EP2144720B1 - Method and device for profile bending - Google Patents

Method and device for profile bending Download PDF

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Publication number
EP2144720B1
EP2144720B1 EP08734653A EP08734653A EP2144720B1 EP 2144720 B1 EP2144720 B1 EP 2144720B1 EP 08734653 A EP08734653 A EP 08734653A EP 08734653 A EP08734653 A EP 08734653A EP 2144720 B1 EP2144720 B1 EP 2144720B1
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EP
European Patent Office
Prior art keywords
roller
bending
roller system
longitudinal axis
component
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EP08734653A
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German (de)
French (fr)
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EP2144720A1 (en
Inventor
Matthias Hermes
Matthias Kleiner
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Technische Universitaet Dortmund
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Technische Universitaet Dortmund
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Publication of EP2144720A1 publication Critical patent/EP2144720A1/en
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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
    • B21D7/00Bending rods, profiles, or tubes
    • B21D7/08Bending rods, profiles, or tubes by passing between rollers or through a curved die
    • 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
    • B21D7/00Bending rods, profiles, or tubes
    • B21D7/04Bending rods, profiles, or tubes over a movably-arranged forming menber

Definitions

  • the invention relates to a method for the planar and spatial bending of rod-shaped, having a longitudinal axis components, such as tubes and profiles (2), with two along the longitudinal axis successively arranged roller systems A and B, wherein the component driven by the roller system A and in the Roller system B is introduced and wherein by a movement of the roller system B relative to the roller system A transversely to the longitudinal axis while the component is transported by the roller systems, the rod-shaped member is bent.
  • the invention also relates to a device for carrying out the method.
  • a method and a device of the type mentioned is from the DE 197 17 232 A1 known.
  • a gimbal-mounted bending head station is used, which has 4 cross-shaped arranged in end shields rolls / rollers.
  • For the propulsion of the profile to be bent support rollers are used, which are set before the bending process and detected in this position.
  • NC program a control program for a bending device in which the springback when twisting the profile to be deformed is to be counteracted.
  • a control signal is formed from the difference between the theoretically calculated relative rotation and the actual relative rotation. The profile is then twisted until the permanent torsion corresponds to the desired value, even after springing back the profile.
  • the object of the present invention is to provide a method and a device in order to be able to bend any rod-shaped components in two or three dimensions without springback. It should be bent in two or three dimensions in addition to cross-sectionally circular tubes and any profile cross-sections. The total length of the tubes and profiles should not be limited by the structure of the device according to the invention.
  • dumbbells For bending pipes, mainly dumbbells are used today ( Franz, W.-D .: wortlles Rohrbiegen. Procedures and machines. VDI publishing house, ISBN 3-18-400814-2, 1988 ).
  • 3D bending the pipe to be bent is rotated by rotating the tube cross-section and brought into another bending plane in these machines, in which then bent further. This change in the bending planes produces corresponding 3D contours.
  • only fixed, predetermined by the bending tools radii are possible.
  • the generation of 3D bends in profiles on such machines is impossible because changing the bending plane in a profile, unlike tubes with a circular cross-section, the required tool cross-section changes.
  • any rod-shaped components can be bent in two or three dimensions.
  • any desired profiles can be bent two- or three-dimensionally, with the total length of the tubes or profiles not being limited by the construction of the device according to the invention.
  • the invention according to claim 1 relates to a method of bending rod-shaped members having a longitudinal axis, such as e.g. Tubes or profiles in which the propulsion of the pipe or profile through the machine via a first roller system A, the transport rollers, frictionally engaged.
  • a second roller system B At the output of the machine, a second roller system B, the bending rollers, arranged.
  • the roller system A As a drive tilting or distortion of a component between a pusher and Biegehülsen, as they occur in known devices avoided.
  • the rollers of the roller system A can be arranged in a plane, or they can be arranged distributed around the tube or profile cross-section, wherein they partially or completely enclose them.
  • the introduction of force takes place via a plurality of rollers lying next to and / or behind one another on the component.
  • rollers on the pipe or profile exerting a force acting substantially perpendicular to the pipe or profile longitudinal axis force to improve the frictional propulsion.
  • the rollers may be profiled and / or have a coating which optimizes the frictional contacts.
  • roller profiling which are pressed elastically on the component surface, the holding force of the roller system A is advantageously increased.
  • elastic coatings the pressure force is distributed more evenly and a plastic deformation of the Component in the roller system A preferably avoided at superimposed shear forces.
  • Such a coating may consist of a polymer. In a particularly advantageous embodiment, it consists of a vulcanized layer of an Elasiomers.
  • roller system A with controlled adjustable contact pressure components of different wall thickness or of different materials of different elasticity can be supplied to the roller system B with part and component dependent set holding force advantageous.
  • a plastic deformation in the roller system A is thus reliably avoided and the deformation in the area of the forming zone always achieves the same result.
  • a bent components can be provided with a constant production speed.
  • This production can be integrated particularly advantageous in clocked, continuous production processes.
  • the roller drive system components of any length can be presented at a constant speed.
  • the second roller system B At the output of the machine, the second roller system B, the bending rollers, arranged.
  • the roller system B consists of pairs arranged around the pipe or profile circumference rollers.
  • the entire roller system B is disposed on an independent support system and movable relative to the roller system A in at least a first plane.
  • the bend of the tube or profile is made by changing the relative position of the roller systems A and B to each other while the tube or profile is being transported by the roller systems.
  • a transverse force is preferably distributed uniformly over the component cross section.
  • a tangential support of the roller system B is guaranteed on the component. Rollers with a larger contact surface are tracked during bending in tangential alignment of the support surface to the component surface. Tilting of the component between the roller systems A and B is thus safely avoided.
  • the roller systems enclosing the rod-shaped component have adjusting mechanisms.
  • the roll systems can be be adjusted by each adjustable in their distance from the longitudinal axis rollers on components with asymmetrically profiled sections having different cross-sections.
  • Such structured sections can be bent in sections, adjusting the roller systems to the changed component cross-section directly, without lengthy replacement of roles.
  • the contact pressure of the rollers can be adjusted to ensure a frictional transport in the roller system A.
  • the rollers of the roller system B are thereby preferably set to a low coefficient of friction, which additionally favors the sliding of the component along the preferably tangentially guided bearing surfaces of the rollers.
  • the rollers of the roller system B are likewise drivable.
  • the drive of the component takes place at an angle ⁇ to the longitudinal axis of the rod-shaped component.
  • About frictional contact in the roller bearing surfaces can be superimposed by increased or reduced propulsion of the roller system B in the forming zone between the roller systems an additional tensile or compressive stress.
  • the roller system B in a further plane, which is aligned at right angles to the first plane E1, by a rotational angle ⁇ rotatable.
  • the rotational angle ⁇ is varied in the process of the roller system so that the bearing surfaces of the rollers are guided tangentially to the component surface.
  • the roller system B in a further plane, which is aligned at right angles to the first plane, by a rotational angle ⁇ rotatable.
  • the rotational angle ⁇ is varied in the process of the roller system so that the bearing surfaces of the rollers are guided tangentially to the component surface.
  • the roller systems A and B are each rotatable about the profile longitudinal axis by appropriate rotary mechanisms.
  • the bending plane can be rotated about the profile longitudinal axis, whereby a third plane can be influenced and 3D-curved components can be produced.
  • the first axis moves the roller system at the exit of the machines and thus generates the bending of the profile. Due to the rotation of the roller systems A and B, the second axis makes it possible to change the bending planes and thus the bending of 3D contours.
  • a torsional moment is introduced into the bending zone between the roller system A and the roller system B.
  • the axis of rotation of the machine is set around the profile longitudinal axis at different angles in the outlet roller system and in the other roller systems. This can be done, as with all moving axes of the machine, by manual or NC control of the drive axles, which may be electrical or hydraulic.
  • a mandrel system is mounted, which comprises a mandrel, e.g. holds in a limb-dome-like design, in the forming zone of the process and so the occurrence of cross-sectional deformations z. B. may occur in hollow sections, reduced.
  • Fig. 1 one sees an exemplary embodiment of the invention.
  • two profiled roller pairs 1 have been arranged one behind the other for the axial drive of the profile 2.
  • These pairs of rollers are arranged on a housing 4, in which the corresponding drive of all roles and a mechanism for adjusting and pressing the pairs of rollers are integrated.
  • the ring 5 and the shaft socket 6 are mounted, which allow in the bearing housings 7 and 8, a rotation of the entire housing.
  • This rotational movement is in this embodiment by a hydraulic cylinder 9, which allows in this case a rotation of 90 degrees in total; but here is also a rotary drive (electrical or hydraulic type), which would enable a full 360 degrees.
  • a hydraulic cylinder 9 which allows in this case a rotation of 90 degrees in total; but here is also a rotary drive (electrical or hydraulic type), which would enable a full 360 degrees.
  • the roller system 3 which is located at the outlet of the machine is executed like a die and encloses the profile cross-section of four sides by means of bending rollers 3a, b, c, d. It can also be adjusted radially when changing the profile type to the corresponding profile cross-section.
  • This system is also able in this embodiment to carry out the rotation about the longitudinal axis of the profile to be bent, and is also driven. This allows in this embodiment, in addition to changing the bending plane, the introduction of a torsional moment in the process with the advantages mentioned above.
  • An additional axis of rotation perpendicular to the profile longitudinal axis is required to ensure the tangency of the roller assembly with changing bending radii.
  • the formation of the bending radii is achieved by the method of the carriage 10 on the linear axis 11, which generates the bending radius by its relative position.
  • FIG. 2 one can see a sectional drawing of the exemplary embodiment of the invention.
  • the assembly with the transport rollers 1 is denoted by A there, the entire assembly with the bending rollers 3a, 3b, 3c, 3d with B.
  • Fig. 3 is a front view of the device, in which also the cutting of Fig. 2 is shown with the bending rollers 3a, 3b, 3c, 3d shown.
  • Fig. 4 shows a plan view of the system, in which the machine setting of the bending roller assembly for bending a left bend with the radius R1 and the angle ⁇ is drawn.
  • a change of the bending plane is clarified.
  • a new radius R2 is bent in a new bending direction and bending plane in the profile 2 likewise twisted about the longitudinal axis.
  • a tactile contour sensor 12 is mounted, which tracks the bends with a roller and the profile during the process missing. This makes it possible to correct the setting parameters of the machine axes in order to arrive at the required bending contour.
  • profile-specific material properties can also be determined with the device and the method according to the invention and the data obtained from this can be used for accurate process simulation and improved process planning. This is done advantageously in that in the pairs of rollers A and / or B sensors for measuring the forces and moments occurring during bending and twisting of the profile are arranged. From this and optionally in conjunction with the data determined by the aforementioned contour sensor, the profile-specific material data required for process simulation or improved process planning can be determined by means of conventional programs.
  • a process planning tool is shown schematically as a block diagram.
  • the profile 2 leaves the roller system 3
  • its bending contour is detected via the contour sensor 12 and thereby the bending radius R b is input via line 12 a into a process computer 13.
  • the bending moment encoder 14 arranged on the carriage 10 is connected to the process computer 13 in order to determine the bending moment M b .
  • the process data for an accurate process simulation 13 a and an improved process planning are used in the process computer 13. It is therefore possible to refer to the entire device as a process planning device, with the help of which two- or three-dimensional bends can be optimized in terms of process technology.
  • An additional extension and improvement of the device according to the invention is achieved by the use of a special cutting tool for flying Disconnect allows.
  • This additional device is particularly useful for applications in which very long semi-finished products (profile 2 in the example) used or manufactured by coil profiles are processed.
  • FIG. 9 shows such a cutting tool for flying separation, which is installed at the end of the device according to the invention in the region of the bending rollers 3a, b, c, d of the roller system 3.
  • FIG. 9 To be considered as an exemplary solution presented cutting tool for flying separation.
  • the movement of the extendable cutting blade 16 is initiated via a cutting hydraulic cylinder 17.
  • the cutting tool can not only be realized in the form of a shear cut, but also in the form of a cutting tool with rotating tool movement, with effect of several sides or by a cutting or thermal cutting process. It is advantageous that the orientation of the cutting tool is always carried tangentially to the profile contour. Also, the fixed installation at the end of the bending device makes sense, since it allows a flying cut during the process without consuming entraining devices.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Bending Of Plates, Rods, And Pipes (AREA)

Description

Die Erfindung betrifft ein Verfahren für das ebene und räumliche Biegen von stabförmigen, eine Längsachse aufweisenden Bauteilen, wie Rohre und Profile (2), mit zwei entlang der Längsachse hintereinander angeordneten Rollensystemen A und B, wobei das Bauteil von dem Rollensystem A angetrieben und in das Rollensystem B eingeführt wird und wobei durch eine Bewegung des Rollensystems B relativ zu dem Rollensystem A in Querrichtung zur Längsachse während das Bauteil durch die Rollensysteme transportiert wird, das stabförmige Bauteil gebogen wird. Die Erfindung betrifft auch eine Vorrichtung zur Durchführung des Verfahrens.The invention relates to a method for the planar and spatial bending of rod-shaped, having a longitudinal axis components, such as tubes and profiles (2), with two along the longitudinal axis successively arranged roller systems A and B, wherein the component driven by the roller system A and in the Roller system B is introduced and wherein by a movement of the roller system B relative to the roller system A transversely to the longitudinal axis while the component is transported by the roller systems, the rod-shaped member is bent. The invention also relates to a device for carrying out the method.

Ein Verfahren und eine Vorrichtung der eingangs genannten Art ist aus der DE 197 17 232 A1 bekannt. Hierzu wird eine kardanisch gelagerte Biegekopfstation verwendet, die 4 kreuzförmig in Lagerschilden angeordnete Walzen/Rollen aufweist. Für den Vortrieb des zu biegenden Profils werden Stützrollen verwendet, die vor dem Biegeprozess eingestellt und in dieser Position festgestellt werden.A method and a device of the type mentioned is from the DE 197 17 232 A1 known. For this purpose, a gimbal-mounted bending head station is used, which has 4 cross-shaped arranged in end shields rolls / rollers. For the propulsion of the profile to be bent support rollers are used, which are set before the bending process and detected in this position.

Ferner ist aus der DE 196 30 025 A1 eine Einrichtung zum Biegen von stabförmigen Bauteilen bekannt, bei der eine Biegerolle vor dem eigentlichen Biegeprozess in ihrer Position eingestellt und fixiert wird.Furthermore, from the DE 196 30 025 A1 a device for bending rod-shaped components known, in which a bending roller is set and fixed in position before the actual bending process.

In der EP 1 087 278 A2 wird ein Steuerungsprogramm (NC-Programm) für eine Biegevorrichtung beschrieben, bei dem der Rückfederung beim Tordieren des zu verformenden Profils entgegen gewirkt werden soll. Hierzu wird ein Steuerungssignal aus der Differenz der theoretisch berechneten relativen Rotation (logical relative rotation) und der aktuellen relativen Rotation (actual relative rotation) gebildet. Das Profil wird dann soweit tordiert, bis die bleibende Torsion auch nach Rückfederung des Profils dem gewünschten Wert entspricht.In the EP 1 087 278 A2 a control program (NC program) is described for a bending device in which the springback when twisting the profile to be deformed is to be counteracted. For this purpose, a control signal is formed from the difference between the theoretically calculated relative rotation and the actual relative rotation. The profile is then twisted until the permanent torsion corresponds to the desired value, even after springing back the profile.

Aufgabe der vorliegenden Erfindung ist es, ein Verfahren und eine Vorrichtung bereit zu stellen, um beliebige stabförmige Bauteile zwei- oder dreidimensional ohne Rückfederung biegen zu können. Es sollen dabei neben im Querschnitt kreisförmigen Rohren auch beliebige Profilquerschnitte zwei- oder dreidimensional gebogen werden. Die Gesamtlänge der Rohre und Profile soll nicht durch den Aufbau der erfindungsgemäßen Vorrichtung beschränkt werden.The object of the present invention is to provide a method and a device in order to be able to bend any rod-shaped components in two or three dimensions without springback. It should be bent in two or three dimensions in addition to cross-sectionally circular tubes and any profile cross-sections. The total length of the tubes and profiles should not be limited by the structure of the device according to the invention.

Zur Lösung dieser Aufgabe wird ein Verfahren mit den Merkmalen von Patentanspruch 1 vorgeschlagen, eine Vorrichtung zur Durchführung des Verfahrens ist in Anspruch 15 dargestellt. Weitere vorteilhafte Ausgestaltung ergeben sich aus den abhängigen Patentansprüchen 2-14 und 16-21.To solve this problem, a method with the features of claim 1 is proposed, an apparatus for performing the method is shown in claim 15. Further advantageous embodiment will become apparent from the dependent claims 2-14 and 16-21.

Für das Biegen von Rohren werden heutzutage hauptsächlich Dombiegemaschinen eingesetzt ( Franz, W.-D.: Maschinelles Rohrbiegen. Verfahren und Maschinen. VDI-Verlag, ISBN 3-18-400814-2, 1988 ). Zum 3D-Biegen wird bei diesen Maschinen das zu biegende Rohr durch Verdrehen des Rohrquerschnitts gedreht und so in eine andere Biegeebene gebracht, in der dann weitergebogen wird. Durch diesen Wechsel der Biegeebenen entstehen entsprechende 3D-Konturen. Dabei sind aber nur feste, durch die Biegewerkzeuge vorgegebene Radien möglich. Ferner ist die Erzeugung von 3D-Biegungen in Profilen auf solchen Maschinen unmöglich, da sich bei Änderung der Biegeebene bei einem Profil, anders als bei Rohren mit kreisrundem Querschnitt, der erforderliche Werkzeugquerschnitt ändert.For bending pipes, mainly dumbbells are used today ( Franz, W.-D .: Maschinelles Rohrbiegen. Procedures and machines. VDI publishing house, ISBN 3-18-400814-2, 1988 ). For 3D bending, the pipe to be bent is rotated by rotating the tube cross-section and brought into another bending plane in these machines, in which then bent further. This change in the bending planes produces corresponding 3D contours. However, only fixed, predetermined by the bending tools radii are possible. Furthermore, the generation of 3D bends in profiles on such machines is impossible because changing the bending plane in a profile, unlike tubes with a circular cross-section, the required tool cross-section changes.

Weiterhin sind sogenannte "Freiformer" bekannt, die ebenfalls nur bei Rohren zum Einsatz kommen und häufig als Sonderwerkzeuge in Dornbiegemaschinen eingebaut werden ( Rasi Maschinenbau GmbH.: Alles unter Kontrolle beim Rohrbiegen. Blech Rohre Profile, 09. 2002., S. 40 ff ). Das Prinzip dieser "Freiformer" ist das Rollenbiegen, wobei die Rohre zwischen mindestens 3 Rollen in einer Ebene geführt werden. Um die Biegeebene zu ändern, muss das Rohr zuerst zwischen den Rollen verdreht werden. Sehr hilfreich ist hier wiederum der kreisrunde Querschnitt von Rohren. Es ist mit diesem Prinzip nicht möglich, nicht-kreisförmige Profile räumlich zu biegen, da sich diese in den Biegerollen verklemmen.Furthermore, so-called "free formers" are known, which are also used only for pipes and are often installed as special tools in mandrel bending machines ( Rasi Maschinenbau GmbH .: Everything under control during tube bending. Sheet metal pipes profiles, 09. 2002., p. 40 ff ). The principle of this "freeformer" is roll bending, whereby the pipes are guided between at least 3 rolls in one plane. To change the bending plane, the tube must first be twisted between the rollers. Very helpful here again is the circular cross section of pipes. It is not possible with this principle to bend non-circular profiles spatially, as they jam in the bending rollers.

Weiter sind in den letzten Jahren Freiformbiegemaschinen bekannt geworden, die mit Gleitführungen arbeiten ( Neugebauer R.; Blau P.; Drossel W-G.: 3D-Freiformbiegen von Profilen. ZWG, 2001, 11-12 .). Das Rohr oder Profil wird dabei durch entsprechende, relative zuelnander verselzie Führungshülsen geschoben, die dabel das Profil krümmen. Hier ist von Nachteil, dass ein zusätzlicher starker Pusher erforderlich ist, und dass die auftretenden großen Reibungskräfte die Oberfläche des Rohrs oder Profils beschädigen können. Daher werden bei diesen Maschinen in der Regel Schmierstoffe eingesetzt, welche nach der Bearbeitung aufwendig von den Werkstücken entfernt werden müssen. Nachteilig ist hier zudem, dass für jeden Profiltyp jeweils passende Hülsen angefertigt werden müssen, die, bedingt durch die hohen Flächenpressungen, aus teuren keramischen Werkstoffen bestehen. Bei diesen Freiformbiegemaschinen ist die Raumrichtung, in der das Profil aus der Maschine tritt, immer von der Kontur des Biegeteils abhängig. Daher ist dort eine aufwendige, mehrachsige Kinematik der Führungshülsen notwendig, um die Raumkurve des Biegeteiles exakt abzubilden, was eine solche Freiformbiegemaschine sehr komplex und teuer werden lässt. Ferner ist für den Fall, dass eine Vermessung des Profils am Austritt der Maschine während des Prozesses erwünscht ist (z.B. für Regelungszwecke), eine komplizierte Sensorik notwendig, die in der Lage ist, 3D-Koordinaten aufzunehmen.Furthermore, in recent years, free-form bending machines have become known which operate with sliding guides ( Neugebauer R .; Blue P .; Drossel WG .: 3D free-form bending of profiles. ZWG, 2001, 11-12 .). The tube or profile is thereby pushed through corresponding, relative zuelnander verselzie guide sleeves, the dabel bend the profile. Here is a disadvantage that an additional strong pusher is required, and that the large frictional forces that occur can damage the surface of the pipe or profile. Therefore, lubricants are usually used in these machines, which must be removed after processing consuming of the workpieces. The disadvantage here is also that for each type of profile each matching sleeves must be made, which, due to the high surface pressures, made of expensive ceramic materials. In these free-form bending machines, the spatial direction in which the profile exits the machine always depends on the contour of the bent part. Therefore, there is a complex, multi-axis kinematics of the guide sleeves necessary to accurately map the space curve of the bending part, which can be very complex and expensive such a free-form bending machine. Furthermore, in the event that a measurement of the profile at the exit of the machine is desired during the process (eg for regulatory purposes), a complicated sensor system capable of taking up 3D coordinates is necessary.

Bei allen Systemen, die heute verwendet werden, kommt ein relativ aufwendiger Pusher zum Einsatz, der das Profil über die Längsachse formschlüssig schiebt. Dabei muss das Profil relativ aufwendig geführt werden, um ein Ausknicken des Profils durch die Längskraft zu vermeiden. Ferner ist dies von Nachteil, weil durch einen Pusher die Gesamtlänge der verarbeitbaren Rohre und Profile begrenzt wird.In all systems that are used today, a relatively expensive pusher is used, which pushes the profile over the longitudinal axis form fit. The profile must be performed relatively expensive in order to avoid buckling of the profile by the longitudinal force. Furthermore, this is disadvantageous because the overall length of the processable tubes and profiles is limited by a pusher.

Aufgabe der vorliegenden Erfindung ist es daher, ein Verfahren und eine Vorrichtung bereitzustellen, womit beliebige, stabförmige Bauteile zwei- oder dreidimensional gebogen werden können. Insbesondere können damit neben kreisförmigen Rohren auch beliebige Profile zwei- oder dreidimensional gebogen werden, wobei die Gesamtlänge der Rohre oder Profile nicht durch den Aufbau der erfindungsgemäßen Vorrichtung beschränkt wird.It is therefore an object of the present invention to provide a method and a device with which any rod-shaped components can be bent in two or three dimensions. In particular, in addition to circular tubes, any desired profiles can be bent two- or three-dimensionally, with the total length of the tubes or profiles not being limited by the construction of the device according to the invention.

Die Lösung der erfindungsgemäßen Aufgabe ergibt sich aus den kennzeichnenden Merkmalen der Ansprüche 1 und 15 in Zusammenwirken mit den Merkmalen des Oberbegriffes. Weitere vorteilhafte Ausgestaltungen der Erfindung ergeben sich aus den Unteransprüchen.The solution of the object according to the invention results from the characterizing features of claims 1 and 15 in cooperation with the features of the preamble. Further advantageous embodiments of the invention will become apparent from the dependent claims.

Die Erfindung gemäß Anspruch 1 betrifft ein Verfahren zum Biegen von stabförmigen, eine Längsachse aufweisenden Bauteilen wie z.B. Rohre oder Profile, bei welcher der Vortrieb des Rohres oder Profils durch die Maschine über ein erstes Rollensystem A, die Transportrollen, reibschlüssig erfolgt. Am Ausgang der Maschine ist ein zweites Rollensystem B, die Biegerollen, angeordnet. Durch die Verwendung des Rollensystems A als Antrieb werden Verkantungen oder Verspannungen eines Bauteils zwischen einem Pusher und Biegehülsen, wie sie bei bekannten Vorrichtungen auftreten, vermieden. Durch den längsachsenparallelen. Vorschub im Rollensystem A wird eine Umformzone diskret zwischen den Rollensystemen A und B fixiert. Wechselwirkungen mit über das gesamte Bauteil aufgebrachten Spannungen und damit verbundene Schwankungen der Umformung können im erfindungsgemäßen Verfahren nicht mehr auftreten.The invention according to claim 1 relates to a method of bending rod-shaped members having a longitudinal axis, such as e.g. Tubes or profiles in which the propulsion of the pipe or profile through the machine via a first roller system A, the transport rollers, frictionally engaged. At the output of the machine, a second roller system B, the bending rollers, arranged. By using the roller system A as a drive tilting or distortion of a component between a pusher and Biegehülsen, as they occur in known devices avoided. Due to the longitudinal axis parallel. Feed in the roll system A, a forming zone is fixed discreetly between the roll systems A and B. Interactions with applied over the entire component voltages and associated variations in the deformation can no longer occur in the process of the invention.

Die Rollen des Rollensystems A können in einer Ebene angeordnet sein, oder sie können rund um den Rohr- oder Profilquerschnitts verteilt angeordnet sein, wobei sie diesen teilweise oder vollständig umschließen. Die Krafteinleitung erfolgt über mehrere, neben- und/oder hintereinander am Bauteil aufliegende Rollen. Durch gleichmäßig über die Rollen aufgebrachte Andruckkraft wird eine mindestens teilumschließende, längsachsenparallele Halterung erzielt, bei der die Andruckkraft sicher unterhalb des plastischen Bereichs gehalten wird.The rollers of the roller system A can be arranged in a plane, or they can be arranged distributed around the tube or profile cross-section, wherein they partially or completely enclose them. The introduction of force takes place via a plurality of rollers lying next to and / or behind one another on the component. By evenly applied over the rollers pressure force an at least teilumschließende, longitudinal axis parallel support is achieved, in which the pressing force is securely held below the plastic region.

Dabei ist es weiterhin möglich, mit den Rollen auf das Rohr oder Profil eine im Wesentlichen senkrecht zur Rohr- oder Profillängsachse wirkende Kraft auszuüben, um den reibschlüssigen Vortrieb zu verbessern. Die Rollen können profiliert sein und/oder eine Beschichtung aufweisen, welche die Reibungskontakte optimiert. Durch Rollen-Profilierungen, die elastisch auf die Bauteiloberfläche aufgepresst werden, wird die Haltekraft des Rollensystems A vorteilhaft erhöht. Durch elastische Beschichtungen wird die Andruckkraft gleichmäßiger verteilt und eine plastische Deformation des Bauteils im Rollensystem A bei überlagerten Scherkräften bevorzugt sicher vermieden. Eine solche Beschichtung kann aus einem Polymer bestehen. In einer besonders vorteilhaften Ausführungsform besteht sie aus einer aufvulkanisierten Schicht eines Elasiomers. Mit einem Rollensystem A mit kontrolliert einstellbarer Andruckkraft können vorteilhaft Bauteile von unterschiedlicher Wandstärke oder aus verschiedenen Materialien unterschiedlicher Elastizität mit abschnitts- und bauteilabhängig eingestellter Haltekraft dem Rollensystem B zugeführt werden. Eine plastische Deformation im Rollensystem A wird so sicher vermieden und die Umformung im Bereich der Umformzone erzielt stets das gleiche Ergebnis.It is also possible, with the rollers on the pipe or profile exerting a force acting substantially perpendicular to the pipe or profile longitudinal axis force to improve the frictional propulsion. The rollers may be profiled and / or have a coating which optimizes the frictional contacts. By roller profiling, which are pressed elastically on the component surface, the holding force of the roller system A is advantageously increased. By elastic coatings, the pressure force is distributed more evenly and a plastic deformation of the Component in the roller system A preferably avoided at superimposed shear forces. Such a coating may consist of a polymer. In a particularly advantageous embodiment, it consists of a vulcanized layer of an Elasiomers. With a roller system A with controlled adjustable contact pressure components of different wall thickness or of different materials of different elasticity can be supplied to the roller system B with part and component dependent set holding force advantageous. A plastic deformation in the roller system A is thus reliably avoided and the deformation in the area of the forming zone always achieves the same result.

Durch konstanten Vortrieb über das Rollensystem A können gebogene Bauteile mit konstanter Produktionsgeschwindigkeit bereitgestellt werden. Diese Fertigung kann besonders vorteilhaft in getaktete, kontinuierliche Fertigungsabläufe integriert werden. Durch das Rollenantriebssystem können Bauteile beliebiger Länge mit konstanter Geschwindigkeit vorgelegt werden.By constant propulsion through the roller system A bent components can be provided with a constant production speed. This production can be integrated particularly advantageous in clocked, continuous production processes. By the roller drive system components of any length can be presented at a constant speed.

Am Ausgang der Maschine ist das zweite Rollensystem B, die Biegerollen, angeordnet. Das Rollensystem B besteht aus paarweise um den Rohr- oder Profilumfang angeordneten Rollen. Das gesamte Rollensystem B ist auf einem unabhängigen Trägersystem angeordnet und relativ zu dem Rollensystem A in mindestens einer ersten Ebene beweglich. Die Biegung des Rohrs oder Profils erfolgt durch eine Änderung der relativen Stellung der Rollensysteme A und B zueinander, während das Rohr- oder Profil durch die Rollensysteme transportiert wird.At the output of the machine, the second roller system B, the bending rollers, arranged. The roller system B consists of pairs arranged around the pipe or profile circumference rollers. The entire roller system B is disposed on an independent support system and movable relative to the roller system A in at least a first plane. The bend of the tube or profile is made by changing the relative position of the roller systems A and B to each other while the tube or profile is being transported by the roller systems.

Mit gegenüberliegend angeordneten Rollenflächen im System B wird eine Querkraft bevorzugt gleichmäßig über den Bauteilquerschnitt verteilt aufgebracht. Durch kleinflächige, im Idealfall punkt- oder querlinienförmige Auflage der Rollen auf der Bauteiloberfläche, ist eine tangentiale Auflage des Rollensystems B auf dem Bauteil gewährleistet. Rollen mit größerer Auflagefläche werden während des Biegens in tangentialer Ausrichtung der Auflagefläche zur Bauteiloberfläche nachgeführt. Ein Verkanten des Bauteils zwischen den Rollensystemen A und B wird so sicher vermieden.With oppositely arranged roller surfaces in the system B, a transverse force is preferably distributed uniformly over the component cross section. By small-area, ideally point or cross-line support of the rollers on the component surface, a tangential support of the roller system B is guaranteed on the component. Rollers with a larger contact surface are tracked during bending in tangential alignment of the support surface to the component surface. Tilting of the component between the roller systems A and B is thus safely avoided.

Dabei ermöglicht bereits eine Beweglichkeit des Rollensystems B in einer Achse das Biegen von 2D-Konturen. Dabei sind z.B. S-förmige ebene Konturen durch ein entsprechendes Positionieren des Rollensystems B zum festen Rollensystem A möglich.In this case, already allows a mobility of the roller system B in one axis, the bending of 2D contours. In this example, S-shaped planar contours are possible by a corresponding positioning of the roller system B to the fixed roller system A.

In einer vorteilhaften Ausführungsform weisen die das stabförmige Bauteil umschließenden Rollensysteme Einstellmechanismen auf. Dadurch ist das Bearbeiten von Rohren und Profilen mit unterschiedlichem Querschnitt möglich. So können die Rollensysteme z.B. durch jeweils in Ihrem Abstand zur Längsachse einstellbare Rollen an Bauteile mit asymmetrisch profilierten Abschnitten, die abweichende Querschnitte aufweisen, angepasst werden. Solche strukturierten Abschnitte können abschnittsweise unter Anpassung der Rollensysteme an den geänderten Bauteilquerschnitt direkt, ohne langwieriges Austauschen von Rollen, gebogen werden. Ferner kann damit der Anpressdruck der Rollen eingestellt werden, um einen reibschlüssigen Transport im Rollensystem A zu gewährleisten. Die Rollen des Rollensystems B werden dabei bevorzugt auf einen niedrigen Reibungskoeffizienten eingestellt, der das Gleiten des Bauteils entlang der bevorzugt tangential geführten Auflageflächen der Rollen zusätzlich begünstigt.In an advantageous embodiment, the roller systems enclosing the rod-shaped component have adjusting mechanisms. This makes it possible to machine pipes and profiles with different cross sections. For example, the roll systems can be be adjusted by each adjustable in their distance from the longitudinal axis rollers on components with asymmetrically profiled sections having different cross-sections. Such structured sections can be bent in sections, adjusting the roller systems to the changed component cross-section directly, without lengthy replacement of roles. Furthermore, so that the contact pressure of the rollers can be adjusted to ensure a frictional transport in the roller system A. The rollers of the roller system B are thereby preferably set to a low coefficient of friction, which additionally favors the sliding of the component along the preferably tangentially guided bearing surfaces of the rollers.

In einer weiteren, vorteilhaften Ausführungsform sind die Rollen des Rollensystems B gleichfalls antreibbar. Der Antrieb des Bauteils erfolgt in einem Winkel α zur Längsachse des stabförmigen Bauteils. Über reibschlüssigen Kontakt in den Rollenauflageflächen kann durch erhöhten oder verringerten Vortrieb des Rollensystems B im Bereich der Umformzone zwischen den Rollensystemen eine zusätzliche Zug- oder Druckspannung überlagert werden.In a further advantageous embodiment, the rollers of the roller system B are likewise drivable. The drive of the component takes place at an angle α to the longitudinal axis of the rod-shaped component. About frictional contact in the roller bearing surfaces can be superimposed by increased or reduced propulsion of the roller system B in the forming zone between the roller systems an additional tensile or compressive stress.

Durch zusätzlich überlagerte Spannungen können Rückfederung und elastische Verformung bereits während des Biegens kompensiert werden. Die angestrebte Umformung kann so in nur einem Umformungsprozess ohne zeitaufwendige Nachbearbeitung erhalten werden. Insbesondere profilierte Bauteile können so formentreu unter Erhalt ihres Bauteilquerschnitts ohne Einknickungen gebogen werden.By additionally superposed stresses springback and elastic deformation can already be compensated during bending. The desired transformation can thus be obtained in only one forming process without time-consuming post-processing. In particular, profiled components can thus be faithfully bent while preserving their component cross-section without buckling.

In einer weiteren, vorteilhaften Ausführungsform ist das Rollensystem B in einer weiteren Ebene, welche rechtwinklig zur ersten Ebene E1 ausgerichtet ist, um einen Drehwinkel β verdrehbar. Der Drehwinkel β wird bei dem Verfahren des Rollensystems so variiert, dass die Auflageflächen der Rollen tangential zur Bauteiloberfläche geführt werden. Durch die zusätzliche Verdrehung kann der Umformzone eine Torsionsspannung zur vorbeschriebenen Kompensation überlagert werden.In a further advantageous embodiment, the roller system B in a further plane, which is aligned at right angles to the first plane E1, by a rotational angle β rotatable. The rotational angle β is varied in the process of the roller system so that the bearing surfaces of the rollers are guided tangentially to the component surface. As a result of the additional rotation, a torsional stress for the above-described compensation can be superimposed on the deformation zone.

In einer weiteren, vorteilhaften Ausführungsform ist das Rollensystem B in einer weiteren Ebene, welche rechtwinklig zur ersten Ebene ausgerichtet ist, um einen Drehwinkel β verdrehbar. Der Drehwinkel β wird bei dem Verfahren des Rollensystems so variiert, dass die Auflageflächen der Rollen tangential zur Bauteiloberfläche geführt werden. Durch die zusätzliche Verdrehung kann der Umformzone eine Torsionsspannung zur vorbeschriebenen Kompensation überlagert werden.In a further advantageous embodiment, the roller system B in a further plane, which is aligned at right angles to the first plane, by a rotational angle β rotatable. The rotational angle β is varied in the process of the roller system so that the bearing surfaces of the rollers are guided tangentially to the component surface. As a result of the additional rotation, a torsional stress for the above-described compensation can be superimposed on the deformation zone.

Die Rollensysteme A und B sind jeweils um die Profillängsachse durch entsprechende Drehmechaniken drehbar. Dadurch kann während des Biegeprozesses die Biegeebene um die Profillängsachse verdreht werden, wodurch eine dritte Ebene beeinflusst werden kann und 3D-gekrümmte Bauteile erzeugt werden können. Bei ausreichender Drehbarkeit der Rollensysteme können somit alle möglichen Raumkurven erzeugt werden. Das heißt, in dieser Ausführung werden durch den Einsatz von nur zwei angetriebenen Achsen bereits Biegungen in allen drei Raumrichtungen möglich. Die erste Achse verfährt das Rollensystem am Ausgang der Maschinen und erzeugt somit die Biegung des Profils. Die zweite Achse ermöglicht durch die Verdrehung der Rollensysteme A und B den Wechsel der Biegeebenen und somit die Biegung von 3D-Konturen. Dies ist im Vergleich zu den Freiformem im Stand der Technik von Vorteil, welche mit vielen synchronisiert zu verfahrenden Achsen erheblich aufwendiger sind. Durch Verdrehung der Rollensysteme gegeneinander kann während des Umformens eine zusätzliche Torsionsspannung zur vorbeschriebenen Kompensation überlagert werden.The roller systems A and B are each rotatable about the profile longitudinal axis by appropriate rotary mechanisms. As a result, during the bending process, the bending plane can be rotated about the profile longitudinal axis, whereby a third plane can be influenced and 3D-curved components can be produced. With sufficient rotation of the roller systems thus all possible space curves can be generated. That is, in this embodiment, bends in all three spatial directions are already possible through the use of only two driven axles. The first axis moves the roller system at the exit of the machines and thus generates the bending of the profile. Due to the rotation of the roller systems A and B, the second axis makes it possible to change the bending planes and thus the bending of 3D contours. This is advantageous in comparison to the freeforms in the prior art, which are considerably more expensive with many synchronized axes to be traversed. By rotation of the roller systems against each other, an additional torsional stress can be superimposed for the above-described compensation during forming.

Vorteilhaft bei dieser Vorrichtung ist, dass im Gegensatz zu den vorher beschriebenen Freiformbiegemaschinen das Profil bezüglich der Maschine immer nur in einer Ebene aus dem Rollensystem kommt. Für eine Vermessung des Profils während des Prozesses sind daher relativ einfache Systeme, welche nur 2D-Koordinaten aufzeichnen, ausreichend. Falls die Lage des letzten Rollenpaares aufgenommen wird, in dem sichergestellt wird, dass das Profil tangential aus dem System läuft, ist sogar nur eine 1 D-Vermessung des austretenden Profils ausreichend, um die gesamte Kontur zu erfassen.An advantage of this device is that, in contrast to the previously described free-form bending machines, the profile with respect to the machine always comes in only one plane from the roller system. For a measurement of the profile during the process therefore relatively simple systems, which record only 2D coordinates, are sufficient. If the position of the last pair of rollers is taken to ensure that the profile is tangential to the system, even only a 1-D measurement of the exiting profile is sufficient to detect the entire contour.

Die ermittelten Daten werden in die Steuerungseinheit der Maschine zurückgeführt und erlauben so einen geregelten Prozess, der die Schwankungen im Biegeverhalten der Halbzeuge im Hinblick auf eine genauere Kontur ausregelt. Dabei ist es erfindungsgemäß besonders vorteilhaft, wenn charakteristische Beziehungen zwischen den Einstellwerten der Maschinenachsen und dem Biegeergebnis in einer Datenbank abgelegt und vom Steuerprogramm beim Betrieb berücksichtigt werden. In der Dissertation von S. Chatti "Optimierung der Fertigungsgenauigkeit beim Profilbiegen", Dr. Ing. Dissertation Universität Dortmund, Shaker Verlag Aachen 1998 sind die entsprechenden Grundlagen für die Beziehungen zwischen den Einstellwerten der Maschinenachsen zur Regelung von Profilbiegeprozessen dargestellt.The data obtained are fed back into the control unit of the machine, thus allowing a controlled process that corrects the fluctuations in the bending behavior of the semi-finished products with regard to a more accurate contour. In this case, it is particularly advantageous according to the invention if characteristic relationships between the setting values of the machine axes and the bending result are stored in a database and taken into account by the control program during operation. In the dissertation of S. Chatti "Optimization of manufacturing accuracy in profile bending", Dr. Ing. Ing. Dissertation University of Dortmund, Shaker Verlag Aachen 1998 the corresponding bases for the relationships between the setting values of the machine axes for controlling profile bending processes are shown.

Bei der erfindungsgemäßen Biegevorrichtung wird in die Biegezone zwischen dem Rollensystem A und dem Rollensystem B ein Torsionsmoment eingebracht. Dadurch ist es z.B. möglich, durch eine Torsionsspannungsüberlagerung die Biegekräfte zu reduzieren oder bei unsymmetrischen Profilquerschnitten der ungewollten Torsion entgegenzuwirken. So kann insbesondere bei profilierten Bauteilen eine formentreue Umformung erreicht werden. Hierzu wird die Drehachse der Maschine um die Profillängsachse in unterschiedlichen Winkeln im Auslaufrollensystem und in den anderen Rollensystemen eingestellt. Dies kann, wie bei allen beweglichen Achsen der Maschine, durch eine manuelle oder eine NC-Steuerung der Antriebsachsen erfolgen, welche elektrischer oder hydraulischer Art sein kann.In the bending device according to the invention, a torsional moment is introduced into the bending zone between the roller system A and the roller system B. Thereby it is e.g. possible to reduce the bending forces by a Torsionsspannungsüberlagerung or counteract the asymmetrical profile cross sections of the unwanted torsion. Thus, in particular with profiled components a form faithful forming can be achieved. For this purpose, the axis of rotation of the machine is set around the profile longitudinal axis at different angles in the outlet roller system and in the other roller systems. This can be done, as with all moving axes of the machine, by manual or NC control of the drive axles, which may be electrical or hydraulic.

In einer weiteren vorteilhaften Ausführungsform wird am hinteren Teil der Vorrichtung, an der das Profil als Halbzeug in den Prozess eingeführt wird, ein Dornsystem montiert, welches einen Dorn, z.B. in einer gliederdomartigen Ausführung, in der Umformzone des Prozesses hält und so das Auftreten von Querschnittsdeformationen, die z. B. bei Hohlprofilen auftreten können, vermindert.In a further advantageous embodiment, at the rear part of the device, at which the profile is introduced as a semi-finished product into the process, a mandrel system is mounted, which comprises a mandrel, e.g. holds in a limb-dome-like design, in the forming zone of the process and so the occurrence of cross-sectional deformations z. B. may occur in hollow sections, reduced.

Im Folgenden wird die Erfindung anhand mehrerer Ausführungsbeispiele näher erläutert.In the following the invention will be explained in more detail with reference to several embodiments.

Es zeigen:

Figur 1:
Gesamtansicht der Vorrichtung mit einer Vergrößerung des Rollensystems B mit einem eingespannten Profil während der Biegung in einer Ebene
Figur 2:
Längsschnitt der Biegevorrichtung mit der Abgrenzung der Baugruppen der beiden Rollensysteme A und B
Figur 3:
Vorderansicht der Vorrichtung bei einer Biegung in einer Ebene.
Figur 4:
Draufsicht der Vorrichtung bei einer Biegung in einer Ebene.
Figur 5:
Gesamtdarstellung der Biegevorrichtung bei Biegeebenenwechsel durch Verdrehen der Rollensysteme A und B bei gleichzeitigem Wechsel der Biegerichtung.
Figur 6:
Vorderansicht des Biegeebenenwechsels und Richtungswechsels.
Figur 7:
Draufsicht auf eine Vorrichtung mit taktilem Kontursensor.
Figur 8:
Prinzipieller Aufbau zur Regelung eines Biegeprozesses
Figur 9:
Erfindungsgemäße Biegevorrichtung mit einer Schneidwerkzeugerweiterung für fliegendes Abtrennen
Show it:
FIG. 1:
Overall view of the device with an enlargement of the roller system B with a clamped profile during the bending in a plane
FIG. 2:
Longitudinal section of the bending device with the delimitation of the assemblies of the two roller systems A and B.
FIG. 3:
Front view of the device when bent in a plane.
FIG. 4:
Top view of the device at a bend in a plane.
FIG. 5:
Overall view of the bending device for bending plane change by turning the roller systems A and B while changing the bending direction.
FIG. 6:
Front view of the bending plane change and change of direction.
FIG. 7:
Top view of a device with a tactile contour sensor.
FIG. 8:
Basic structure for controlling a bending process
FIG. 9:
Inventive bending device with a cutting tool extension for flying separation

In Fig. 1 sieht man eine beispielhafte Ausgestaltung der Erfindung. Dort sind zum axialen Antrieb des Profils 2 drei profilierte Rollenpaare 1 hintereinander angeordnet worden. Diese Rollenpaare sind auf einem Gehäuse 4 angeordnet, in welches der entsprechende Antrieb aller Rollen und ein Mechanismus zur Justierung und Anpressung der Rollenpaare integriert sind. An dem Gehäuse 4 sind der Ring 5 und der Wellenstutzen 6 angebracht, welche in den Lagergehäusen 7 und 8 eine Drehung des kompletten Gehäuses ermöglichen. Diese Drehbewegung wird in dieser Ausgestaltung durch einen Hydraulikzylinder 9, der in diesem Fall eine Verdrehung von insgesamt 90 Grad zulässt; denkbar ist hier aber auch ein Drehantrieb (elektrischer oder hydraulischer Art), der volle 360 Grad ermöglichen würde. Durch diese Drehbewegung und das voll umschlossene Profil kann das Profil während des Biegeprozesses um die Längsachse verdreht werden.In Fig. 1 one sees an exemplary embodiment of the invention. There, two profiled roller pairs 1 have been arranged one behind the other for the axial drive of the profile 2. These pairs of rollers are arranged on a housing 4, in which the corresponding drive of all roles and a mechanism for adjusting and pressing the pairs of rollers are integrated. On the housing 4, the ring 5 and the shaft socket 6 are mounted, which allow in the bearing housings 7 and 8, a rotation of the entire housing. This rotational movement is in this embodiment by a hydraulic cylinder 9, which allows in this case a rotation of 90 degrees in total; but here is also a rotary drive (electrical or hydraulic type), which would enable a full 360 degrees. Through this rotation and the fully enclosed profile, the profile can be twisted around the longitudinal axis during the bending process.

Das Rollensystem 3, welches sich am Auslauf der Maschine befindet, ist matrizenartig ausgeführt und umschließt den Profilquerschnitt von vier Seiten mittels Biegerollen 3a, b, c, d. Dabei kann es zusätzlich bei Wechsel des Profiltyps radial auf den entsprechenden Profilquerschnitt eingestellt werden. Dieses System ist in dieser Ausgestaltung ebenfalls in der Lage, die Drehung um die Längsachse des zu biegenden Profils mit auszuführen, und ist ebenfalls angetrieben. Dies ermöglicht in dieser Ausgestaltung zusätzlich zum Wechsel der Biegeebene das Einbringen eines Torsionsmomentes in den Prozess mit den oben genannten Vorteilen. Eine zusätzliche Drehachse senkrecht zu der Profillängsachse ist erforderlich, um die Tangentialität der Rollenanordnung bei wechselnden Biegeradien zu gewährleisten. Die Ausbildung der Biegeradien wird durch das Verfahren des Schlittens 10 auf der Linearachse 11 erzielt, welcher durch seine relative Position den Biegeradius erzeugt.The roller system 3, which is located at the outlet of the machine is executed like a die and encloses the profile cross-section of four sides by means of bending rollers 3a, b, c, d. It can also be adjusted radially when changing the profile type to the corresponding profile cross-section. This system is also able in this embodiment to carry out the rotation about the longitudinal axis of the profile to be bent, and is also driven. This allows in this embodiment, in addition to changing the bending plane, the introduction of a torsional moment in the process with the advantages mentioned above. An additional axis of rotation perpendicular to the profile longitudinal axis is required to ensure the tangency of the roller assembly with changing bending radii. The formation of the bending radii is achieved by the method of the carriage 10 on the linear axis 11, which generates the bending radius by its relative position.

In Fig. 2 sieht man eine Schnittzeichnung der beispielhaften Ausgestaltung der Erfindung. Die Baugruppe mit den Transportrollen 1 wird dort mit A bezeichnet, die gesamte Baugruppe mit den Biegerollen 3a, 3b, 3c, 3d mit B.In Fig. 2 one can see a sectional drawing of the exemplary embodiment of the invention. The assembly with the transport rollers 1 is denoted by A there, the entire assembly with the bending rollers 3a, 3b, 3c, 3d with B.

In Fig. 3 ist eine Vorderansicht der Vorrichtung, in der auch der Schnittverlauf von Fig. 2 eingezeichnet ist, mit den Biegerollen 3a, 3b, 3c, 3d dargestellt. Fig. 4 zeigt eine Draufsicht des Systems, in der die Maschineneinstellung der Biegerollenbaugruppe zum Biegen einer Linksbiegung mit dem Radius R1 und dem Winkel α eingezeichnet ist.In Fig. 3 is a front view of the device, in which also the cutting of Fig. 2 is shown with the bending rollers 3a, 3b, 3c, 3d shown. Fig. 4 shows a plan view of the system, in which the machine setting of the bending roller assembly for bending a left bend with the radius R1 and the angle α is drawn.

In Fig. 5, 6 und 7 ist ein Wechsel der Biegeebene verdeutlicht. Durch die Verdrehung der Rollensysteme A und B bzw. der Biegerollen 3a, 3b, 3c, 3d und des Ringes 5 für die Rollenpaare 1 wird ein neuer Radius R2 in einer neuen Biegerichtung und Biegebene in dem dadurch ebenfalls um die Längsachse verdrehten Profil 2 gebogen. In Fig. 7 ist ferner am Ausgang der Rolle beispielhaft ein taktiler Kontursensor 12 angebracht, der mit einer Rolle die Biegungen mitverfolgt und das Profil während des Prozesses vermisst. Dadurch ist eine Korrektur der Einstellparameter der Maschinenachsen möglich, um zu der geforderten Biegekontur zu gelangen.In Fig. 5 . 6 and 7 a change of the bending plane is clarified. As a result of the rotation of the roller systems A and B or the bending rollers 3a, 3b, 3c, 3d and the ring 5 for the roller pairs 1, a new radius R2 is bent in a new bending direction and bending plane in the profile 2 likewise twisted about the longitudinal axis. In Fig. 7 Further, by way of example, at the exit of the roller, a tactile contour sensor 12 is mounted, which tracks the bends with a roller and the profile during the process missing. This makes it possible to correct the setting parameters of the machine axes in order to arrive at the required bending contour.

In Erweiterung und Ergänzung der Aufgabe, beliebig, stabförmige Bauteile zwei - oder drei dimensional zu biegen können auch mit der erfindungsgemäßen Vorrichtung und dem erfindungsgemäßen Verfahren profilspezifische Werkstoffeigenschaften ermittelt und die daraus gewonnenen Daten für eine genaue Prozesssimulation und eine verbesserte Prozessplanung eingesetzt werden. Dieses erfolgt vorteilhafter Weise dadurch, dass in den Rollenpaaren A und/oder B Sensoren für die Messung der beim Biegen und Verdrehen des Profils auftretenden Kräfte und Momente angeordnet sind. Daraus und gegebenenfalls in Verbindung mit den durch den vorher erwähnten Kontursensor ermittelten Daten können anhand üblicher Programme die für eine Prozesssimulation oder verbesserte Prozessplanung erforderlichen profilspezifischen Werkstoffdaten ermittelt werden. Als Beispiel für die Prozesssimulation mit üblichen Programmen ist auf folgende Veröffentlichung hinzuweisen: Dirksen, U.; Chatti, S.; Kleiner, M.: Closed-loop Control System for the Three-roll-bending Process Based on Methods of Computational Intelligence. In Proceedings of the 8th International Conference on Technology of Plasticity, 2005 In extension and completion of the task to bend two-dimensional or three-dimensionally bar-shaped components as desired, profile-specific material properties can also be determined with the device and the method according to the invention and the data obtained from this can be used for accurate process simulation and improved process planning. This is done advantageously in that in the pairs of rollers A and / or B sensors for measuring the forces and moments occurring during bending and twisting of the profile are arranged. From this and optionally in conjunction with the data determined by the aforementioned contour sensor, the profile-specific material data required for process simulation or improved process planning can be determined by means of conventional programs. As an example for the process simulation with usual programs the following publication should be pointed out: Dirksen, U .; Chatti, S .; Kleiner, M .: Closed-loop Control System for the Three-Roll-Bending Process Based on Methods of Computational Intelligence. In Proceedings of the 8th International Conference on Technology of Plasticity, 2005

Zur Verdeutlichung des Aufbaus eines Sensoriksystems ist in Fig. 8 ein Prozessplanungswerkzeug schematisch als Blockschaltbild dargestellt. Nachdem das Profil 2 das Rollensystem 3 verlässt, wird seine Biegekontur über den Kontursensor 12 erfasst und dabei der Biegeradius Rb über Leitung 12a in einen Prozessrechner 13 eingegeben. Ferner wird der am Schlitten (10) angeordnete Biegemoment-Geber 14 zur Bestimmung des Biegemomentes Mb mit dem Prozessrechner 13 verbunden. Zusammen mit dem aus einem Torsionsmoment-Geber 15 erhaltenen Torsionsmoment Mt werden im Prozessrechner 13 die Prozessdaten für eine genaue Prozesssimulation 13a und eine verbesserte Prozessplanung genutzt. Man kann daher die gesamte Vorrichtung als Prozessplanungswerkeug bezeichnen, mit dessen Hilfe zwei- oder dreidimensionale Biegungen prozess-technisch optimiert werden können.To clarify the structure of a sensor system is in Fig. 8 a process planning tool is shown schematically as a block diagram. After the profile 2 leaves the roller system 3, its bending contour is detected via the contour sensor 12 and thereby the bending radius R b is input via line 12 a into a process computer 13. Furthermore, the bending moment encoder 14 arranged on the carriage 10 is connected to the process computer 13 in order to determine the bending moment M b . Together with the torsion moment M t obtained from a torsion moment generator 15, the process data for an accurate process simulation 13 a and an improved process planning are used in the process computer 13. It is therefore possible to refer to the entire device as a process planning device, with the help of which two- or three-dimensional bends can be optimized in terms of process technology.

Eine zusätzliche Erweiterung und Verbesserung der erfindungsgemäßen Vorrichtung wird durch die Verwendung eines speziellen Schneidwerkzeuges für fliegendes Abtrennen ermöglicht. Diese ergänzende Vorrichtung ist insbesondere für Anwendungen sinnvoll, bei denen sehr lange Halbzeuge (im Beispiel Profil 2) verwendet bzw. von Coil gefertigte Profile verarbeitet werden.An additional extension and improvement of the device according to the invention is achieved by the use of a special cutting tool for flying Disconnect allows. This additional device is particularly useful for applications in which very long semi-finished products (profile 2 in the example) used or manufactured by coil profiles are processed.

Figur 9 zeigt ein derartiges Schneidwerkzeug für fliegendes Abtrennen, das am Ende der erfindungsgemäßen Vorrichtung im Bereich der Biegerollen 3a, b, c, d des Rollensystems 3 installiert ist. Somit kann nach der Fertigung eines Biegeteiles bzw. des gebogenen Profilsystems 2 der Strang bzw. eine bestimmte Profillänge abgetrennt und damit ein in allen Dimensionen konturgerecht geformtes Biegeteil zur Verfügung gestellt werden. FIG. 9 shows such a cutting tool for flying separation, which is installed at the end of the device according to the invention in the region of the bending rollers 3a, b, c, d of the roller system 3. Thus, after the production of a bent part or of the curved profile system 2, the strand or a certain profile length can be separated and thus a bending part which is contoured in all dimensions can be made available.

Selbstverständlich ist das in Figur 9 dargestellte Schneidwerkzeug für fliegendes Abtrennen als eine beispielhaftgebende Lösung anzusehen. Die Bewegung des ausfahrbaren Schneidmessers 16 wird über einen Schneidhydraulikzylinder 17 eingeleitet. Das Schneidwerkzeug kann jedoch nicht nur in Form eines Scherschnittes realisiert werden, sondern auch in Form eines Schnittwerkzeuges mit drehender Werkzeugbewegung, mit Wirkung von mehreren Seiten oder durch einen spanenden oder thermischen Schneidprozess erfolgen. Vorteilhaft ist, dass die Ausrichtung des Schnittwerkzeuges immer tangential zur Profilkontur mitgeführt wird. Auch ist die feste Installation am Ende der Biegevorrichtung sinnvoll, da diese ohne aufwendige mitführende Vorrichtungen ein fliegendes Abschneiden während des Prozesses ermöglicht.Of course that is in FIG. 9 To be considered as an exemplary solution presented cutting tool for flying separation. The movement of the extendable cutting blade 16 is initiated via a cutting hydraulic cylinder 17. However, the cutting tool can not only be realized in the form of a shear cut, but also in the form of a cutting tool with rotating tool movement, with effect of several sides or by a cutting or thermal cutting process. It is advantageous that the orientation of the cutting tool is always carried tangentially to the profile contour. Also, the fixed installation at the end of the bending device makes sense, since it allows a flying cut during the process without consuming entraining devices.

BezugszeichenlisteLIST OF REFERENCE NUMBERS

11
Rollenpaarroller pair
22
Profilsystemprofile system
33
Rollensystem 3a, 3b, 3c, 3d BiegerollenRoller system 3a, 3b, 3c, 3d bending rollers
44
Gehäusecasing
55
Ringring
66
Wellenstutzenshaft stub
77
Lagergehäusebearing housing
88th
Lagergehäusebearing housing
99
Hydraulikzylinderhydraulic cylinders
1010
Schlittencarriage
1111
Linearachselinear axis
1212
Kontursensorcontour sensor
1313
Prozessrechnerprocess computer
1414
BiegemomentgeberBending moment donors
1515
TorsionsmomentgeberTorsionsmomentgeber
1616
Schnittmessercutting knife
1717
Schneidzylindercutting cylinder

Claims (21)

  1. Method for the planar and spatial bending of rod-shaped components having a longitudinal axis, such as tubes and profiles (2), comprising two roller systems A and B that are disposed behind each other along the longitudinal axis, wherein the component is driven by the roller system A and inserted into the roller system B, and the rod-shaped component is bent by a movement of the roller system B relative to the roller system A in the transverse direction to the longitudinal axis while the component is being conveyed through the roller systems, characterized in that torsional moments are superposed in a controlled manner on the bending zones of the roller systems A and B to compensate spring-back, and that in addition to the bending stress a controlled torsional stress is superposed on the components during the bending process.
  2. Method according to claim 1, characterised in that the roller system A consists of pairwise-opposite rollers (1) which can be separately adjusted in relation to their distance to the longitudinal axis and which are drivable, and that the rollers (1) of the roller system A partially or completely enclose the component in at least one cross-sectional plane, wherein during the continuous feed the components are pivoted via the roller system A about the longitudinal axis in a first plane E1.
  3. Method according to any one of the preceding claims, characterised in that the component is guided via the roller system B comprising roller pressing surfaces bearing against the component at opposite sides, wherein by means of transverse displacement of the roller system B relative to the longitudinal axis and simultaneous pivoting about a centre axis of the roller system B that is perpendicular to the longitudinal axis, bending of the components with a controlled bending contour is effected.
  4. Method according to any one of the preceding claims, characterised in that when changes in the bending radii occur, the roller pressing surfaces of the roller system B are each tangentially adjusted to the component surface.
  5. Method according to any one of the preceding claims, characterised in that the rollers (1, 3a - 3d) of the roller systems A and B can be pressed on perpandicularly to the longitudinal axis of the components, the contact pressure being adjusted such that a frictional contact is adjusted in a defined manner.
  6. Method according to any one of the preceding claims, characterised in that the roller system B is configured to be pivotable relative to the longitudinal axis of the component and is simultaneously displaced, in relation to the roller system A, in two further spatial axes, with the component being fed out perpendicularly to the plane defined by the roller system B, at a constant rate.
  7. Method according to any one of the preceding claims, characterised in that the roller system A enables a feed in the longitudinal direction, and the roller system B enables a drive of the component at an angle α to the longitudinal axis of the rod-shaped components.
  8. Method according to any one of the preceding claims, characterised in that during the continuous feed the roller system B is pivoted in at least one further plane which is oriented perpendicularly to the first plane, with a rotation angle β being varied during the bending process by moving the roller system B in such a way that the rollers (3a - 3d) are pressed on tangentially to the component surface.
  9. Method according to any one of the preceding claims, characterised in that a change of bending planes is effected by a transverse displacement and simultaneous pivoting of the roller systems A and B relative to each other about the respective longitudinal axis.
  10. Method according to any one of the preceding claims, characterised in that the contour of a bent component is recorded by at least one sensor, is then converted into data, and the data is fed to a control unit comprising a correction programme for machine setting, and that, preferably via a contour sensor (12), the bend of the component is followed at the outlet of the roller system B, and that if a deviation from the desired contour occurs the setting parameters α, β and the transverse displacement of the roller pairs A, B are adjusted such that a compensation of the deviation measured by the contour sensor occurs.
  11. Method according to any one of the preceding claims, characterised in that in the roller pairs A and/or B the forces and moments occurring during bending are measured independently and profile-specific material properties are derived therefrom which are used for a precise process simulation and improved process planning, and that, preferably, the data received from the contour sensor (12) are stored and are processed, together with the forces and moments that have been measured on the roller pairs A and/or B, for process simulation and process planning.
  12. Method for the planar and spatial bending of rod-shaped components having a longitudinal axis, such as tubes and profiles (2), comprising two roller systems A and B that are disposed behind each other along the longitudinal axis, according to any one of the preceding claims,
    characterised in that
    the roller system A produces a feed in the longitudinal direction, and the roller system B performs a movement in the direction transverse to the longitudinal axis of the rod-shaped components,
    that during the continuous feed of the components along the longitudinal axis via the roller system A, bending in a first plane is adjusted by positioning the roller systems A and B relative to each other in said first plane, and
    that bending or twisting in at least one further plane is adjusted by pivoting the roller systems A and B relative to each other and about the respective position of the longitudinal or transverse axis in the component.
  13. Method according to any one of the preceding claims, characterised in that in the roller system A the components are frictionally driven and guided by the rollers, and that the components are driven in the roller system B via roller contact surfaces which are arranged opposite each other.
  14. Method according to the preceding claim, characterised in that the components are subjected, section by section, to a controlled tensile or compressive stress during bending.
  15. Device for the planar and spatial bending of rod-shaped components having a longitudinal axis, such as tubes and profiles (2), comprising two roller systems A and B, wherein the feed along the longitudinal axis can be produced via the roller system A, and wherein the roller systems A, B are disposed in at least one first plane E 1 in a displaceable manner relative to each other, characterised in that each of the roller systems A and B can be pivoted about the longitudinal axis of the profile, and that, for bending the component, the position of the roller systems A and B relative to each other can be changed while the component is being conveyed through the roller systems.
  16. Device according to claim 15, characterised in that the rollers of the roller system B are likewise drivable, an additional tensile or compressive stress being superposed in the region of the forming zone between the roller systems via a frictional contact in the roller contact surfaces and through increased or decreased feed of the roller system B.
  17. Device according to any one of the preceding claims 15 to 16, characterised in that sensors for the forces and moments occurring when the profile is being bent and twisted are disposed in the roller systems A and/or B, and that, optionally, in addition thereto, a contour sensor (12) for following the bend in the component is disposed at the outlet of the roller system B, and all of said sensors may be connected to each other via a process control computer (13) to determine the profile-specific material properties and for precise process simulation and improved process planning.
  18. Device according to any one of the preceding claims 15 to 17, characterised in that the roller systems are movable independently of each other on a plurality of axes in space or on at least one plane, and that, optionally, the rotation angles of the drive axles of the roller systems A and B can be adjusted separately, and, preferably, the drive axles can be adjusted manually, or electronically or hydraulically by means of numerical control.
  19. Device according to any one of the preceding claims 15 to 18, characterised in that a guide path of the rod-shaped component ends immediately behind the last roller assembly, in a spatially fixed plane.
  20. Device according to any one of the preceding claims 15 to 19, characterised in that the roller devices comprise a mechanism by means of which the roller position can be adjusted to varying component cross-sections, and that, preferably, individual rollers or all of the rollers are profiled, and that, in particular, individual rollers or all of the rollers have a friction-optimised coating.
  21. Device according to any one of the preceding claims 15 to 20, characterised in that the device has a mandrel system at the rear part thereof to reduce cross-section deformation, and that individual rollers or all rollers have a friction-optimised coating which may consist of a polymer, preferably of an elastomer.
EP08734653A 2007-03-20 2008-03-19 Method and device for profile bending Not-in-force EP2144720B1 (en)

Applications Claiming Priority (2)

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DE102007013902A DE102007013902A1 (en) 2007-03-20 2007-03-20 Device for profile bending
PCT/EP2008/002171 WO2008113562A1 (en) 2007-03-20 2008-03-19 Method and device for profile bending

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EP2144720A1 EP2144720A1 (en) 2010-01-20
EP2144720B1 true EP2144720B1 (en) 2013-01-30

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EP (1) EP2144720B1 (en)
JP (1) JP5460338B2 (en)
KR (1) KR101478852B1 (en)
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KR101478852B1 (en) 2015-01-02
US20100116012A1 (en) 2010-05-13
JP5460338B2 (en) 2014-04-02
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EP2144720A1 (en) 2010-01-20
US9227236B2 (en) 2016-01-05

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