edge. In most cases, however, it will be useful to mold a more or less U-shaped profile with side walls that vary symmetrically in height, onto which the second metal strip is welded as a cover plate. This results in a hollow profile with the desired cross-sectional profile.

Die Erfindung macht also die Effizienz und Produktionsgeschwindigkeit einer Profiliermaschine mit Rollformwerkzeugen auch zur Produktion eines Hohlprofils mit variierendem Querschnitt erstmals nutzbar. Die sich hierdurch insbesondere bei einer Massenproduktion ergebenden Kostenvorteile liegen auf der Hand.Thus, the invention makes the efficiency and production speed of a profiling machine with roll forming tools also usable for the production of a hollow profile with varying cross section for the first time. The resulting in particular in a mass production cost advantages are obvious.

Das Verschweißen wird vorzugsweise mit einer Laser-Schweißanlage vorgenommen, die ein punktgenaues Schweißen mit hoher örtlicher Variabilität des Wirkungsortes ermöglicht. Die Laserstrahlung wird hierbei vorzugsweise im wesentlichen senkrecht zu Längsachse des offenen Profils auf die Kontaktbereiche zwischen dem offenen Profil und dem zweiten Metallband gerichtet. Hierdurch kann die Laserstrahlung mit relativ geringer Intensität dennoch auf den gesamten zu verschweißenden Kontaktbereich einwirken.The welding is preferably carried out with a laser welding system, which allows a pinpoint welding with high local variability of the site of action. The laser radiation is preferably directed substantially perpendicular to the longitudinal axis of the open profile on the contact areas between the open profile and the second metal strip. As a result, the laser radiation with relatively low intensity can nevertheless act on the entire contact area to be welded.

Da erfindungsgemäß Hohlprofile hergestellt werden, deren Querschnitt nicht konstant bleibt, ist es ganz besonders vorteilhaft, wenn die Schweißvorrichtung so ausgestaltet ist, dass deren Wirkungsort lageveränderlich ist; denn nur dann kann der Schweißkopf oder können die Schweißköpfe einem mehr oder weniger wellenförmigen Verlauf der zu verschweißenden Kanten beim kontinuierlichen Transport des Profils durch die Schweißstation nachgeführt werden, wodurch sich aufwendige Mechanismen erübrigen, die sicherstellen würden, dass die herzustellende Schweißnaht immer exakt am entsprechenden Schweißkopf geradlinig vorbeigeführt wird.Since, according to the invention, hollow sections are produced whose cross-section does not remain constant, it is particularly advantageous if the welding device is designed such that its site of action is variable in position; because only then, the welding head or welding heads can be tracked a more or less wavy course of the edges to be welded during continuous transport of the profile through the welding station, thereby eliminating costly mechanisms that would ensure that the weld to be produced always exactly on the appropriate welding head is passed straight ahead.

Die entsprechende Ausgestaltung der Schweißstation mit einer hinsichtlich ihres Wirkungsortes lageveränderlichen Schweißvorrichtung umfasst erfindungsgemäß auch eine Abtasteinrichtung zur Erkennung der aktuellen Lage von mindestens einer der Kontaktstellen zwischen dem offenen Profil und dem zweiten Metallband. Diese Abtasteinrichtung kann insbesondere elektronisch, optisch oder mechanisch ausgebildet sein, wobei sie zweckmäßigerweise die Schweißvorrichtung so steuert, dass deren Wirkungsort immer genau auf die zu verschweißenden Kanten gerichtet ist, unabhängig von deren beim Transport des Hohlprofils sich verändernden momentanen Lage in der Schweißstation. Es kann hierbei für jede herzustellenden Schweißnaht eine Abtasteinrichtung vorgesehen sein; bei U-förmigen Profilen mit nach oben wellenförmigen Seitenwangen, die rechts und links in ihrer Form übereinstimmen, ist es beispielsweise auch möglich, nur eine Abtasteinrichtung für beide herzustellenden Schweißnähte zu verwenden, auch wenn in diesem Fall vorzugsweise zwei Schweißköpfe, die rechts und links des Hohlprofils angeordnet sind, verwendet werden.According to the invention, the corresponding configuration of the welding station with a welding device variable in position with regard to its point of action also comprises a scanning device for detecting the current position of at least one of the contact points between the open profile and the second metal strip. This scanning device may in particular be designed electronically, optically or mechanically, wherein it expediently controls the welding device in such a way that its point of action is always directed precisely to the edges to be welded, irrespective of their changing instantaneous position in the welding station during transport of the hollow profile. It can be provided in this case for each weld to be produced a scanning device; For example, in the case of U-shaped profiles with upwardly undulating side cheeks which conform to their shape on the right and left, it is also possible to use only one scanning device for both welds to be produced, even if in this case preferably two welding heads, the right and left of the Hollow sections are arranged to be used.

Besonders zuverlässig, robust und einfach zu realisieren ist eine mechanische Abtasteinrichtung zur Steuerung der Bewegung der Schweißvorrichtung: Es kann insbesondere vorgesehen sein, eine Rolle zu verwenden, die auf dem auf das offene Profil aufgelegten zweiten Metallband abrollt und hierdurch den aktuellen Verlauf der zu verschweißenden Kante erkennt und an die Schweißvorrichtung weitergibt.Particularly reliable, robust and easy to implement is a mechanical scanning device for controlling the movement of the welding device: It may be provided in particular to use a roller which rolls on the laid on the open profile second metal strip and thereby the current profile of the edge to be welded recognizes and passes on to the welding device.

Eine solche Rolle hat den zusätzlichen Vorteil, dass mit ihr auf einfachste Weise die Relativgeschwindigkeit zwischen den zu verschweißenden Kanten und der Schweißvorrichtung detektiert werden kann, wobei diese Größe vorzugsweise zur Regelung der Schweißleistung verwendet wird. Wie unmittelbar einleuchtet, wird die Relativgeschwindigkeit zwischen der zu verschweißenden Kante und der Schweißvorrichtung dann größer, wenn diese Kante nicht geradlinig durch die Schweißstation läuft, sondern von der Längsachse des Hohlprofils abweicht, so dass der Schweißkopf oder die Schweißköpfe eine senkrecht zur Vorschubrichtung des Profils verlaufende Bewegung machen müssen.Such a role has the additional advantage that with it in the simplest way, the relative speed between the edges to be welded and the welding device can be detected, this size is preferably used to control the welding performance. As is readily apparent, the relative velocity between the edge to be welded and the welding device becomes greater when that edge is not straight through the welding station but deviates from the longitudinal axis of the hollow profile so that the welding head or heads are perpendicular to the advancing direction of the profile Have to move.

Das zweite Metallband wird bevorzugt mittels einer Führungsrolleneinrichtung auf das offene Profil aufgelegt, so dass es ohne weiteres auf den mehr oder weniger wellenförmigen Verlauf der zu verschweißenden Ränder bzw. Kanten des offenen Profils bündig aufgelegt werden kann. Ein weiterer großer Vorteil der vorliegenden Erfindung ergibt sich dann dadurch, dass eine solche Führungsrolleneinrichtung gleichzeitig als Abtasteinrichtung dienen kann, und zwar mit oder ohne Steuerung der Schweißleistung. Hierzu kann beispielsweise eine federbelastete Führungsrolleneinrichtung vorgesehen sein, die die Verstellung einer senkrecht zur Längsachse des Profils verstellbaren Schweißvorrichtung steuert. Besonders einfach wird dies, wenn ein oder mehrere Schweißköpfe der Schweißvorrichtung direkt auf der Führungsrolleneinrichtung befestigt sind. Dies führt zu einer besonders einfachen und kompakten Schweißstation für Hohlprofile mit variierenden Querschnitten.The second metal strip is preferably placed on the open profile by means of a guide roller device, so that it can be placed flush on the more or less wavy course of the edges or edges of the open profile to be welded. Another great advantage of the present invention then results from the fact that such a guide roller device can simultaneously serve as a scanning device, with or without control of the welding power. For this purpose, for example, a spring-loaded guide roller device can be provided, which controls the adjustment of an adjustable perpendicular to the longitudinal axis of the profile welding device. This is particularly simple when one or more welding heads of the welding device are mounted directly on the guide roller device. This leads to a particularly simple and compact welding station for hollow sections with varying cross sections.

Weitere Vorteile ergeben sich beim erfindungsgemäßen Verfahren, wenn für das erste und das zweite Metallband unterschiedliche Materialien verwendet werden. Es ergibt sich so eine Art Verbund-Hohlprofil mit variierendem Querschnitt, das hinsichtlich seiner Stabilität und Gewichtsverteilung bisher unbekannte Möglichkeiten bietet.Further advantages result in the method according to the invention, when different materials are used for the first and the second metal strip. This results in a kind of composite hollow profile with varying cross-section, which offers previously unknown possibilities in terms of its stability and weight distribution.

Das zweite Metallband kann vor dem Auflegen auf das offene Profil auch mit Stanzungen und/oder Aufbiegungen versehen werden. Diese Weiterbildung des erfindungsgemäßen Verfahrens ermöglicht also, Funktionselemente eines fertigen Hohlprofils gleich bei dessen Produktion auf einfachste Weise anzubringen, ohne das fertige Hohlprofil nochmals entsprechend bearbeiten zu müssen.The second metal band can also be provided with punched holes and / or bends before being placed on the open profile. This development of the method according to the invention thus makes it possible to attach functional elements of a finished hollow profile immediately during its production in the simplest manner, without having to process the finished hollow profile again accordingly.

Ein Ausführungsbeispiel der Erfindung wird im Folgenden anhand der beigefügten Zeichnungen näher beschrieben und erläutert. Es zeigen:

Figur 1
eine schematische Seitenansicht einer erfindungsgemäßen Vorrichtung;
Figur 2
eine schematische Ansicht einer Schweißstation zur Verwendung bei der vorliegenden Erfindung;
Figur 3
ein erfindungsgemäß hergestelltes Hohlprofil.
An embodiment of the invention will be described and explained in more detail below with reference to the accompanying drawings. Show it:
FIG. 1
a schematic side view of a device according to the invention;
FIG. 2
a schematic view of a welding station for use in the present invention;
FIG. 3
a hollow profile produced according to the invention.

Figur 1 zeigt in einer schematischen Seitenansicht den Aufbau eines Ausführungsbeispiels der erfindungsgemäßen Vorrichtung: Ein erstes, in der Breite variierendes Metallband 1 und ein zweites, in üblicher Weise mit parallelen Längskanten versehenes Metallband 2 werden von einer ersten Abwickelhaspel 3 und einer zweiten Abwickelhaspel 4 für den kontinuierlichen Herstellungsprozess abgenommen. Das erste Metallband 1 durchläuft eine Umformanlage 5 mit fünf hier dargestellten Gestellen 6, in denen jeweils ein zusammenwirkendes Paar von angetriebenen oder freilaufenden Rollformwerkzeugen 9 ein stufenweises Umformen des ersten Metallbandes 1 in ein offenes Profil 7 bewirken. Das zweite Metallband 2 wird an den Rollformwerkzeugen 9 vorbeigeführt und zusammen mit dem eingeformten offenen Profil 7 durch eine Schweißstation 8 transportiert. Dort wird, wie unten näher beschrieben, das zweite Metallband 2 auf die offene Seite des Profils 7 bündig aufgelegt und mit diesem verschweißt. Anschließend an die Schweißstation 8 werden nochmals zwei Gestelle mit Rollformwerkzeugen 9 durchlaufen, um das in der Schweißstation 8 hergestellte Hohlprofil zu richten. Das diese Richtstation verlassende fertige Hohlprofil 11, das erfindungsgemäß einen über dessen Länge variierenden Querschnitt aufweist, wird anschließend in einer Trennmaschine 10 mit mitlaufender Schere 12 auf die gewünschte Länge abgelängt.Figure 1 shows a schematic side view of the structure of an embodiment of the device according to the invention: A first, varying in width metal strip 1 and a second, provided in the usual way with parallel longitudinal edges metal strip 2 of a first unwinding reel 3 and a second unwinding reel 4 for continuous production process. The first metal strip 1 passes through a forming system 5 with five frames 6 shown here, in each of which a cooperating pair of driven or free-running roll forming tools 9 effect a stepwise forming of the first metal strip 1 into an open profile 7. The second metal strip 2 is guided past the roll forming tools 9 and transported together with the molded open profile 7 through a welding station 8. There, as described in more detail below, the second metal strip 2 is placed flush on the open side of the profile 7 and welded thereto. Subsequent to the welding station 8, two racks with roll forming tools 9 are again run through in order to direct the hollow profile produced in the welding station 8. The this finished straightening finished hollow section 11, which according to the invention has a varying over the length of its cross-section, is then cut to length in a cutting machine 10 with scissors 12 to the desired length.

Wie anhand Figur 1 gut zu erkennen ist, handelt es sich beim erfindungsgemäßen Verfahren also um ein kontinuierliches Verfahren, mit dem eine kostengünstige und schnelle Massenproduktion von Profilen mit variierendem Querschnitt möglich ist.As can be seen clearly from FIG. 1, the method according to the invention is thus a continuous method with which a cost-effective and rapid mass production of profiles with a varying cross-section is possible.

Figur 2 zeigt in rein schematischer Darstellung die wichtigsten Funktionselemente der Schweißstation 8. Das offene Profil 7, das als U-förmiges Profil mit einer flächigen, von parallel verlaufenden Kanten begrenzten Basis 13 und zwei Seitenwangen 14 eingeformt ist, deren obere Begrenzungskanten 15 einen rechts und links identischen wellenförmigen Verlauf aufweisen, wird mittels einer angetriebenen, in einem Gestell 16 gelagerten Führungsrolle 17 kontinuierlich durch die Schweißstation geführt, wobei das zweite Metallband 2 bündig auf die Kanten 15 aufgelegt und mittels einer Führungsrolleneinrichtung 18 zum Verschweißen positioniert wird. Die Führungsrolleneinrichtung 18 ist nicht angetrieben und wird mittels zweier Federn 19 gegen das zweite Metallband 2 vorgespannt, so dass sie im Zusammenspiel mit der Führungsrolle 17 für ein sauberes Anliegen des zweiten Metallbandes 2 auf den Kanten 15 des offenen Profils 7 sorgt.Figure 2 shows a purely schematic representation of the main functional elements of the welding station 8. The open profile 7, which as a U-shaped profile with a flat, bounded by parallel edges edges base 13 and two side walls 14 is formed, the upper boundary edges 15 have a right and left identical wavy course is continuously guided by a driven, mounted in a frame 16 guide roller 17 through the welding station, the second metal strip 2 is placed flush on the edges 15 and positioned by means of a guide roller device 18 for welding. The guide roller device 18 is not driven and is biased by two springs 19 against the second metal strip 2, so that it provides in cooperation with the guide roller 17 for a clean concern of the second metal strip 2 on the edges 15 of the open profile 7.

Die Kontaktfläche zwischen dem Profil 7 und dem zweiten Metallband 2 wird also durch die untere Oberfläche des zweiten Metallbandes 2 definiert, so dass die momentane Lage der vorderen Rollen 20 der Führungsrolleneinrichtung jeweils den genauen Ort der herzustellenden Schweißnaht repräsentieren. Diese Rollen 20 nehmen außerdem die momentane Gesamtgeschwindigkeit des zweiten Metallbandes 2 und somit der Kante 15 des Profils 7 auf, die sich aus der Vorschubgeschwindigkeit des Profils 7 und der senkrecht zur Längsachse des Profils 7 verlaufenden Bewegung der Führungsrolleneinrichtung 18 zusammensetzt. Die Rotationsgeschwindigkeit der Rollen 20 wird zur Regelung der Schweißleistung verwendet.The contact surface between the profile 7 and the second metal strip 2 is thus defined by the lower surface of the second metal strip 2, so that the instantaneous position of the front rollers 20 of the guide roller device each represent the exact location of the weld to be produced. These rollers 20 also take the current overall speed of the second metal strip 2 and thus the edge 15 of the profile 7, which is composed of the feed rate of the profile 7 and the perpendicular to the longitudinal axis of the profile 7 extending movement of the guide roller device 18. The rotational speed of the rollers 20 is used to control the welding power.

Stirnseitig an den vorderen Rollen 20 der Führungsrolleneinrichtung 18 sind ein erster und ein zweiter Schweißkopf 21, 22 an der Achse der Rollen 20 befestigt, welche jeweils einen Laserstrahl auf den Kontaktbereich zwischen der Kante 15 des Profils 7 und dem Metallband 2 fokussieren. Auf diese Art und Weise der Anordnung der Schweißköpfe 21, 22 überträgt die Führungsrolleneinrichtung 18 automatisch die variierende Kontur des Profils 7 auf die Schweißköpfe 21, 22, so dass diese sehr exakt der Kante 15 des Profils 7 nachgeführt werden.At the front side on the front rollers 20 of the guide roller device 18, a first and a second welding head 21, 22 are fixed to the axis of the rollers 20, which each focus a laser beam on the contact area between the edge 15 of the profile 7 and the metal strip 2. In this way, the arrangement of the welding heads 21, 22, the guide roller device 18 automatically transmits the varying contour of the profile 7 on the welding heads 21, 22, so that they are tracked very exactly the edge 15 of the profile 7.

Zum Verständnis der Figur 2 sei angemerkt, dass das Gestell 16 zur besseren Erkennbarkeit der funktionswesentlichen Teile der dargestellten Schweißstation nur schematisch dargestellt ist, wobei das vordere Teil 16' des Gestells aus seiner eingebauten Position herausgenommen wurde.For the understanding of Figure 2 it should be noted that the frame 16 is shown only schematically for better visibility of the functionally essential parts of the welding station shown, wherein the front part 16 'of the frame has been removed from its installed position.

Das die in Figur 2 dargestellte Schweißstation 8 verlassende Hohlprofil 11 mit variierendem Querschnitt ist nochmals in Figur 3 zu sehen. Es handelt sich um ein von der Trennmaschine 10 abgelängtes Teil des Hohlprofils 11, das aus einem U-Profil 7 mit wellenförmigen Seitenwangen 14 und einem auf die Seitenwangen aufgelegten und mit diesen verschweißten Deckband 23 besteht.The hollow profile 11 with varying cross section leaving the welding station 8 shown in FIG. 2 can be seen again in FIG. It is a part of the hollow section 11 which is cut to length by the cutting machine 10 and consists of a U-profile 7 with wave-shaped side cheeks 14 and a shroud 23 which is laid onto the side cheeks and welded thereto.

Die in Figur 3 dargestellte Geometrie kann recht einfach hergestellt werden, indem das erste Metallband entweder bereits eine vorgefertigte, variierende Breite aufweist, oder aber in einer in Linie nach dem Coil angeordneten Vorstanzanlage eine der unterschiedlichen Endhöhen des U-Profils 7 entsprechende Kontur der Bandlängskanten eingestanzt bekommt. Die Umformanlage 5 sorgt für die Umformung des ersten Metallbands 1 zu dem U-Profil 7, wobei die seitliche Bandführung mittels gefedert gelagerter Seitenrollen gewährleistet werden kann. Das während des Verfahrens kontinuierlich zugeführte Deckband 23 in Form eines zweiten Metallbandes 2 wird in der Schweißstation 8 auf die wellenförmig verlaufenden Kanten 15 der Seitenwangen 14 aufgeschweißt, wobei die Schweißleistung auf den rein horizontal verlaufenden Abschnitten des hier gezeigten Hohlprofils niedriger gewählt wurde, als an den rampenförmigen Abschnitten, die im kontinuierlichen Durchlaufprozess naturgemäß eine höhere Relativgeschwindigkeit zur Schweißvorrichtung aufweisen, als die horizontalen Abschnitte.The geometry shown in Figure 3 can be made quite easily by the first metal strip either already has a prefabricated, varying width, or stamped in a arranged in line to the coil pre-punching one of the different end heights of the U-profile 7 corresponding contour of the tape longitudinal edges gets. The forming 5 ensures the deformation of the first metal strip 1 to the U-profile 7, wherein the lateral band guide can be ensured by means of sprung mounted side rollers. The continuously supplied during the process shroud 23 in the form of a second metal strip 2 is welded in the welding station 8 on the undulating edges 15 of the side walls 14, wherein the welding power was chosen lower on the purely horizontal sections of the hollow section shown here, as to the Ramp-shaped sections, which naturally have a higher relative speed to the welding device in the continuous flow process, as the horizontal sections.

BezugszeichenlisteLIST OF REFERENCE NUMBERS

11
Metallband (erstes)Metal band (first)
22
Metallband (zweites)Metal band (second)
33
Abwickelhaspel (erste)Uncoiler (first)
44
Abwickelhaspel (zweite)Uncoiler (second)
55
Umformanlageforming plant
66
Gestelleracks
77
Profilprofile
88th
Schweißstationwelding station
99
RollformwerkzeugeRoll forming tools
1010
TrennmaschineRipper
1111
Hohlprofilhollow profile
1212
Scherescissors
1313
Basis (von 7)Base (from 7)
1414
Seitenwangen (von 7)Sidewalls (from 7)
1515
Kanten (von 14)Edges (from 14)
1616
Gestellframe
1717
Führungsrolleleadership
1818
FührungsrolleneinrichtungGuide roller device
1919
Federnfeathers
2020
Rollenroll
2121
Schweißkopf (erster)Welding head (first)
2222
Schweißkopf (zweiter)Welding head (second)
2323
Deckbandshroud

Claims (21)

  1. Method of producing a hollow profile with a cross-section varying over its length, wherein the deformation of a first metal strip (1) with a width varying along the length thereof to form an open profile (7) is carried out by means of roller shaping tools (9), characterised in that a second metal strip (2) is laid onto the edges (15) which delimit the open side of the open profile (7) and the second metal strip (2) is welded to the open profile (7) to form a hollow profile (11).
  2. Method as claimed in Claim 1, characterised in that the method steps are carried out in a continuous process in line one after the other.
  3. Method as claimed in Claim 2, characterised in that the welding takes place by means of laser radiation.
  4. Method as claimed in Claim 3, characterised in that the laser radiation is directed substantially perpendicular to the longitudinal axis of the open profile (7) onto the contact regions between the open profile (7) and the second metal strip (2).
  5. Method as claimed in any one of Claims 2 to 4, characterised in that the second metal strip (2) is laid onto the open profile (7) by a guide roller device.
  6. Method as claimed in any one of Claims 2 to 5, characterised in that a welding device (21, 22) is used which is displaceable substantially perpendicularly to the longitudinal axis of the profile (7).
  7. Method as claimed in Claims 5 and 6, characterised in that a spring-loaded guide roller device (18) is used which controls the displacement of the welding device (21, 22).
  8. Method as claimed in any one of Claims 2 to 7, characterised in that the welding power is controlled as a function of the relative speed between the edges to be welded and the welding device.
  9. Method as claimed in Claim 8, characterised in that the welding power is controlled by way of the rotational speed of a roller (20) rolling on the laid second metal strip (2).
  10. Method as claimed in any one of Claims 1 to 9, characterised in that different materials are used for the first and the second metal strips.
  11. Method as claimed in any one of Claims 1 to 10, characterised in that the second metal strip is provided with stampings and/or bends before being laid onto the open profile.
  12. Apparatus for producing a hollow profile with cross-section varying over its length, comprising a deforming device (5) with a plurality of driven or free-running roller shaping tools (9) for the deformation of a first metal strip (1) into an open profile (7), wherein the deforming device (5) is constructed in such a way that it is suitable for deformation of a first metal strip (1) with a width varying along its length, characterised in that the apparatus further comprises a welding station (8) with guide elements (17, 18) for bringing together the open profile (7) with a second metal strip (2) and with a welding device (21, 22) for welding the second metal strip (2) with the open profile (7) to form a hollow profile (11),
  13. Apparatus as claimed in Claim 12, characterised in that the welding device is a laser welding system.
  14. Apparatus as claimed in Claim 13, characterised in that the laser radiation is directed substantially perpendicular to the longitudinal axis of the open profile (7) onto the contact regions between the open profile (7) and the second metal strip (2).
  15. Apparatus as claimed in Claim 12, characterised in that a sensing device (18, 20) is provided in the welding station for detecting the current position of at least one of the contact points between the open profile (7) and the second metal strip (2), and that the welding device (21, 22) is constructed so as to be variable in position with respect to its operating location, wherein the sensing device (18, 20) is operatively connected to the welding device (21, 22) in order to control the movement of the latter.
  16. Apparatus as claimed in Claim 15, characterised in that the sensing device (18, 20) comprises a roller (20) which rolls on the second metal strip (2) laid onto the open profile (7).
  17. Apparatus as claimed in Claim 16, characterised in that the roller (20) is constructed as a guide roller.
  18. Apparatus as claimed in any one of Claims 16 or 17, characterised in that welding power of the welding device is controllable as a function of the rotational speed of the roller (20).
  19. Apparatus as claimed in any one of Claims 15 to 18, characterised in that the sensing device (18, 20) is formed by a guide roller device (18) for bringing together the open profile (7) with the second metal strip (2).
  20. Apparatus as claimed in Claim 19, characterised in that the welding device contains at least one welding head (21, 22) which is mounted on the guide roller device (18).
  21. Apparatus as claimed in any one of Claims 19 or 20, characterised in that the guide roller device (18) is spring-loaded and is constructed so as to be movable substantially perpendicularly to the longitudinal axis of the profile (7).
EP03010747A 2002-06-14 2003-05-14 Method and apparatus for the manufacturing of a hollow profile Expired - Lifetime EP1371430B1 (en)

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DE10226517A DE10226517C1 (en) 2002-06-14 2002-06-14 Hollow profile manufacturing method has metal band welded across open side of open profile formed from metal band of varying width
DE10226517 2002-06-14

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EP1371430A3 (en) 2004-01-07
EP1371430A2 (en) 2003-12-17
ES2280644T3 (en) 2007-09-16
DE50306292D1 (en) 2007-03-08
US20030230555A1 (en) 2003-12-18
CA2429933A1 (en) 2003-12-14
DK1371430T3 (en) 2007-05-21
DE10226517C1 (en) 2003-10-30

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