EP2616199B1 - Method and device for expanding metal elements - Google Patents

Description

The present invention relates to an apparatus and method for expanding elongated, longitudinally-moving, strip-shaped metal elements suitable for forming open profile elements, such as upright or plaster profiles, or closed profile elements, such as channels or pipes. Furthermore, the invention is directed to a corresponding method for expanding such metal elements.

Such metal elements are, for example, in the non-prepublished German patent application DE 10 2010 026 320 described. These metal elements have two longitudinal sections with meandering longitudinal edges, which are connected in sections with each other to produce without additional cost of materials compared to the original band-shaped metal element widened metal element.

The problem is to connect the separate longitudinal sections of the metal element with high feed rate in inline operation with economically justifiable effort. The to be joined, preferably to be welded sections of the longitudinal edges must be placed exactly together to ensure the desired quality of the compounds can. In order to achieve a sufficiently high throughput, this must be ensured even at the usually high speeds, as they occur in inline production (for example, 40 m / min to over 100 m / min).

In the US 4,896,818 on which the preamble of claims 1 and 17 is based, a device and a method for expanding elongated, longitudinally moving, suitable for forming open or closed profile elements strip-shaped metal elements are described. However, this document does not contain any indication as to how, in the case of the high feed rates occurring in in-line operation, two longitudinal sections of the respective metal elements can be positioned precisely relative to one another.

It is therefore an object of the present invention to provide a device and a method of the type mentioned, which ensure a high throughput while maintaining a simple and reliable design.

According to the invention, this object is achieved by a device of the type mentioned above with a feed station, a cutting station, a positioning station and a connection station, wherein the feed station is designed for at least substantially continuous feeding at least one metal element to the cutting station, the cutting station for generating at least one continuous is formed in the longitudinal direction of the at least one metal element extending, meandering section through which at least two longitudinal sections of the at least one metal element are generated with meandering longitudinal edges, the positioning station comprises at least one particular circumferential positioning device with a plurality of positioning elements, wherein the positioning elements for engaging in formed in the at least one metal element openings and for positioning of portions of the meandering Längssk are formed to each other in predefined positions, and wherein the connection station is designed to connect the mutually positioned sections of the meandering longitudinal edges.

In the method according to the invention, the at least one metal element is fed from a feed station at least substantially continuously to a cutting station, in the cutting station at least one continuous, in the longitudinal direction of the at least one metal element extending, meandering cut generated by the at least two longitudinal sections of the at least one metal element Meander-shaped longitudinal edges are produced, the longitudinal sections are guided through a positioning station that engage on a particular rotating positioning positioning provided in the at least one metal element formed openings, so that portions of the meandering longitudinal edges are positioned to each other in predefined positions, and the mutually positioned portions of the meandering longitudinal edges in a connection station connected to each other.

The invention thus provides an automatic and exact alignment of the subsections of the meandering longitudinal edges to be joined to one another, so that the longitudinal sections of the metal element can be connected to one another at high speed. This allows the profile elements with high throughput can be produced in an economical manner inline process.

According to an advantageous embodiment of the invention, an offset station for forming a particular sagging loop of at least one of the longitudinal sections of the metal element is provided between the cutting station and the positioning station, so that the separate longitudinal sections of the at least one metal element in Longitudinal direction and / or in the transverse direction are mutually displaceable. Since the guided metal elements have a relatively high stiffness in the longitudinal and transverse directions, advantageously offset from each other in the longitudinal or transverse direction is carried out with a corresponding offset station. The loop may comprise only one or more longitudinal sections of the metal element or all longitudinal sections, ie the entire metal element. As a result of the formed loop, a limp area of the at least one metal element or of the longitudinal section or sections within the production line is produced, which ensures that the longitudinal sections of the at least one metal element can be displaced in the longitudinal direction as well as alternatively in the transverse direction. In this way, the required for the final positioning of the sections of the meandering longitudinal edges to be joined together displacement of the two longitudinal sections against each other or the separation of the longitudinal sections can be easily achieved. The respective offset transversely or longitudinally to the transport direction is defined by the desired type of connection of the two longitudinal sections, as will be explained in more detail in the context of this application.

According to a further advantageous embodiment of the invention, in each case two adjacent rows of positioning elements are provided in the transport direction. Depending on the type of connection of the two longitudinal sections, however, it is also possible for the positioning device to comprise only one row of positioning elements lying one behind the other.

Depending on the arrangement of the openings in the at least one metal element, the positioning elements of the two rows can not be offset from each other in the transport direction or arranged offset from one another be. It is also dependent on the arrangement of the openings, whether a number of successive positioning elements or two juxtaposed in the transport direction rows of positioning elements are provided.

Advantageously, the positioning device is designed as a toothed wheel, toothed belt or toothed rack or as a chain or belt conveyor with positioning elements. Other elements suitable for feeding with corresponding positioning elements can also form a positioning device according to the invention.

According to a further advantageous embodiment, the positioning elements, in particular in their base area, have a cross-sectional shape substantially complementary to the openings of the at least one metal element. As a result, a form-fitting connection between the positioning elements and the openings of the at least one metal element is achieved, so that the subsections of the meandering longitudinal edges to be welded together can be exactly aligned with one another.

According to a further preferred embodiment of the invention, the positioning elements are designed to engage in openings formed by the meandering longitudinal edges. Such openings can be created by the longitudinal sections are shifted against each other after introduction of the meandering cut in the transverse direction or in the transverse and longitudinal direction.

However, it is also possible that the positioning elements for engaging in independently of the meandering longitudinal edges in the at least one metal element, in particular in its edge regions, provided openings are formed. The positioning device can be designed in this case in the manner of a traction device, for example as a chain conveyor with needle grippers. Due to the fixed distances between the openings provided in the edge regions and the sections of the meandering longitudinal edges intended for welding, an exact positioning of the subsections to be joined together is ensured in this case as well.

Advantageously, the feed station comprises a reel on which the at least one metal element is wound up. In this way, a uniform supply of at least one metal element to the other stations of the device according to the invention can be achieved. Advantageously, the feed station may comprise a device for welding together successive metal elements. Thereby, upon complete unwinding of the at least one metal element from the reel, the continuous operation can be maintained by welding a respective further metal element to the end of the preceding metal element.

According to a further preferred embodiment of the invention, a straightening station for the at least one metal element and the longitudinal sections produced therefrom is provided between the feed station and the cutting station and / or between the cutting station and the positioning station. As a result, irregularities in the surface or stresses in the at least one metal element, which arise for example by welding two successive sections when changing a coil of the supply reel or when generating the meandering cut, can be compensated. In particular, for example, bent-over sections of the at least one metal element, which may arise during the cutting process, are bent back into the plane of the respective metal strip.

Advantageously, the positioning device is actively driven. This means that the positioning device acts as a feed device for the at least one metal element. However, it is also possible in principle that the positioning device is only passively driven and a separate feed device is provided. In this case, only the positioning of the two longitudinal sections to each other is effected by the positioning means, while the actual forward movement of the at least one metal element is achieved by a separate feed device.

Advantageously, the positioning station in front of the connection station, in particular in the inlet region of the connection station, i. arranged close to the connection station. However, it is also possible for the positioning station to reach the connection station, in particular in the exit area of the connection station, i. is arranged near the output of the connection station.

According to a further advantageous embodiment, the connecting station comprises a lateral band guide, by means of which the longitudinal sections of the at least one metal element are positioned against one another and held together in particular, that the subsections of the meandering longitudinal edges to be welded together abut one another, in particular under pressure. In this way, it is achieved that the positioning achieved by the positioning station to be joined together sections of the meandering longitudinal edges is maintained exactly within the connection station. In particular, by pressing together of each other connecting sections of the meandering longitudinal edges are achieved that an exact connection seam, in particular an exact weld can be produced.

Advantageously, the connection station can comprise a vertical band guide, through which the longitudinal sections of the at least one metal element are guided substantially in the same plane or lying flat on one another. This also high quality of the connection and in particular an optimal surface of the metal strip produced can be achieved.

Advantageously, the cutting station may comprise a rotary cutting device or a laser cutting device. Basically, a Hubschneidverfahren is conceivable if this is designed so that a substantially continuous manufacturing process is made possible.

Also preferably, the connection station is designed as a welding station, which in particular comprises a laser welding device. With a laser welding device very accurate and clean welds can be generated, so that the quality of the profile element produced is very high. In addition, a very small area of high heat is generated by a laser welding process directly at the two contacting edges of the longitudinal sections. The molten zone produced in this region by the laser welding process has a significantly smaller transverse extent than a correspondingly melted zone in other fusion welded joints, so that exactly in the middle between the two longitudinal sections an increased strength of the final metal profile is achieved.

Advantageously, after the connection station, a feed unit may be provided for the at least one metal element, in particular in the form of a roller guide. Furthermore, an embossing station and / or a forming station for the at least one metal element may also preferably be provided after the connection station, by means of which desired impressions in the form of stiffening beads or deeply drawn regions, in particular in the region of the openings, can be produced and, secondly Cross section of the at least one metal element can be brought into an intermediate shape or in its final shape. For example, the at least one metal element can be formed into a C or U profile or another suitable open or even closed profile.

When using a laser welding method, the laser beam is preferably moved during the welding process with the moving at least one metal element, wherein the forward movement of the laser beam is slower than the transport speed of the at least one metal element. In particular, the forward movement of the laser beam and hence the welding speed can be substantially half as fast as the transport speed of the at least one metal element.

Advantageously, in each case after welding of two mutually positioned portions of the meandering longitudinal edges of the laser beam can be positioned in opposite to the transport direction lying portions of the meandering longitudinal edges and these are then welded together.

Since the welding speed is limited during laser welding, this can be compared to the maximum welding speed higher transport speed of the at least one metal element can be achieved. By entraining the laser beam during the welding process with the moving at least one metal element, the maximum welding speed is defined only by the relative speed between the laser beam and the at least one metal element. The absolute transport speed of the at least one metal element can thereby be higher than the maximum possible welding speed. Since due to the meandering longitudinal edges no continuous, but only an interrupted welded joint is required, the laser beam can be positioned after generating a partial weld at high speed on the opposite to the direction of transport next to be welded portion. The connection of these next sections can in turn be generated by carrying the laser beam at a reduced speed relative to the transport speed.

In principle, it is also possible for a plurality of laser beams to be used in parallel, which each weld successive subsections of the meandering longitudinal edges to one another. After the welding process, the laser beams can then be offset in parallel by a corresponding number of sections and repositioned. In this way, the transport speed of the metal element can be further increased.

Advantageously, the cutting station can be supplied with at least two metal elements lying flat against each other, in the cutting station the contiguous metal elements are divided by the meandering cut together into two longitudinal sections each, which lie on the same side of the meandering section Longitudinal portions of the metal elements lie flat against each other and each form longitudinally extending portions of the meandering longitudinal edges of the juxtaposed longitudinal sections directly adjoining connecting edges which are separated by a juxtaposed longitudinal sections of the other juxtaposed longitudinal sections, the connecting edges of a longitudinal section with the connecting edges of him adjacent longitudinal portion connected, in particular welded, and one of the two longitudinal sections relative to the associated with him other longitudinal portion is pivoted about the connecting edges, that the longitudinal sections along bent abutting edges are interconnected and between sections of the meandering longitudinal edges, the openings are formed.

In this embodiment, therefore, not a single metal element with the meandering cut is separated into two longitudinal sections, which are then shifted from each other and ultimately connected to each other, but at least two metal elements lying flat against each other are used as the starting material. These are provided lying against each other with a common meander-shaped section, so that each of the metal elements is divided into two longitudinal sections. In contrast to the other embodiments, the at least two adjoining longitudinal sections, ie one longitudinal section each of the one and one longitudinal section of the other metal element (s) along the connecting edges are then joined together and ultimately unfolded into the desired profile element with openings , The individual processing steps of the two halves separated by the meandering slot can be carried out in parallel in the respective same stations or in separate stations. Basically, several meandering Slots are introduced so that several longitudinal sections are generated.

Further advantageous embodiments of the invention are specified in the subclaims.

Fig. 1

eine schematische Perspektivdarstellung eines mit einem erfindungsgemäßen Verfahren bzw. einer erfindungsgemäßen Vorrichtung hergestellten Profilelements,

Fig. 2 bis 4

verschiedene Zwischenschritte für die Herstellung eines Profilelements nach Fig. 1,

Fig. 5 und 6

zwei weitere Profilelemente,

Fig. 7

eine schematische Seitenansicht einer erfindungsgemäß ausgebildeten Vorrichtung zum Aufweiten von Metallelementen,

Fig. 8

eine Seitenansicht einer Positionierungseinrichtung,

Fig. 9

eine Draufsicht auf die Positionierungseinrichtung nach Fig. 8,

Fig. 10

eine Draufsicht auf eine weitere erfindungsgemäß ausgebildete Positionierungseinrichtung,

Fig. 11

eine Draufsicht auf ein mit einer Positionierungseinrichtung zusammenwirkendes Profilelement,

Fig. 12

eine weitere Ausführungsform einer erfindungsgemäß ausgebildeten Positionierungseinrichtung,

Fig. 13

eine Seitenansicht einer weiteren erfindungsgemäß ausgebildeten Positionierungseinrichtung,

Fig. 14

ein weiteres Profilelement,

Fig. 15

eine weitere Positionierungseinrichtung,

Fig. 16

ein weiteres Profilelement,

Fig. 17

eine weitere Positionierungseinrichtung,

Fig. 18

eine schematische Draufsicht auf einen Teil einer erfindungsgemäß ausgebildeten Schweißstation,

Fig. 19

eine schematische Perspektivdarstellung eines Profilelements zur Verdeutlichung des Schweißvorgangs,

Fig. 20a) bis d)

vier Schritte des erfindungsgemäßen Schweißvorgangs in schematischer Darstellung,

Fig. 21

eine perspektivische Darstellung von zwei aufeinander liegenden Materialabschnitte zum Herstellen eines Profilelements nach einem weiteren Ausführungsform der Erfindung,

Fig. 22

einen Zwischenschritt bei der Herstellung des Profilelements und

Fig. 23

das Profilelement nach dem Aufklappen der beiden Längsabschnitte.

The invention will now be described in more detail by means of exemplary embodiments with reference to the drawings, in which:

Fig. 1

3 is a schematic perspective view of a profile element produced by means of a method or a device according to the invention;

Fig. 2 to 4

various intermediate steps for the production of a profile element according to Fig. 1 .

FIGS. 5 and 6

two further profile elements,

Fig. 7

a schematic side view of an inventively designed device for expanding metal elements,

Fig. 8

a side view of a positioning device,

Fig. 9

a plan view of the positioning device according to Fig. 8 .

Fig. 10

a plan view of a further inventively formed positioning device,

Fig. 11

a top view of a cooperating with a positioning device profile element,

Fig. 12

a further embodiment of a positioning device according to the invention,

Fig. 13

a side view of a further inventively designed positioning device,

Fig. 14

another profile element,

Fig. 15

another positioning device,

Fig. 16

another profile element,

Fig. 17

another positioning device,

Fig. 18

a schematic plan view of a part of an inventively designed welding station,

Fig. 19

a schematic perspective view of a profile element to illustrate the welding process,

Fig. 20a) to d)

four steps of the welding process according to the invention in a schematic representation,

Fig. 21

a perspective view of two superimposed material sections for producing a profile element according to a further embodiment of the invention,

Fig. 22

an intermediate step in the manufacture of the profile element and

Fig. 23

the profile element after unfolding the two longitudinal sections.

Fig. 1 shows a profile element 1, which is designed as a C-profile. The profile 1 comprises a profile body 2, which has a profile web 3, and two laterally adjoining profile leg 4, which are each angled at right angles to the profile web 3. The free longitudinal edges of the profile legs 4 are each angled in turn by 90 ° to form the C-profile. In principle, the profile element 1 can also be designed, for example, as a U-profile, L-profile, T-profile, H-profile, top-hat profile or Z-profile.

In the profile web 3, a plurality of openings 5 is formed, which can serve for example as through holes for cables or other elements to be laid.

The openings 5 of the profile element are produced according to the invention without loss of material, as described below with reference to FIG Fig. 2 to 4 is explained in more detail.

Fig. 2 shows a metal element 54 in the form of a strip of material 6, for example a sheet metal strip, which serves as a starting material for the profile body 2. While in the Fig. 2 to 4 in each case only a relatively narrow region of the material strip 6 is shown, which ultimately leads to the formation of the profile web 3 is used, at the outer edges 7, 8 each further material areas adjoin, are formed by the corresponding bending example, the profile leg 4.

In the material strip 6, a meandering slot 9 extending in the longitudinal extent of the material strip 6 is formed, through which the material strip 6 and thus the profile body 2 is divided into two separate longitudinal sections 10, 11. Through the meander-shaped slot 9, the longitudinal sections 10, 11 each receive a meandering longitudinal edge 12, 13, which in the illustration in accordance with Fig. 2 fit seamlessly together. The meandering longitudinal edges 12, 13 each comprise longitudinally extending and perpendicularly extending edge portions.

By the meandering longitudinal edges 12, 13 respectively web-shaped connecting portions 14, 15 of the longitudinal sections 10, 11 are formed, which are each integrally connected to elongate sections 16, 17 of the longitudinal sections 10, 11 and laterally project beyond this. How to continue Fig. 2 can be seen, the web-shaped connecting portions 14 are bounded by the meandering longitudinal edge 12 and the web-shaped connecting portions 15 of the meandering longitudinal edge 13.

To produce the final shape of the profile web 3, the two longitudinal sections 10, 11 according to two arrows 18, 19 are pulled apart transversely to the longitudinal extent of the strip of material 6 until they are in Fig. 3 occupy the position shown. In this position are in the longitudinal direction of the longitudinal sections 10, 11 extending connecting edges 20, 21 of the connecting portions 14, 15 on a dashed line shown straight line 22, which also extends in the longitudinal direction of the longitudinal sections 10, 11.

According to Fig. 4 are in a next step, the two longitudinal sections 10, 11 according to arrows 25, 26 in the longitudinal direction of the longitudinal sections 10, 11 against each other, until each connecting section 14 a connecting portion 15 is opposite. Accordingly, in each case a connecting edge 20 abuts against a connecting edge 21 in this position, as shown in FIG Fig. 4 is shown.

Subsequently, the longitudinal sections 10, 11 along the abutting joint edges 20, 21 are welded together, for example, laser welded, whereby the final shape of the profile web 3 is achieved with the openings 5.

In Fig. 4 are shown with dashed lines stiffening beads 30, 31, which extend on the one hand in the longitudinal direction of the strip of material 6 and the other transverse thereto. By stiffening beads 30, 31 an increased rigidity of the profile element produced is achieved.

The embodiment according to Fig. 5 differs from the embodiment according to the Fig. 2 to 4 in that the two longitudinal sections 10, 11 are pulled apart from one another transversely to the longitudinal extension of the strip of material 6 only to the extent that the connecting sections 14, 15 still engage in one another like a comb, as shown in FIG Fig. 5 is shown. In this position, the butting abutting edges of the connecting portions 14, 15 form the connecting edges 20, 21, which are butt welded together.

According to the embodiment Fig. 6 the connecting portions are formed as hexagonal connecting portions 37, 38. The hexagonal connecting portions 37, 38 each include a hexagonal Region 39 and an adjoining trapezoidal region 40, which is respectively connected to the elongated portion 16 and 17, respectively. The connecting edges 20, 21 are formed as obliquely extending edges of the hexagonal regions 39 and extend in particular at a 45 ° angle to the longitudinal extent of the material strip 6. The connecting edges 20, 21 and adjoining edges 41 of the hexagonal regions 39 each close an angle of 90 °, so that corresponding angles α, β of the openings 5 are formed as 90 ° angle.

The connecting edges 20, 21 abut each other abutting each other and are, analogous to the embodiment according to Fig. 5 , butt welded together, especially laser welded.

While in the embodiment of the Fig. 2 to 4 the longitudinal sections 10, 11 must be offset from each other both in the longitudinal direction and transversely thereto, the longitudinal sections 10, 11 in the embodiments according to the FIGS. 5 and 6 only offset transversely to the longitudinal direction of the metal element or transversely to the transport direction against each other.

In all cases, however, the two longitudinal sections 10, 11 are welded together abutting portions 50, 51 of the meandering longitudinal edges 12, 13, so that an exact alignment of the two longitudinal sections 10, 11 to each other is required.

According to the invention, a device is used for this purpose, as used for example in Fig. 7 schematically illustrated by an embodiment.

On the input side, the device comprises a feed station 52, which comprises a roll of the elongated band-shaped metal element 54 wound onto a reel 53. The reel 53 is rotatably mounted about an axis of rotation 56 according to an arrow 55, so that the metal element 54 can be unwound from the reel 53 according to an arrow 57.

The metal element 54 is fed via guide rollers 58 to a cutting station 59, which is designed as a rotary cutting device 60 with a rotary cutting roller 61 and a counter roller 62. With the rotary cutting device 60, a meander-shaped section 9 is introduced into the elongated metal element 54, as it is for example in the Fig. 2 is shown. The invention is not on the in the Fig. 2 to 6 shown pattern limited, but it can be used any meandering cuts. In this regard, in particular on the DE 10 2010 026 320 referenced, in which a variety of suitable patterns are shown. In particular, with regard to the shape of these patterns and the way in which the longitudinal sections of the metal element formed by the pattern are moved apart and ultimately welded together, reference is explicitly made to this document whose contents are explicitly included in the disclosure of the present application.

The metal element 54 provided with the meander-shaped section 9 is then guided through a straightening station 63, which comprises a plurality of straightening rollers 64. In principle, the straightening station can also comprise other straightening units, such as a press. In the straightening station 63, in particular, high-level areas of the metal element 54, which have been bent up, for example during the cutting process in the cutting station 59, are smoothly rolled again, so that the metal element 54 follows Leaving the straightening station 63 has substantially a smooth surface.

After passing through the straightening station 63, the metal element 54 is fed to an offset station 65 in which a sagging loop 66 of the metal element 54 is formed. The sagging loop 66 is formed so long that both a movement apart of the longitudinal sections 10, 11 of the metal element 54 transversely to the transport direction and a mutually sliding in the transport direction is possible without significant stresses on the metal element 54 act. In Fig. 7 a corresponding offset in the longitudinal direction by an offset of the two longitudinal sections 10, 11 is shown.

The offset station 65 is adjoined by a positioning station 67, which comprises a positioning device 69 embodied as a gear 68. The positioning device 69 comprises positioning elements 71 formed as teeth 70 of the toothed wheel 68, which engage in the openings 5 of the metal element 54, so that the subsections 50, 51 of the meandering longitudinal edges 12, 13 to be welded together are exactly aligned with each other in predefined positions, as shown will be explained in more detail below.

The longitudinal sections 10, 11 of the metal element 54 aligned in this way are subsequently fed to a welding station 72, which is designed in particular as a laser welding station. Within the welding station 72, a laser welding head 73 is arranged, which is pivotable according to an arrow 74, so that a laser beam 75 can be pivoted accordingly. The pivoting of the laser beam, for example, by a pivoting mirror or a rotating Mirror wheel done, the laser welding head can be arranged fixed.

Furthermore, the welding station 72 comprises a vertical band guide 76, through which the longitudinal sections 10, 11 of the metal element 54 are guided in substantially the same plane. The vertical tape guide 76 can accordingly Fig. 4 For example, upper and lower tape guides 77, 78 include. In principle, any type of guide can be used with which the two flat longitudinal sections 10, 11 of the metal element 54 are held parallel to each other in the same plane. For example, spring-loaded, hydraulic, pneumatic or mechanical guides in the form of rollers, plates, belts or caterpillars can be used. The guides can also serve as a means of transport for the metal element 54 and be formed, for example, as a clamping, magnetic, hydraulic, mechanical, pneumatic transport guide.

At the output of the welding station 72, a feed unit 79 is provided, which may be formed for example by two rollers 80 or other suitable elements.

After the feed unit 79, an embossing station and / or a forming station 81 is provided, in which the metal element 54 can receive an intermediate shape or its final cross-sectional shape, for example a C-shape or a U-shape or any other suitable open or closed profile shape. In the embossing station or the forming station, the metal element can also be provided with stiffening beads.

In the Fig. 8 to 10 It can be seen that the positioning device 69, for example, positioning elements 71 formed as teeth 70 may extend either over the entire width of the formed as a gear 68 positioning means 69 or only over a part thereof.

It is essential that the positioning elements 71 are formed so that they according to Fig. 11 engage in the openings 5 of the metal element 54, that a clear positional fixation of the longitudinal sections 10, 11 takes place in the longitudinal direction and / or in the transverse direction. For example, in Fig. 11 illustrated how the two longitudinal sections 10, 11 opposite to in Fig. 3 shown starting position are arranged offset in the longitudinal direction by half a period of the meandering section 9 and are held in this position by a hatched positioning element 71 of the positioning device 69 in the longitudinal direction immovably against each other. Since the two longitudinal sections 10, 11 are still formed integrally in the upstream cutting station 59 or are closer to each other after the cutting operation than in the offset station 65, only a fixation of the longitudinal sections 10, 11 in the longitudinal direction is necessarily required because the two longitudinal sections 10, 11 are pressed together in the transverse direction due to their original one-piece design. To further enhance this compression, additional lateral guide elements can be provided, as they are in Fig. 11 are indicated by rollers 82. Instead of the rollers 82, other suitable guide elements, such as guide surfaces, plates, beads, belts or other suitable elements such as screws, racks, timing belt can be provided with matrices.

It is also possible that according to Fig. 12 corresponding circumferential shoulders 83 are formed on the positioning device 69 itself, by which a corresponding guidance of the outer edges of the metal element 54 is ensured.

In Fig. 13 is shown schematically that the positioning device can also be designed as a particular endless belt or chain-shaped positioning device 84. As a result, a guide of the metal element 54 is ensured over a longer distance section, so that the guide is further improved.

The FIGS. 14 and 15 show how a profile element according to Fig. 5 can be performed with a positioning device according to the invention. In the profile element according to Fig. 14 the two longitudinal sections 10, 11 are moved against each other only in the transverse direction, whereby the openings 5 are formed. The openings 5 are arranged alternately offset from each other in this case, as it Fig. 14 can be seen.

In a similar way are in the in Fig. 15 shown roller-shaped positioning means 85, the positioning elements 86 also arranged alternately. Thus, the positioning means 85 comprises two longitudinally juxtaposed rows of positioning elements 86, wherein the positioning elements 86 of the two rows are arranged offset in the transport direction against each other.

With the positioning device 85 after Fig. 15 Thus, both an exact offset of the two longitudinal sections 10, 11 transversely to the transport direction and an exact alignment in the transport direction are ensured, so that the sections 50, 51 of the meandering longitudinal edges 12, 13, which are to be welded together, exactly abut each other.

The FIGS. 16 and 17 show that the openings used for the alignment of the longitudinal sections 10, 11 need not necessarily be formed by the meandering longitudinal edges 12, 13, but may also be formed as separate openings 87. These openings 87 are formed in particular in the edge regions of the longitudinal sections 10, 11 and can, for example, according to the traction principle, an alignment of the two longitudinal sections 10, 11 against each other. So can the in Fig. 17 Positioning device 88 shown corresponding corresponding arranged in the edge region pins 89 or needles, which are designed to engage in the openings 87. The pins 89 or needles can, as in Fig. 17 represented, be arranged on a cylindrical base body or, for example, accordingly Fig. 13 be provided on a belt or chain conveyor.

In the plan view of the welding station 72 according to Fig. 18 It can be seen that these two lateral tape guides 90 includes, which in turn are only exemplified as tape guides. Also, the lateral tape guides 90 may be formed again in any other suitable manner, for example by roller guides, plate guides, chain guides or other suitable guide elements. It is essential that the corresponding guides according to arrows 91 exert a force on the two longitudinal sections 10, 11 of the metal element 54 such that the subsections 50, 51 of the meandering longitudinal edges 12, 13 to be welded together come into abutment with each other and are optionally slightly pressed against each other , The tape guides can also serve as a means of transport for the metal element 54 and be designed, for example, as a clamping, magnetic, hydraulic, mechanical or pneumatic transport guides in particular with correction possibility.

The welding by means of the laser welding head 73 is based on the FIGS. 19 and 20 described in more detail below.

Fig. 19 shows first in a schematic perspective view, the two longitudinal sections 10, 11, which are arranged in the welding station 72 so that the to be welded together sections 50, 51 of the meandering longitudinal edges 12, 13 abut each other. The laser welding head 73 is designed such that the laser beam 75 is directed onto the two contiguous partial sections 50, 51 and can be pivoted in accordance with the arrow 74 such that the laser beam 75 is ultimately guided along the abutting partial sections 50, 51.

The leadership of the laser beam 75 is carried out as in the Fig. 20a ) to d). Here are in Fig. 20 each three successive, to be welded sections 50, 51 by lines 92, 93, 94, which corresponds to the movement of the metal element 54 in the Fig. 20a ) to c) move from left to right.

To the in Fig. 20a ), the laser beam 75 impinges on the right end of the sections 50, 51 represented by the line 92. The metal element 54 is moved according to an arrow 95 in the transport direction, at the same time the laser beam 75 is guided according to the arrow 74 in the same direction, but at half speed.

To the in Fig. 20b ), the metal element 54 has already covered the path 0.5x, while the laser beam 75 has merely been pivoted such that the spot of weld impinging on the metal element 54 has covered the path 0.25x. At this time are the sections 50, 51 welded together along the line 92 in half.

When the metal element 54 according to Fig. 20c ) has moved in the transport direction about the path x, the welding point of the laser beam 75 impinging on the metal element 54 has traveled the path 0.5x and is thus in accordance with FIG Fig. 20c ) at the left end of the weld representing line 92, which is thus completed.

At this time, according to an arrow 101, the laser beam is rapidly pivoted or positioned directly opposite to the previous tracking direction toward the right end of the next weld to be produced by the line 93, whereupon this weld is produced in the same way.

By this intermittent welding, the transport speed of the metal element 54 can be set twice as high as the maximum possible welding speed, so that the throughput for the production of the welded profile element can be significantly increased.

By using a plurality of parallel laser beams 75, a multiplication of the transport speed can be achieved in a corresponding manner.

In Fig. 21 two substantially equal thickness, flat strips of material 6, 6 'are arranged so that they lie flat on each other. In both strips of material 6, 6 ', a uniform meander-shaped slot 9 was introduced, through which the strips of material 6, 6' in two longitudinal sections 10, 11 and 10 ', 11' are shared. In contrast to the previously described Embodiments in this embodiment, the profile element 1 is not formed by the originally contiguous longitudinal sections 10, 11 and 10 ', 11', but there are two profile elements formed, one of the longitudinal sections 10, 10 'and the other from the longitudinal sections 11th '11' exists.

For this purpose, after generating the meandering slot 9, the superimposed longitudinal sections 10, 10 'are separated from the respective other longitudinal sections 11, 11' in order to form together mutually independent profile elements.

In the FIGS. 22 and 23 is an example of the production of the profile element 1 with the longitudinal sections 11, 11 'shown. The superimposed longitudinal sections 11, 11 'are welded together at longitudinally extending connecting edges 97, so that along the end faces 98 of the connecting edges 97 extending welds 99 are generated. Subsequently, the longitudinal sections 11, 11 'are unfolded, as in Fig. 22 is indicated by an arrow 100. For this purpose, for example, the longitudinal portion 11 is pivoted about the connecting edges 97 according to the arrow 100 by approximately 180 ° until it the in Fig. 23 shown position occupies. In this position, the longitudinal sections 11, 11 'lie substantially in a common plane.

By pivoting the interconnected connecting edges 97 are bent so that they form bent abutting edges 96, via which the longitudinal sections 11, 11 'are connected to each other in shock. At the same time, the openings 5 are formed by the pivoting between sections of the meandering longitudinal edges 12, 13, without this being associated with material loss.

In principle, the connection between the bent abutting edges 96 can also be achieved by other types of connection, e.g. Overlap welding, folding, gluing, clinching, riveting or stapling are produced. This also applies to the connection of the sections of the meandering longitudinal edges for all other embodiments described in this application. In addition, the pivoting of the longitudinal sections can also take place at a different angle of 180 °, in particular smaller or larger, depending on which shape is to receive the final profile element. The production of the profile element by unfolding was explicitly described only in conjunction with the web-shaped connecting portions 14, 15, however, this production is also possible with the other in the context of this application connection sections as long as the connecting edges to be joined extend in the longitudinal direction of the strip of material.

Preferably, individual elements of the device according to the invention can be synchronized with each other. Thus, for example, the positioning device and the respective feed devices, the guide device and the tracking of the laser beam can be synchronized with each other. It is possible that a detection of the movement of the metal element, for example, in an optical, mechanical or electronic manner is provided to implement a corresponding feed control, for example by means of a control loop.

Furthermore, during and after completion of the profile element testing centers can be provided for checking the quality of the manufactured profile element. These can, for example, by optical or electronic means, the aligned portions of the meandering Check longitudinal edges for minimal misalignment or the generated weld for cleanliness.

LIST OF REFERENCE NUMBERS

1

profile element

2

profile body

3

profile web

4

profile leg

5

openings

6, 6 '

strips of material

7

outer edge

8th

outer edge

9

meandering slot

10, 10 '

longitudinal section

11, 11 '

longitudinal section

12

meandering longitudinal edge

13

meandering longitudinal edge

14

web-shaped connecting sections

15

web-shaped connecting sections

16

long stretched sections

17

long stretched sections

18

arrow

19

arrow

20

connecting edges

21

connecting edges

22

line

30

reinforcing beads

31

reinforcing beads

37

hexagonal connecting sections

38

hexagonal connecting sections

39

hexagonal areas

40

trapezoidal areas

41

edge

50

sections

51

sections

52

feeding

53

reel

54

metal element

55

arrow

56

axis of rotation

57

arrow

58

guide rollers

59

cutting station

60

A rotary cutter

61

cutting roller

62

backing roll

63

straightening station

64

straightening rollers

65

offset station

66

loop

67

positioning station

68

gear

69

positioning device

70

teeth

71

positioning elements

72

welding station

73

Laser welding head

74

arrow

75

laser beam

76

vertical tape guide

77

upper band guide

78

lower band guide

79

feed unit

80

roll

81

Embossing / forming station

82

roll

83

Shoulder

84

positioning device

85

positioning device

86

positioning elements

87

openings

88

positioning device

89

pencils

90

lateral tape guide

91

arrows

92

line

93

line

94

line

95

arrow

96

bent edges

97

connecting edges

98

front sides

99

welds

100

arrow

101

arrow

Claims (18)

1. An apparatus designed for expanding elongated, ribbon-shaped metal elements (54) moving in the longitudinal direction and suitable for forming open section elements (1) such as upright sections or plaster sections or closed section elements such as passages or pipes,
   having a feed station (52), a cutting station (59), a positioning station (67) and a connection station (72), wherein
   the feed station (52) is formed for the at least substantially continuous feed of at least one metal element (54) to the cutting station (59);
   wherein the cutting station (59) is formed for producing at least one continuous meandering incision (9) which extends in the longitudinal direction of the at least one metal element (54) and by which at least two longitudinal portions (10, 11) of the at least one metal element (54) with meandering longitudinal edges (12, 13) are produced;
   and wherein the connection station (72) is formed for connecting the mutually positioned part portions (50, 51) of the meandering longitudinal edges (12, 13),
   characterized in that
   the positioning station (67) includes at least one, in particular rotating or revolving, positioning device (69, 84, 85, 88) having a plurality of positioning elements (71, 86), with the positioning elements (71, 86) being formed in predefined positions for engaging into openings (5, 87) formed in the at least one metal element (54) and for positioning part portions (50, 51) of the meandering longitudinal edges (12, 13) with respect to one another.
2. An apparatus in accordance with claim 1,
   characterized in that
   an offset station (65) for forming an in particular slack loop (66) of at least one of the longitudinal portions (10, 11) of the metal element (54) is provided between the cutting station (59) and the positioning station (67) so that the mutually separate longitudinal portions (10, 11) of the at least one metal element (54) can be mutually offset in the longitudinal direction and/or in the transverse direction.
3. An apparatus in accordance with claim 1 or claim 2, characterized in that
   two respective rows of positioning elements (71, 86) disposed next to one another in the transport direction are provided.
4. An apparatus in accordance with claim 3,
   characterized in that
   the positioning elements (71, 86) of the two rows are not arranged mutually offset in the transport direction
   or
   in that the positioning elements (71, 86) of the two rows are arranged mutually offset in the transport direction.
5. An apparatus in accordance with at least one of the preceding claims,
   characterized in that
   the positioning device (69, 84, 85, 88) is formed as a toothed wheel (68), toothed belt or gear rack or as a chain conveyor or belt conveyor having positioning elements (71, 86).
6. An apparatus in accordance with at least one of the preceding claims,
   characterized in that
   the positioning elements (71, 86) are formed for engaging in openings (5) formed by the meandering longitudinal edges (12, 13); and/or
   in that the positioning elements (71, 86) are formed for engaging in openings (87) provided independently of the meandering longitudinal edges (12, 13) in the at least one metal element (54), in particular in its marginal regions.
7. An apparatus in accordance with at least one of the preceding claims,
   characterized in that
   the feed station (52) includes a reel (53) on which the at least one metal element (54) is wound;
   and/or
   in that the feed station (52) includes an apparatus for welding together mutually following metal elements (54).
8. An apparatus in accordance with at least one of the preceding claims,
   characterized in that
   a straightening station (63) for the at least one metal element (54) is provided between the feed station (52) and the cutting station (59) and/or between the cutting station (59) and the positioning station (67).
9. An apparatus in accordance with at least one of the preceding claims,
   characterized in that
   the positioning station (67) is arranged in front of the connection station (72), in particular in the run-in region of the connection station (72);
   and/or
   in that the positioning station (67) is arranged after the connection station (72), in particular in the run-out region of the connection station (72).
10. An apparatus in accordance with at least one of the preceding claims,
    characterized in that
    the connection station (72) includes a lateral belt guide (90) by which the longitudinal portions (10, 11) of the at least one metal element (54) are positioned with respect to one another and are in particular held together so that the part portions (50, 51) of the meandering longitudinal edges (12, 13) to be welded together contact one another, in particular under pressure.
    and/or
    in that the connection station (72) includes a vertical belt guide (76) by which the longitudinal portions (10, 11) of the at least one metal element (54) are guided substantially in the same plane or lying areally on one another.
11. An apparatus in accordance with at least one of the preceding claims,
    characterized in that
    the cutting station (59) includes a rotational cutting apparatus (60) or a laser cutting apparatus.
12. An apparatus in accordance with at least one of the preceding claims,
    characterized in that
    a feed unit (79) for the metal element (54) is provided, in particular in the form of a roll guide, inside and/or in front of and/or after the connection station (72).
13. A method of expanding elongated, ribbon-shaped metal elements (54) moving in the longitudinal direction and suitable for forming open section elements (1) such as upright sections or plaster sections or closed section elements such as passages or pipes, wherein at least one metal element (54) is fed at least substantially continuously to a cutting station (59) by a feed station (52); wherein at least one continuous meandering incision (9) is produced which extends in the longitudinal direction of the at least one metal element (54) and by which at least two longitudinal portions (10, 11) of the at least one metal element (54) having meandering longitudinal edges (12, 13) are produced;
    and wherein the mutually positioned part portions (50, 51) of the meandering longitudinal edges (12, 13) are connected to one another in a connection station (72).
    characterized in that
    the longitudinal portions (10, 11) are guided through a positioning station (67) such that positioning elements (71, 86) provided at an in particular rotating or revolving positioning device (69, 84, 85, 88) engage into openings (5, 87) formed in the at least one metal element (54) so that part portions (50, 51) of the meandering longitudinal edges (12, 13) are mutually positioned in predefined positions;
14. A method in accordance with claim 13,
    characterized in that
    the at least one metal element (54) is fed to an offset station (65) in which an in particular slack loop (66) of at least one of the longitudinal portions (10, 11) of the at least one metal element (54) is formed so that the mutually separate longitudinal portions (10, 11) of the at least one metal element (54) can be mutually offset in the longitudinal direction and/or in the transverse direction.
15. A method in accordance with claim 13 or claim 14, characterized in that
    the mutually positioned part portions (50, 51) of the meandering longitudinal edges (12, 13) are welded to one another and are in particular laser welded to one another by means of a laser beam (75).
16. A method in accordance with claim 15,
    characterized in that
    the laser beam (75) is moved along with the moving at least one metal element (54) during the welding process, with the forward movement of the laser beam (75) being slower than the transport speed of the at least one metal element (54), in particular in that the forward movement of the laser beam (75) and thus the welding speed is substantially half as fast as the transport speed of the at least one metal element (54).
17. A method in accordance with claim 16,
    characterized in that
    after welding two mutually positioned part portions (50, 51) of the meandering longitudinal edges (12, 13), the laser beam (75) is in each case positioned onto part portions (50, 51) of the meandering longitudinal edges (12, 13) disposed opposite to the transport direction and these are subsequently welded to one another.
18. A method in accordance with at least one of the claims 13 to 17, characterized in that
    at least two areally mutually contacting metal elements (54) are fed to the cutting station (59);
    the mutually contacting metal elements (54) are jointly divided by the meandering incision (9) in the cutting station (59) into two longitudinal portions (10, 10', 11, 11') each, with the respective longitudinal portions (10, 10', 11, 11') of the metal elements (54) disposed on the same side of the meandering incision (9) mutually areally contacting and part portions (50, 51) of the meandering longitudinal edges (12, 13) of the mutually contacting longitudinal portions (10, 10', 11, 11') respectively extending in the longitudinal direction forming directly mutually contacting connection edges (97); the one mutually contacting longitudinal portions (10, 10') are separated from the other mutually contacting longitudinal portions (11, 11');
    the connection edges (97) of the one longitudinal portion (10, 11) are connected, in particular welded, to the connection edges (97) of the longitudinal portion (10', 11') contacting it; and
    one of the two longitudinal portions (10, 10', 11, 11') is pivoted about the connection edges (97) with respect to the other longitudinal portion (10, 10', 11, 11') connected to it so that the longitudinal portions (10, 10', 11, 11') are connected to one another along bent over abutment edges (96) and the openings (5) are formed between portions of the meandering longitudinal edges (12, 13).

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