EP2576095B1 - Apparatus for shaping a component comprising a particularly sheet-like semifinished product - Google Patents

Description

The present invention relates to a device for forming a component from a particularly flat semi-finished product, for example a metal strip, in a roll forming process or a roll profiling line, with at least one processing device which has a forming device which reshapes at least a portion of the semi-finished product or mechanically processes the like. Such a device according to the preamble of claim 1 is for example from U.S. 2,436,821 A known.

Furthermore, such a device shows, for example DE 10 2007 045 644 , wherein the processing device for reshaping the flat semi-finished product has at least one cooperating pair of rollers, which, for example in the form of a lower and upper roller, enable reshaping of the component and in particular the reshaping of an end flange of the component.

In the scope of the invention, “forming” is understood to mean not only bending over, folding over, everting, folding, buckling, upsetting, etc., but also any other type of mechanical processing, for example punching, cutting, pressing, etc.

The forming is usually carried out in a roll forming or similar roll profiling line by means of processing devices which fix the semi-finished product in certain areas and process it mechanically using certain processing devices.

In the course of these forming processes, it is necessary to fix and stabilize certain areas of the semi-finished product using suitable processing devices in such a way that these areas do not deform or only deform to a permissible extent when deforming, in particular, adjacent areas. However, especially in the case of forming processes in the edge area of the semifinished product or in areas where there is no sufficient pressing and holding surface for these "stabilizing devices", this sometimes leads to major problems. In certain areas of the semifinished product that have already been reshaped, it is no longer possible to arrange corresponding processing devices for fixing without these areas being reshaped.

Similar problems also arise with the step-by-step reshaping of semi-finished products, i.e. mechanical processing with several different processing steps. Here, too, it is necessary to position the processing devices in such a way that forming work or similar mechanical work is carried out only in certain areas of the semi-finished product. For this purpose, precise positioning of the semifinished product within the roll form or the like roll profiling section and in particular relative to the respective processing devices is necessary.

From the above U.S. 2,436,821 A a punching submission is known in which the punching tool punches out circular disks from a semi-finished product. In order to save material, the semifinished product has undulated side edges which, via a type of gearwheels, control the punching tool in a synchronized manner with the undulation. The preparation of the semi-finished product is complex and only allows synchronization with a punch which follows the pattern of the undulation.

The device for reshaping a component described above does not meet these requirements.

In this respect, the invention is based on the object of offering a device for reshaping a component from an in particular flat semi-finished product of the type mentioned at the beginning, which allows versatile and precise reshaping of the semi-finished product.

This object is achieved by a device according to patent claim 1.

In particular, this object is achieved by a device for reshaping a component from a particularly flat semi-finished product, for example a sheet metal strip, in a roll forming process or a roll profiling line, with at least one processing device which has the following: a forming device which is designed such that it at least a partial area of the semi-finished product is formed or the like is mechanically processed, and a synchronization device which has a free-running synchronization roller and is designed and arranged in such a way that it is in or can be brought into synchronization with areas of the semi-finished product that have already been formed and the semi-finished product is positioned precisely to the forming device.

As already explained, in addition to bending, folding over, turning inside out, folding, kinking, upsetting, etc. also any other type of mechanical processing, for example punching, cutting, pressing, etc., is understood here, in principle any type of Machining of a semi-finished product that occurs in a roll forming or similar roll profiling process in order to transform a semi-finished product into a component.

According to the invention, the synchronization device enables the semifinished product to be precisely positioned relative to the shaping device, whereby for this purpose it is or can be brought into synchronizing engagement with regions of the semifinished product that have already been deformed. If, in a roll forming process, recesses are made in a semifinished product orthogonally to the roll forming direction, which later serve as inlet openings for a cover grate, for example, the synchronization device is designed in such a way that it is in synchronizing engagement with these recesses or can be brought into synchronization with the at least partially formed semifinished product to position to a (further) forming device.

This synchronization via the synchronization device using already formed areas of the semi-finished product results in a very precise and technically uncomplicated calibration of the device for reshaping a semi-finished product.

The synchronization roller is preferably in roller synchronization with the areas of the semifinished product that have already been deformed or is in roller synchronization with the areas that have already been deformed of the semi-finished product can be brought into roll synchronization. The synchronization roller is designed to run freely. The synchronization roller and the forming device are coupled in such a way that the semi-finished product is precisely positioned to the forming device via the roller synchronization engagement.

The synchronization device preferably has synchronization projections which are or can be brought into synchronization engagement with the already formed regions of the semifinished product. These synchronization extensions are preferably designed in such a way that they can be brought into operative connection essentially precisely with already formed areas of the semifinished product, so that the at least partially deformed semifinished product is positioned relative to the forming device.

The synchronization extensions are preferably distributed at least partially over the circumference of the synchronization roller. Such an embodiment is, for example, a synchronization roller designed as a “gearwheel”. The formation of the synchronization extensions over the circumference of the synchronization roller allows the synchronization device to be brought into synchronization in a rolling manner, which offers particular advantages in particular in the case of a continuous roll forming process. The synchronization roller rolls along the already partially formed semifinished product, with its synchronization projections continuously positioning the semifinished product in rolling synchronization engagement with areas of the semifinished product that have already been formed.

The forming device preferably has a contour device whose surface is designed to be complementary to already formed areas of the semifinished product, so that it is in contour engagement with these or can be brought into such without further forming these areas. Such a contour device thus contains, for example, recesses which are designed complementary to bulges on the semifinished product, these recesses coming into precise engagement with the bulges during the forming process, but without further reshaping these areas. Such a contour device enables the semifinished product to be precisely fixed, even in areas that have already been deformed. The area of application of such a contour device lies in areas on the semifinished product in which fixation with forming devices without a contour device is not possible, since this leads to a renewed or further forming of already formed areas.

The contour device is preferably designed as a contour roller which is in operative connection with a forming device designed as a forming roller. A forming device designed as a forming roller will be discussed in detail below. Combined with the synchronization roller, this results in a device that positions the semi-finished product in rolling operation during the forming process over the already partially deformed semi-finished product, positions it and also fixes it in the areas where the forming device and the contouring device come into operative connection with the semi-finished product or reshaped.

By using the synchronization device and, in particular, a synchronization device designed as a synchronization roller, the contour device can easily be brought into contact with the at least partially formed semi-finished product, since the synchronization device guarantees the precise orientation relative to the forming device and the contour device formed on it.

The reshaping device has at least one reshaping roller which enables the semifinished product to be rolled, the reshaping roller being arranged coaxially with the synchronization roller. As with the design of the synchronization device as a synchronization roller, the design of the forming device as a forming roller enables continuous roll forming, the synchronization device or synchronization roller ensuring the correct positioning of the semi-finished product relative to the forming roller. The coaxial arrangement of the forming roller relative to the synchronization roller leads to a processing device with very complex dimensions, so that the overall dimensions of the device for forming a semi-finished product are significantly reduced.

The synchronization device is preferably arranged on the shaping device. This also leads to significantly reduced component dimensions and, moreover, to a device in which a non-positive coupling between the forming device and the synchronization device is possible. If, for example, the shaping device is driven by its own drive, the synchronization device can make use of it. If, on the other hand, the semifinished product is moved relative to the shaping device, the coupling between the shaping device and the synchronization device leads to the fact that both devices engage with the moving semifinished product with an exact fit relative to one another.

The synchronization device and at least part of the shaping device are preferably designed in one piece with one another. This also applies to the embodiment of a shaping device with a contour device, which can then also be at least partially formed in one piece with the synchronization device. Such a one-piece design allows the cost-effective production of particularly very resistant components.

At least one free-wheeling device of the forming device is preferably arranged on the device so as to be movable relative to the synchronization device and / or to the rest of the forming device. If the forming device has a forming roller and / or the synchronization device has a synchronization roller, at least one free-wheeling device of the forming device is preferably arranged so as to be movable and in particular rotatable relative to the synchronization device. The freewheel device also preferably has a freewheel forming roller which is arranged on the device so as to be movable, in particular rotatable, relative to the synchronization device. In principle, it applies to the freewheel devices or freewheel forming rollers that they can also be designed as contour freewheel devices or contour freewheel rollers. In principle, the formation of a free-wheeling device on the forming device allows the forming to take place independently of the positioning of the semi-finished product. If the semifinished product consists, for example, of an area with already formed elements and an area in which no forming has yet been carried out, it is possible to design the forming device in such a way that in this area, in which no forming has been carried out so far, it is decoupled from the rest of the part Freewheel device and in particular a freewheel forming roller is arranged. This considerably reduces the energy consumption of the forming process.

The forming roller is preferably rotatably mounted on the device and in particular on the synchronization device and / or the forming device. As before, this design leads to a very complex configuration of the device.

The free-running forming roller is preferably arranged on the forming roller in a ring bearing device that revolves around the axis of rotation of the forming roller. Such a ring bearing device can be, for example, a ball bearing device or a similar bearing device which is formed in a corresponding receiving recess on the forming roller. In this way, the free-running forming roller is decoupled from the forming roller in the direction of rotation.

Further embodiments of the invention emerge from the subclaims.

Fig. 1

eine isometrische Darstellung einer Ausführungsform einer Bearbeitungseinrichtung;

Fig. 2

eine isometrische Draufsicht auf die Ausführungsform gemäß Fig. 1;

Fig. 3

eine isometrische Unteransicht der Ausführungsform gemäß Fig. 1;

Fig. 4

eine isometrische Vorderansicht der Ausführungsform aus Fig. 1;

Fig. 5

eine Seitenansicht der Ausführungsform aus Fig. 1; und

Fig. 6

eine isometrische Explosionsdarstellung der Ausführungsform aus Fig. 1.

The invention is described below using an exemplary embodiment which is explained in more detail by means of the accompanying drawings. Here show:

Fig. 1

an isometric view of an embodiment of a processing device;

Fig. 2

an isometric plan view of the embodiment according to Fig. 1 ;

Fig. 3

an isometric bottom view of the embodiment according to FIG Fig. 1 ;

Fig. 4

Figure 3 is a front isometric view of the embodiment Fig. 1 ;

Fig. 5

a side view of the embodiment from Fig. 1 ; and

Fig. 6

Figure 3 is an exploded isometric view of the embodiment Fig. 1 .

In the following, the same reference numbers are used for identical and identically acting components, with high indices sometimes being used to distinguish them.

The Figures 1 to 5 show different views of an embodiment of the device 1 according to the invention or two processing devices 6 of such a device 1.

Fig. 1 shows the device according to the invention in an isometric view, Fig. 2 in a plan view, Fig. 3 in a bottom view, Fig. 4 in a front view and Fig. 5 in a side view. Essential parts of two processing devices 6, which are designed for reshaping and for synchronizing a movement of a component 2, are shown therein.

The component 2 is here a cover grate for a drainage channel, which is made from a semi-finished product 4, namely a sheet metal strip. This production takes place in a roll forming section, the component 2 or the semi-finished product 4 moving along the direction of movement 3 shown here. In several processing steps 4 drainage openings 30, stabilizing beads 32, longitudinal webs 34, support flanges 36 and other elements are formed from the semi-finished product 4 and thus the finished component 2, namely a cover grating for a drainage channel, is formed.

In order to ensure rapid deformation processing of the semi-finished product 4, a plurality of processing devices and, inter alia, the two processing devices 6 shown here schematically are used.

The processing devices 6 shown here serve to reshape certain areas of the semifinished product 4 and also to synchronize the semifinished product 4 with a shaping device 8 and, as described in detail below, with a contour device 20 provided on the shaping device 8. Each of the machining devices shown here 6 has a shaping device 8 which is used to shape certain areas on the semi-finished product 4. These shaping devices 8 are designed as shaping rollers 18, so that when the semifinished product 4 or the component 2, which is here partially completely shaped, is moved, roll shaping can take place in interaction with these shaping rollers 18.

Usually, the forming rollers shown here also include an oppositely directed forming roller that generates a counterforce to the force that is applied to the semi-finished product by each forming roller 8. This oppositely directed forming roller is dispensed with here for the sake of clarity.

In this embodiment, the forming rollers 18 are also designed as a contour device 20 or contour roller 21, which, when properly synchronized with already formed areas 14 and here with the stabilizing beads 32, can be brought into contour engagement without further deforming these areas 32 and 14.

Associated with the contour roller 21, the forming device 8 also has a freewheeling device 16 in the form of a free-running forming roller 17, which can be rotated relative to the remaining part of the forming device 8 about the common axis of rotation AR. This freewheeling deformation roller 17 can be brought into deformation engagement with a partial area 12 which does not yet contain any deformed areas 14. This partial area is here a longitudinal strip on the support flange 36.

The synchronization device 10 or the synchronization roller 11 is connected in one piece with the forming roller 18 or the contour roller 21. This synchronization roller 11 has synchronization projections 13 which are or can be brought into synchronization engagement with already reshaped areas 15, here the drainage openings 30. As a result of this engagement with the deformed areas 15 or drainage openings 30, which in particular run orthogonally to the direction of movement 3, synchronization between the semi-finished product 4 moved in the direction of movement 3 and the processing devices 6 and in particular the contour rollers 21 is achieved according to the invention.

Only through this synchronization is it ensured that the recesses 23 in the contour roller 21, which in this embodiment also extend into the synchronization roller 11, move precisely with the deformed areas 14 and here the stabilization beads 32.

When the semifinished product 4 moves in the direction of movement 3, the engagement of the synchronization projections 13 with the deformed areas 15 or the drainage openings 30 in the partially deformed component 2 results in synchronization with the forming roller 18 and, at the same time, in a deformation in the area 12 of the semifinished product 4 by means of the freewheeling forming roller 17 decoupled from this synchronization.

As in particular in the Fig. 3 and 5 As can be seen, the synchronization extensions 13 are designed so that they essentially fit precisely into the deformed areas 15, namely the drainage openings 30. This guarantees an exact synchronization between the semifinished product 4, the deformed areas 14 and 15 formed thereon and the deforming device 8.

In Fig. 6 the previously described embodiment of the processing devices 6 is shown in an isometric exploded view. The shaping device 8 on which the synchronizing device 10 is integrally arranged can be seen. The forming device 8 comprises the forming roller 18, which is also designed as a contour device 20 or contour roller 21, and the free-running forming roller 17 rotatably coupled to it. This free-running forming roller 17 is on the forming roller 18 or the contour roller 21 in a ring bearing device rotating around the axis of rotation AR 24 arranged. This ring bearing device 24 can, for example, be a ball bearing device which is arranged in the forming roller 18 and which allows the free-running forming roller 17 to be supported in a rotatable manner relative to this.

Reference list

1

contraption

2

Component

3

Direction of movement

4th

Workpiece

6

Machining facility

8th

Forming device

10

Synchronization device

11

Synchronization role

12th

Section

13th

Synchronization extension

14th

formed area

15

formed area

16

Freewheel device

17th

Free-running forming roller

18th

Forming roller

20th

Contour device

21st

Contour roll

22nd

surface

23

Recess

24

Ring storage facility

30th

Drainage opening

32

Stabilizing bead

34

Longitudinal web

36

Support flange

A _R

Axis of rotation

Claims (9)

1. An apparatus for shaping a component (2) from a particularly sheet-like semi-finished product (4), for example, a metal sheet strip, in a roll forming process line or a roll line for profiling to shape, by means of at least one processing device (6) which includes as follows:

   a shaping device (8) formed such that it shapes or similarly mechanically processes at least a partial area (12) of the semi-finished product (4) or similar, and

   a synchronization device (10),

   characterized in that

   the synchronization device (10) includes a freewheeling synchronization roll (11) and is formed and arranged such that it is or can be brought into synchronization engagement with already shaped areas (15) of the semi-finished product (4) and positions the semi-finished product (4) in precision fit to the shaping device (8), wherein the shaping device (8) includes at least one shaping roll (18) enabling a roll shaping of the semi-finished product (4), wherein the shaping roll (18) is arranged coaxially to the synchronization roll (11).
2. The apparatus according to claim 1,
   characterized in that
   the synchronization roll (11) is or can be brought into roll synchronization engagement with the already shaped areas (15) of the semi-finished product (4).
3. The apparatus according to claim 1 or 2,
   characterized in that
   the synchronization device (10) includes synchronization protrusions (13) which are or can be brought into roll synchronization engagement with the already shaped areas (15) of the semi-finished product (4).
4. The apparatus according to any one of the preceding claims, in particular according to claim 3,
   characterized in that
   the synchronization protrusions (13) are arranged to be at least in part distributed across the circumference of the synchronization roll (11).
5. The apparatus according to any one of the preceding claims,
   characterized in that
   the shaping device (8) includes a contour device (20), the top surface (22) of which is formed to be complementary to already shaped areas (14) of the semi-finished product (4) so that it is or can be brought into contour engagement with these areas without further shaping these areas (14).
6. The apparatus according to any one of the preceding claims,
   characterized in that
   the synchronization device (10) is disposed on the shaping device (8).
7. The apparatus according to any one of the preceding claims,
   characterized in that
   at least one freewheeling device (16) of the shaping device (8) is arranged on the apparatus to be movable relative to the synchronization device (10) and/or to the remaining shaping device (8)
8. The apparatus according to any one of the preceding claims, in particular according to claim 7,
   characterized in that
   the freewheeling device (16) includes a freewheeling shaping roll (17) which is mounted on the apparatus (1) to be movable, in particular rotatable relative to the synchronization device (10).
9. The apparatus according to any one of the preceding claims, in particular according to claim 8,
   characterized in that
   the freewheeling shaping roll (17) is disposed on the shaping roll (18) in an annular bearing device (24) revolving around the axis of rotation A_R of the shaping roll (18).

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