EP2415537A1

EP2415537A1 - Shaping device and method for obtaining local deformations in open sections

Info

Publication number: EP2415537A1
Application number: EP09842117A
Authority: EP
Inventors: Iñaki EGUIA IBARZABAL; Angela MANGAS PÉREZ
Original assignee: Fundacion Labein
Current assignee: Fundacion Tecnalia Research and Innovation
Priority date: 2009-03-26
Filing date: 2009-03-26
Publication date: 2012-02-08
Also published as: EP2415537A4; WO2010109028A1

Abstract

The device comprises an electromagnetic coil (3) assembled on second movement means (4) which can move the coil (3) according to a second movement direction, a die (5) assembled on third movement means (6) which can move the coil (3) according to a second movement direction. The second and third movement means (4)(6) are configured for positioning the coil (3) and the die (5), according to the second movement direction, such that the coil (3) and the die (5) are facing one another and separated a first gap allowing the section (1) to move between the electromagnetic coil (3) and the die (5) according to the first movement direction.

Description

Field of the invention

The present invention relates to the shaping field for obtaining local deformations in sections. It more specifically relates to continuously advancing open sections coming from a profiling station where the shaping of the open sections takes place.

Background of the invention

In profiling stations, a strip of metal is continuously bent by means of the action exerted by pairs of consecutively aligned rollers. These stations can also comprise additional rollers that allow obtaining a variable cross-section throughout its length. Profiling machines are described, for example, in German patent DE10011755A1 and in PCT application WO02/43886A1 .
In these stations, open sections, for example U, T, H sections, or any other configuration, are obtained and can have a constant or variable configuration. The obtained section is then cut to the desired length.
Local deformations are subsequently performed on the shaped section, i.e., that already has its final shape. These local deformations can be, for example, small embossments, holes, grooves or bends, in any area or surface of the section obtained in the shaping station. Said local deformations are generally performed in an independent station on the sections already cut to their final dimensions. These deformations are performed outside the section profiling and movement line (with the immobile section in an independent station) because it is virtually impossible to perform said local deformation operations continuously in the profiling line due to the continuous movement of the section that is being formed.
Even if the drawback of the relative movement between the section that is continuously being shaped and the working tools for shaping the local deformations is eliminated, an extremely long production line would be needed because of the great amount of time necessary for performing the shaping operations of the local deformations. In addition to this space problem required for the resulting facility, considerable investments would also be necessary for the modification of the equipment, resulting in a very expensive and therefore not cost-effective facility.
Therefore, there is still a need in the art for a device and method for the continuous shaping of sections that is economical, fast and reliable, requiring few initial investments and modifications of the profiling equipment.

Summary of the Invention

The object of the invention is a shaping device for obtaining local deformations in continuously advancing open sections moved by first movement means according to a first movement direction.
Throughout the present description, open sections are understood as U, T, H section or any other section configuration obtained continuously in a profiling station bending a strip of metal by means of shaping rollers. These sections can have a constant or variable cross-section.
The shaping rollers furthermore cause the movement of the section obtained according to a first movement direction. The first movement means can be the shaping rollers.
The device of the invention is provided for performing local deformations in any area or surface of the open section, the deformations being shaped with the moving section driven by the shaping rollers, i.e., without the section necessarily being immobile. Throughout the present description, local deformations are understood as any type of embossment, hole or bend that can be made in any area or surface of the open section once it is shaped, i.e., it already has its U, T, H cross-section, etc., configuration.
The shaping device of the invention comprises:

an electromagnetic coil assembled on second movement means which can move the coil according to a second movement direction substantially perpendicular to a plane of advance in which the first movement direction is comprised,
a die assembled on third movement means which can move the coil according to a second movement direction substantially perpendicular to a plane of advance of the section in which the first movement direction is comprised,
the second and third movement means being configured for positioning the coil and the die according to the second movement direction, such that the coil and the die are facing one another and separated a first gap allowing the section to move between the coil and the die according to the first movement direction
control means configured for producing an electromagnetic impulse in the coil synchronized with the movement of the section capable of producing a first local deformation in the section.

According to the device of the invention, the coil is moved (by means of the second movement means) to be positioned close to an area of a section in which the local deformation is to be formed. The die is also moved (by means of the third movement means) to be positioned close to the mentioned area of the section and facing the coil. Between the coil and the die there is a gap allowing the passage of the section (the section is continuously moved), this gap being suitable for the electromagnetic impulse in the coil to produce a deformation in the aforementioned area of the section which will be the local deformation to be obtained.
The die and the coil are positioned with respect to the section according to the second movement direction which, for example, can be a substantially vertical direction and the electromagnetic impulse of the coil is controlled by control means, taking into account the movement of the section according to the first movement direction, such that the local deformation has a specific dimension and position according to the first movement direction. Depending on the magnitude (intensity) of the electromagnetic impulse applied, the deformation could have more or less depth. The dimensions of the deformation according to the first movement direction also approximately correspond with the dimension of the coil according to the first movement direction.
The die can have a contact surface the geometry of which coincides with the first local deformation to be obtained in the section. The coil can have an active surface (the surface closest to the section) with any configuration, for example a flat configuration, but it can also have a configuration close to that of the local deformation to be obtained.
The device can comprise a dolly assembled on fourth movement means configured for positioning the dolly in correspondence with the position of the coil such that the dolly can prevent a movement of the section in the second movement direction during the electromagnetic impulse. When the second movement direction is a vertical direction, i.e., when the open section advances according to a horizontal plane of advance, the dolly is arranged below the section in correspondence with the area in which the electromagnetic impulse of the coil takes place because this electromagnetic impulse causes main force lines which act by producing movement and local deformation of the section against the die, but secondary force lines are also produced in the second movement direction (for example in the downward vertical direction) which tend to move the section in that direction. The purpose of the dolly is to prevent this movement of the section from happening.
The second and third movement means can move the coil and the die in the first movement direction, this movement being performed such that the relative speed between the section and the coil and die is nil. This allows the local deformation to occur as if the section was immobile, which is especially advantageous for producing deformations the axis of which is parallel to the second movement direction such as, for example, vertical grooves or deformations.
The second and third movement means can perform a movement in the transverse direction according to a third movement direction perpendicular to the first movement direction and parallel to the plane of advance of the section. The electromagnetic coil and the die can thus be moved for being positioned with respect to the section, to be adapted to the location thereof, as well as for the gap between the coil and the die to be suitable for producing the local deformation to be obtained.
The device can comprise an additional die assembled on fourth movement means which can move the additional die according to the second movement direction, the fourth movement means being configured for positioning the additional die according to the second movement direction, such that the coil and the additional die are facing one another and separated a second gap allowing the section to pass between the coil and the additional die according to the first movement direction, and in that the electromagnetic impulse in the coil is capable of producing a second local deformation in the section. Local deformations can thus be produced in two different areas of the section, for example producing deformations in the two vertical flanges of a U section. The additional die can have a contact surface the geometry of which coincides with the second local deformation to be obtained in the section.
The device can comprise an additional coil assembled on fifth movement means which can move the additional coil according to the second movement direction, the fifth movement means being configured for positioning the additional coil according to the second movement direction, such that the additional coil and the additional die are facing one another and separated the second gap allowing the section to pass between the coil and the additional die according to the first movement direction, and in that the electromagnetic impulse in the coil is capable of producing the second local deformation in the section.
The electromagnetic impulse produced in the additional coil can be synchronized with the electromagnetic impulse produced in the electromagnetic coil, the first and the second local deformations being produced simultaneously.
Another object of the invention is a shaping method for obtaining local deformations in continuously advancing open sections moved by first movement means according to a first movement direction.
The method of the invention comprises the following phases:

a) positioning an electromagnetic coil close to the section;
b) positioning a die close to the section, the electromagnetic coil and the die facing one another and separated a first gap allowing the section to move between the coil and the die according to the first movement direction.
c) producing an electromagnetic impulse in the electromagnetic coil, synchronized with the movement of the section, capable of producing a first local deformation in the section.

Phase a) of the method can comprise a movement of the electromagnetic coil according to a second movement direction substantially perpendicular to a plane of advance in which the first movement direction is comprised and phase b) can comprise a movement of the die according to a second movement direction substantially perpendicular to a plane of advance in which the first movement direction is comprised. The second movement direction can be a substantially vertical direction.
According to the method of the invention, the coil is moved (according to the second movement direction) to be positioned close to an area of a section in which the local deformation is to be formed. The die is also moved (according to the second movement direction) to be positioned close to the mentioned area of the section facing the coil. Between the coil and the die there is a gap allowing the passage of the section (the section is moved continuously), this gap being suitable for the electromagnetic impulse in the coil to produce a deformation in the aforementioned area of the section which will be the local deformation to be obtained.
The die and the coil are positioned with respect to the section according to the second movement direction which, for example, can be a substantially vertical direction, and the electromagnetic impulse of the coil is controlled by control means, taking into account the movement of the section according to the first movement direction, such that the local deformation has a specific dimension and position according to the first movement direction. Depending on the magnitude (intensity) of the electromagnetic impulse applied, the deformation could have more or less depth. The dimensions of the deformation according to the first movement direction also approximately correspond with the dimension of the coil according to the first movement direction.
The die can have a contact surface the geometry of which coincides with the first local deformation to be obtained in the section. The coil can have an active surface (the surface closest to the section) with any configuration, for example a flat configuration, but it can also have a configuration close to that of the local deformation to be obtained.
The method comprises an additional phase of positioning a dolly in correspondence with the position of the coil such that the dolly can prevent a movement of the section in the second movement direction during the electromagnetic impulse. When the second movement direction is a vertical direction, i.e., when the open section advances according to a horizontal plane of advance, the dolly is arranged below the section in correspondence with the area in which the electromagnetic impulse of the coil is produced to prevent the movement of the section according to the vertical direction.
The method can comprise an additional phase for moving the second and third movement means configured for moving the coil and the die in the first movement direction, this movement being performed such that the relative speed between the section and the coil and die is nil. This allows the local deformation to occur as if the section was immobile, which is especially advantageous for producing deformations the axis of which is parallel to the second movement direction such as, for example, vertical grooves or deformations.
The method can comprise a phase for moving the second movement means in the transverse direction according to a third movement direction perpendicular to the first movement direction and parallel to the plane of advance of the section. The method can comprise a phase for moving the third movement means in the transverse direction according to a third movement direction perpendicular to the first movement direction and parallel to the plane of advance of the section. Thus, the electromagnetic coil and the die can be moved for being positioned with respect to the section, for being adapted to the location thereof, as well as for the gap between the coil and the die to be suitable for producing the local deformation to be obtained.
The method can comprise a phase of positioning an additional die according to the second movement direction, such that the coil and the additional die are facing one another and separated a second gap allowing the section to pass between the coil and the additional die according to the first movement direction, and in that the electromagnetic impulse in the coil is capable of producing a second local deformation in the section. Local deformations can thus be produced in two different areas of the section, for example producing deformations in the two vertical flanges of a U section. The additional die can have a contact surface the geometry of which coincides with the second local deformation to be obtained in the section.
The method can comprise a phase of positioning an additional coil according to the second movement direction, such that the additional coil and the additional die are facing one another and separated the second gap allowing the section to pass between the coil and the additional die according to the first movement direction, and in that the electromagnetic impulse in the coil is capable of producing the second local deformation in the section.
According to the method of the invention, the electromagnetic impulse produced in the additional coil can be synchronized with the electromagnetic impulse produced in the electromagnetic coil.
The use of the electromagnetic shaping, having very reduced operating execution times, has allowed overcoming the aforementioned drawbacks of the prior art, simultaneously advancing the section with the action of electromagnetic shaping.

Brief Description of the Drawings

The present invention will be better understood with reference to the following drawings which illustrate preferred embodiments of the invention, provided by way of example and which should not be interpreted as limiting the invention in any way.

Figure 1 depicts a perspective view of a shaping device according to the present invention acting on a moving open section.
Figure 2 depicts an enlarged perspective view of Figure 1 in which part of the support structures has been eliminated for the sake of clarity.
Figure 3 depicts a perspective view similar to that of Figure 2 in which the open section has still not reached the position of the shaping device.
Figure 4 depicts a detailed perspective view of an electromagnetic coil of the device of the invention positioned for producing a local deformation in a moving open section.
Figures 5a and 5b depict a cross-section view of a section in which a local deformation has been shaped by means of an electromagnetic coil and a die according to the object of the present invention.
Figures 6a and 6b show a plan view with the electromagnetic coil close to a first wall of a section and close to a second wall of the section.
Figure 7 shows a plan view of a section with a variable cross-section, a coil which can be moved transversely for acting on the larger cross-section of the section and a fixed die (a); and a die which can be moved transversely for acting on the smaller cross-section of the section and a fixed coil (b).
Figure 8 shows a schematic perspective view of a section on which an electromagnetic coil, a die and a dolly act.
Figure 9 shows a cross-section view of the section, coil, die and dolly of Figure 6 with the coil positioned and the die and dolly withdrawn.
Figure 10 shows a cross-section view of the section, coil, die and dolly of Figure 6 with the coil, die and dolly positioned.

Detailed Description of the Preferred embodiments

As mentioned, the present invention relates to a device and a method for the continuous electromagnetic shaping of open sections. The electromagnetic shaping method is fast enough to allow forming local deformations on the section without the need for an absence of relative movement between the section and the shaping device. It also allows not excessively increasing the length of the continuous profiling line, thereby preventing excessively large facilities. Likewise, the cost of the shaping device of the invention is less than the cost of a conventional facility for forming local deformations on the section.
Figure 1 shows a shaping device according to an embodiment of the present invention. An open section (1) having U cross-section, shaped by means of continuously advancing shaping rollers (2) moved by first movement means, which can be the shaping rollers (2) themselves or any type of conventional movement device allowing the movement of the sections, has been depicted. The open section (1) could obviously have any other configuration, for example H or T configuration.
The device of the invention comprises an electromagnetic coil (3) assembled on second movement means (4) which can move the coil according to the vertical direction and a die (5) assembled on third movement means (6) which can also be moved according to the vertical direction, such that the electromagnetic coil (3) and the die (5) face one another separated a first gap allowing the section (1) to move between the electromagnetic coil (3) and the die (5). This first gap will be a gap allowing the electromagnetic impulse produced by the electromagnetic coil (3) to produce a local deformation on the section (1), the local deformation corresponding with the geometry of the die (5). The electromagnetic impulse is synchronized with the movement of the section (1) for producing the local deformation in the suitable position. This synchronized operation is performed by means of control means which have not been depicted in Figure 1.
Figure 1 depicts an embodiment in which the coil is housed inside the section and the die is arranged on the outer part of the section, such that a local deformation such as that observed for example in Figure 5a, i.e., a local deformation producing an outward embossment of the section (1) according to the shape of the die (5) can be obtained.
Of course the electromagnetic coil (3) can be arranged on the outer part of the section (1), whereas the die (5) would be housed inside the section (1). A local deformation can thus be obtained by producing, for example, an inward embossment of the section (1), as depicted in Figure 5b.
As observed in Figure 6, the electromagnetic coil (3) can act alternatively on any of the two vertical flanges of the U section. To that end, the second movement means (4) can perform a movement in the transverse direction with respect to the direction of advance (first movement direction) of the section (1). Obviously, in this case, the third movement means can also perform a movement in the transverse direction with respect to the direction of advance for facing the electromagnetic coil (3).
The transverse movement of the second movement means (4) also allows the device to form local deformations in a section (1) having a variable cross-section such as that observed for example in Figure 7. On the left side of Figure (a), a part of the section (1) having a larger cross-section than on the right side of the figure has been depicted. For forming the local deformations in the part of the section (1) having a larger cross-section, the die (5) remains fixed (i.e., without transverse movement), whereas the electromagnetic coil (3) is moved in the transverse direction for approaching the section and producing the local deformation in collaboration with the die (5). For forming the local deformations in the part of the section (1) having a smaller cross-section, the electromagnetic coil remains immobile with respect to the transverse direction, the die (5) being what performs the transverse movement for coming closer to the section (1), allowing the electromagnetic impulse to produce the local deformation on the section (1).
Figure 6 depicts an electromagnetic coil (3) housed inside the section (1) and a die (5) outside the section. Obviously, the die (5) could be housed inside the section (1) and the coil could be arranged on the outer part of the section (1), in which case the transverse movement of the die (5) and of the electromagnetic coil (3) would be opposite that mentioned in the previous case.
In an embodiment that has not been depicted, the second and third movement means can move the electromagnetic coil (3) and the die (5) in a first movement direction which is the movement direction of the section (1), such that the relative speed between the coil and die and the section is cancelled out. Local deformations in the section (1) the axis of which is parallel to the movement direction of the section (1), for example, longitudinal grooves, can thus be formed.
Figures 8, 9 and 10 depict a shaping device according to an alternative embodiment of the invention comprising an electromagnetic coil (3), a die (5) and a dolly (7). The dolly is assembled on fourth movement means configured for positioning the dolly (7) below the section (1) such that the dolly (7) prevents a movement of the section in the vertical direction during the electromagnetic impulse. Obviously the dolly is arranged under the section (1) in correspondence with the position of the electromagnetic coil (3).
Figure 9 depicts the electromagnetic coil (3) in the operating position housed inside the section (1), the die (5) and the dolly (7) being far from their working position. Figure 8 depicts the electromagnetic coil (3), the die (5) and the dolly (7) in the operating position, i.e., in the position in which an electromagnetic impulse generated in the electromagnetic coil (3) produces a local deformation in the section (1), preventing the section (1) from being moved downward as a consequence of the electromagnetic impulse itself.
In another additional embodiment of the device of the present invention, the coil located inside the cavity of the open section (1) can perform the simultaneous shaping, such as embossment, grooving, etc., on two sides of the section (1). To that end, the device has two dies, one die (5) and an additional die (5'), each of the dies (5)(5') facing each of the sides to be shaped. Alternatively, the device can have two coils, each facing a die, an electromagnetic coil (3) and an additional coil (3').
The coils (3)(3') can be located inside and the dies (5)(5') outside the cavity of the section (1) or vice versa. In this case, each of the coils forms the embossment or the grooving of one of the sides of the open section, these embossments or groovings being able to be simultaneous or alternating.
The material used to manufacture the section to be shaped according to the present device and method will generally be conventional profiling material. However, sections can also be shaped from high-strength structural materials, such as high-strength steels of up to 800 MPa of yield stress and of to 1.35 mm thick.

Claims

Shaping device for obtaining local deformations in continuously advancing open sections (1) moved by first movement means according to a first movement direction, characterized in that it comprises:
- an electromagnetic coil (3) assembled on second movement means (4) which can move the coil (3) according to a second movement direction substantially perpendicular to a plane of advance in which the first movement direction is comprised,

- a die (5) assembled on third movement means (6) which can move the coil (3) according to a second movement direction substantially perpendicular to a plane of advance of the section (1) in which the first movement direction is comprised,
the second and third movement means (4)(6) being configured for positioning the coil (3) and the die (5), according to the second movement direction, such that the coil (3) and the die (5) are facing one another and separated a first gap allowing the section (1) to move between the electromagnetic coil (3) and the die (5), according to the first movement direction

- control means configured for producing an electromagnetic impulse in the coil (3) synchronized with the movement of the section (1) capable of producing a first local deformation in the section (1).
Device according to claim 1, wherein the die (5) has a contact surface the geometry of which coincides with the first local deformation to be obtained in the section (1).
Device according to any of the preceding claims, wherein the second movement direction is a substantially vertical direction.
Device according to any of the preceding claims, comprising a dolly (7) assembled on fourth movement means configured for positioning the dolly (7) in correspondence with the position of the coil (3) such that the dolly (7) can prevent a movement of the section (1) in the second movement direction during the electromagnetic impulse.
Device according to any of the preceding claims, wherein the second movement means (4) and the third movement means (6) can move the coil (3) and the die (5) in the first movement direction, this movement being performed such that the relative speed between the section (1) and the coil (3) and die (5) is nil.
Device according to any of the preceding claims, wherein the second movement means (4) can perform a movement in the transverse direction according to a third movement direction perpendicular to the first movement direction and parallel to the plane of advance of the section (1).
Device according to any of the preceding claims, wherein the third movement means (6) can perform a movement in the transverse direction according to a third movement direction perpendicular to the first movement direction and parallel to the plane of advance of the section (1).
Device according to any of the preceding claims, comprising an additional die (5') assembled on fourth movement means which can move the additional die (5') according to the second movement direction, the fourth movement means being configured for positioning the additional die (5') according to the second movement direction, such that the coil (3) and the additional die (5') are facing one another and separated a second gap allowing the section (1) to pass between the coil (3) and the additional die (5') according to the first movement direction, and in that the electromagnetic impulse in the coil (3) is capable of producing a second local deformation in the section (1 ).
Device according to claim 8, wherein the additional die (5') has a contact surface the geometry of which coincides with the second local deformation to be obtained in the section (1).
Device according to claims 8 or 9, comprising an additional coil assembled on fifth movement means which can move the additional coil (3') according to the second movement direction, the fifth movement means being configured for positioning the additional coil (3') according to the second movement direction, such that the additional coil (3') and the additional die (5') are facing one another and separated the second gap allowing the section (1) to pass between the coil (3) and the additional die (5') according to the first movement direction, and in that the electromagnetic impulse in the coil (3) is capable of producing the second local deformation in the section (1 ).
Device according to claim 10, wherein the electromagnetic impulse produced in the additional coil (3') is synchronized with the electromagnetic impulse produced in the coil (3).
Device according to any of the preceding claims, wherein the shaping can be selected from an embossment, a hole or a bend.
Shaping method for obtaining local deformations in continuously advancing open sections moved by first movement means according to a first movement direction, characterized in that it comprises:
a) positioning an electromagnetic coil (3) close to the section (1);

b) positioning a die close to the section (1), the electromagnetic coil (3) and the die (5) facing one another and separated a first gap allowing the section to move between the coil (3) and the die (5) according to the first movement direction;

c) producing an electromagnetic impulse in the electromagnetic coil (3), synchronized with the movement of the section (1), capable of producing a first local deformation in the section (1).
Method according to claim 13, wherein phase a) comprises a movement of the electromagnetic coil (3) according to a second movement direction substantially perpendicular to a plane of advance in which the first movement direction is comprised and wherein phase b) comprises a movement of the die (5) according to a second movement direction substantially perpendicular to a plane of advance in which the first movement direction is comprised.
Method according to any of claims 13 or 14, wherein the die (5) has a contact surface the geometry of which coincides with the first local deformation to be obtained in the section (1).
Method according to any of claims 13 to 15, wherein the second movement direction is a substantially vertical direction.
Method according to any of claims 13 to 16, comprising an additional phase of positioning a dolly (7) in correspondence with the position of the coil (3) such that the dolly (7) can prevent a movement of the section (1) in the second movement direction during the electromagnetic impulse.
Method according to any of claims 13 to 17, comprising an additional phase for moving second and third movement means (4) (6) for moving the coil (3) and the die (5) in the first movement direction, this movement being performed such that the relative speed between the section (1) and the coil (3) and die (5) is nil.
Method according to any of claims 13 to 18, comprising a phase for moving the second movement means (4) in the transverse direction according to a third movement direction perpendicular to the first movement direction and parallel to the plane of advance of the section (1).
Method according to any of claims 13 to 19, comprising a phase for moving third movement means in the transverse direction according to a third movement direction perpendicular to the first movement direction and parallel to the plane of advance of the section (1).
Method according to any of claims 13 to 20, comprising positioning an additional die (5') according to the second movement direction such that the coil (3) and the additional die (5') are facing one another and separated a second gap allowing the section (1) to pass between the coil (3) and the additional die (5') according to the first movement direction, and in that the electromagnetic impulse in the coil (3) is capable of producing a second local deformation in the section (1).
Method according to claim 21, wherein the additional die (5') has a contact surface the geometry of which coincides with the second local deformation to be obtained in the section (1).
Method according to any of claims 13 to 21, comprising positioning an additional coil (3') according to the second movement direction such that the additional coil (3') and the additional die (5') are facing one another and separated the second gap allowing the section (1) to pass between the coil (3) and the additional die (5') according to the first movement direction, and in that the electromagnetic impulse in the coil (3) is capable of producing the second local deformation in the section (1).
Method according to claim 23, wherein the electromagnetic impulse produced in the additional coil (3') is synchronized with the electromagnetic impulse produced in the electromagnetic coil (3).