EP3221066A1

EP3221066A1 - Device and method for producing profiles

Info

Publication number: EP3221066A1
Application number: EP15805405.6A
Authority: EP
Inventors: Albert Sedlmaier; Bernard Poks
Original assignee: Data M Sheet Metal Solutions GmbH
Current assignee: Data M Sheet Metal Solutions GmbH
Priority date: 2014-11-18
Filing date: 2015-11-18
Publication date: 2017-09-27
Anticipated expiration: 2035-11-18
Also published as: CN107000013B; EP3221066B1; WO2016079210A1; DE102014116890A1; PL3221066T3; CN107000013A

Abstract

The invention relates to a device for producing a profile from a semifinished product (8) made of sheet metal, specifically a profile having at least two legs which run in the longitudinal direction of said profile and are angled in relation to one another in the cross-sectional plane thereof, wherein the device comprises a lower shaped strip (6), which defines the desired profile and is intended to support one of the legs over the entire area thereof, and at least one roller (17) for roll-forming the semifinished product (8) supported by the shaped strip (6) to give the desired profile. According to the invention, an upper shaped strip (7) is configured to firmly clamp a part of the semifinished product (8) which forms the first leg of the desired profile between it and the lower shaped strip (6), wherein the mutually facing surfaces of the two shaped strips (6, 7) are complementary and have the same shape as the first leg of the desired profile.

Description

Apparatus and method for producing profiles

The invention relates to an apparatus and a method for producing a profile from a sheet metal, according to the preambles of the independent

Claims.

Such a device and such a method for producing a U-profile with constant height and variable width are known from JP 61086031 A. The device includes a lower width profile specifying the desired width profile

Forming strip for full-surface planar support of the bottom of the desired U-profile and two movable in the horizontal direction tapered rollers for bending the projecting from the molding profile parts, d. H. the later leg, by roll forming, wherein the mold bar is pulled together with the semi-finished thereon on a carriage between the rollers. After replacing the rollers against tapered rollers this process is repeated. The tapered rollers are arranged so that they also press the semi-finished against the mold bar, so that it must be fixed only in the horizontal direction, namely by means of two positioning holes.

The o. G. Technology only allows the production of U-profiles with variable width and level bottom. You also need a set of tapered rollers

different cross-sections, and the tapered rollers for the first roll forming step must be relatively flachkegelig why they rub considerable on the semi-finished product and leave corresponding traces.

From DE 10 2009 022 829 B3 it is indeed known per se to clamp a semifinished product between rod-shaped clamping elements with adapted to the desired profile and possibly also variable cross-sections, which then passes together with the semi-finished by stationary rollers of a roll forming, wherein the Rollers both support the rods and form the semi-finished product. Here, however, not only the rods, but also the rollers must be specially adapted to the profile to be produced, and if more Profilierschritte are required, one needs for every profiling step other roles.

The roll forming of U- or hat profiles with variable height is indeed possible without the use of forming or supporting strips, such. B. from DE 10 2007 059 439 B3, but it requires in addition to lateral roller stands for molding the profile legs a number of adjustable rollers for forming the tread.

The invention is based on the object to further develop the roll profiling of profiles supported on strips to the effect that with relatively little effort, a relatively large variety of profiles can be produced.

This object is achieved by an apparatus and a method having the features of the independent claims. Advantageous developments of the invention are specified in the dependent claims.

The invention enables a roll forming on moldings, which in particular U or hat profiles can be produced, but also other profiles, eg. B. L-profiles or Z-profiles.

The invention enables the production of profiles with constant height and / or width, d. h., with constant cross section.

A development of the invention also enables the production of profiles with variable height and / or width and in particular a profile in which

at least a first leg not a flat shape everywhere. For this development, the mutually facing surfaces of the two moldings are not flat, and the at least one roller is rotatably mounted on a vertically movable base. Thus, all profiles can be made in which at least one leg does not run anywhere in the same plane, but has any curvatures.

In the case of a U-shaped or hat profile whose bottom is formed by the first, curved leg, deviating from the usual usage, in which only the sides of a U-profile are called legs, and the profile sides and possibly

Bends are formed by a flat leg. Although you need different moldings for different profiles, but the cost of their production can be reduced by these modular builds, so that with different compiled mold bar parts

different profiles can be produced.

Otherwise, the effort to adapt the device to different profiles is relatively low. This is especially true for a preferred embodiment in which the lower mold bar and possibly also the upper mold bar, if not only attached to the lower mold bar, is mounted on a carriage which is horizontally movable on a platform along a straight path, wherein on at least on one side of the web a Verstellgerüst is mounted on the platform, each containing a base with a roller mounted thereon.

In an alternative to the aforesaid embodiment, the moldings and the crimped-in profile may be stationary, and instead the adjusting stands are moved along straight tracks along the platform horizontally.

The bending of the profile pages is preferably carried out in small steps, for example in angular increments of 5 ° or 10 °. For smaller quantities, the carriage can be moved back and forth on the platform, with the roller being adjusted accordingly at the end of each pass. For larger numbers, it is advantageous if on one side of the web or on both sides in each case a series of Verstellgerüsten are fixed at intervals on the platform, each containing a base with a roller, the rollers are each set so that each Verstellgerüst performs a deformation by an angular step.

Preferably, the or each roller is not driven, but freely rotatably mounted so that it can roll at the optimum rotational speed on the corresponding profile side, and preferably it is also pivotally mounted as a whole at its base, in a plane transverse to the profile longitudinal direction, so that the role can either adapt itself to the profile angle to be produced in the current profiling step, or alternatively, the role position can easily be adjusted by hand to suit it. Unlike the generic device, the or each roller may be cylindrical or relatively tapered, e.g. B. with a cone angle of less than 30 °. In this case, one can produce a multitude of profiles with only one type of roller.

For the production of profiles with variable height, it is sufficient if the or each base on which a roll is mounted, is vertically movable.

For the production of profiles with variable height and width, the base usually has to be horizontally movable transversely to the longitudinal direction of the profile. However, certain types of profiles with variable height and width,

in particular those in which only the leg angle changes in the profile longitudinal direction, are also produced with one or more rollers, which are only vertically movable.

The adjusting stands can be positioning systems with integrated drive, for. B. so-called bipods, hexapods or hexaglides, as described in DE 10 2007 011 849 B4. The bipod allows movement of the base and thus the role in two degrees of freedom. For profiles with variable height and constant width is sufficient in itself a mobility of the role in one degree of freedom, namely vertical to the platform. A corresponding positioning system can be called Monopod.

Such adjustable stands are already available in many existing roll forming systems, so that the invention can thus be realized with very little effort.

The adjustable stands may alternatively be of a non-integrated drive type, if the position of the or each base by the moldings is mechanical

force-controlled as they are moved with the carriage over the platform. For this purpose, one of the two moldings having one or more longitudinally extending, suitably curved to the desired profile bending control grooves or cams, in each of which engages a positive control element of a Verstellgerüstes or attacks. In this case, the device requires only a single drive, namely for the carriage, which thus brings the entire forming capacity. Such a drive is particularly easy to implement, if only height-variable Profiles are produced, because in this case the adjustment of the rollers and the carriage feed direction are perpendicular to each other and therefore the forces on a control cam on the mold bar can be relatively small.

In any case, only relatively few drives are required for the invention, which facilitates the construction of Walzprofilieranlagen with which height-variable U or hat profiles, as z. B. can be used as a side member in light trucks use, can be produced with very little effort.

The semi-finished product can be placed either in a preformed or a flat state between the two moldings, wherein the first leg of the desired profile forming part of the semifinished product is brought by the moldings in its final form, while the semifinished product is clamped between the two moldings.

The use of moldings as supporting elements during roll forming has the further advantage that the moldings can also be provided with structures which produce structures on the profile during clamping and / or roll forming, for. As indentations, imprints and gills that can not be produced by pure roll forming, or you can roll profiling with appropriate structures preformed semi-finished, which would be damaged by pure roll forming.

The use of moldings has the further advantage that the semifinished product can be supplied or withdrawn during roll-forming by means of the moldings heat in order to achieve an optimum forming temperature. For this purpose, the moldings z. B. be provided with coolant channels or electrical heating elements.

The following is a description of embodiments with reference to the drawings. Show:

Figure 1 shows a U-profile with variable depth.

Figure 2 shows another U-profile with variable depth. Fig. 3 is a hat profile with variable depth;

4 shows a U-profile with variable depth and width;

Fig. 5 is an upper and a lower mold bar, between which a semi-finished

Sheet metal is trapped;

Fig. 6 shows a device for producing a profile with variable height with

Moldings and a monopod; a device for producing a variable height profile with moldings and four monopods; a device for producing a variable height profile with moldings and four bipods;

9 shows a molding for a U-profile with variable bending radii. and

Fig. 10 shows a device for producing a profile with variable height with

Moldings and two hexapods or hexaglides.

The device described below is particularly suitable for the production of U-profiles with variable depth, as shown by way of example in Figures 1 to 4, in particular of U- or hat profiles with variable depth and constant width, as shown in Figures 1 to 3 are shown by way of example. In the case of hat profiles, the corresponding folds can be formed either on a semi-finished product before it is processed with the device described, or in a post-processing step after forming a U-profile.

With adjustable scaffolds, which allow a roller adjustment in more than two dimensions, also corresponding profiles with variable depth and width can be produced, as shown in Fig. 4 by way of example

The device described below is also suitable for the production of L or Z-profiles with variable depth and possibly also variable width. Exemplary L or Z profiles can be recognized by thinking away from one of the two vertical legs in the profiles of FIGS. 1 to 4.

Using the same or similar reference numerals for the same or similar parts, the U- or hat profiles shown each have a bottom 1 or 1 ', which is not everywhere flat over its length, two legs 2 and 3 perpendicular to the profile cross-sectional plane, 2 'and 3' or 2 "and 3", and possibly bends 4 and 5.

To produce the U-profile with variable depth and width shown in Fig. 1, two elongated moldings 6 and 7 are provided, which in Fig. 5 top left in a side view, including in a vertical plan view, right next to it in a front view and bottom right are shown in a perspective view. The lower mold bar 6 is formed on its upper side as well as the inside of the bottom 1 and is a little longer, and the upper mold bar 6 is formed on its underside as well as the outside of the bottom 1 and is a little longer. Thus, the facing surfaces of the two moldings 6 and 7 are complementary to each other, except that the upper mold bar 6 is slightly narrower than the lower mold bar 7 to the rollers described later more

Provide movement latitude during roll forming.

The moldings 6 and / or 7 should be made of a wear-resistant, hardened and surface-treated material, which does not always have to be steel. In particular, the moldings 6 and / or 7 may be composed of several parts, which may also consist of different materials. Thus, the moldings 6 and / or 7 z. B. horizontally, namely in a supporting body made of an easy-to-work material such as aluminum and a hardened steel strip placed thereon.

A semifinished product 8 made of sheet metal is placed between the two moldings 6 and 7 and clamped by means not shown therebetween, so that those portions of the semifinished product 8, which are to be bent to the legs 2, 3, project laterally therefrom. The semi-finished product 8 can either according to the contours of

Moldings 6, 7 and the later floor 1 be pre-bent, or it is by the Pinching brought into the appropriate shape. In this state, the laterally beyond the moldings 6, 7 also protruding portions of the semifinished product 8 are not everywhere flat over their length, although they will be flat later.

The clamping can z. B. be generated mechanically, pneumatically, magnetically, by positive engagement, by screwing or by gluing.

As shown in Fig. 5 lower left in an enlarged section, the lower mold bar can have 6 bending edges 9 with a defined bending radius, and the

Bending edges 9 may project slightly laterally to allow over-bending. Also at other locations than the bending edges 9, the mold bar 6 may have a slightly different shape than they should assume the finished profile. For example, the side surfaces of the molding strip 6 in the region of the bent portions of the bottom 1 of the profile may differ slightly from the nominal cross section of the profile to undesirable

To counteract deformations of the finished profiles in these areas.

Fig. 6 shows an apparatus for producing profiles with variable height and constant width, namely top left as a side view, top right as an end view, bottom left as a top view and bottom right perspective.

In this device, the lower mold bar 6, to which the upper mold bar 7 is fixed while the semi-finished product 8 is clamped therebetween, mounted on a carriage 10 which is horizontally movable by means of a drive, not shown, on a horizontal platform 11, the guides 12th which define a straight path 13 along which the carriage 0 can move.

In Fig. 6, an adjustment frame 14 is mounted on the platform 11 on one side of the web 13. The Verstellgerüst 14 is a positioning system with integrated drive and includes a vertically movable base 15, as best in the central

Sectional enlargement in Fig. 6 recognizes. The base 15 carries a semicircular bracket 16, between the ends of a cylindrical roller 17 is mounted freely rotatable with a relatively small diameter.

The bracket 16 is pivotable relative to the base such that the axis of the roller 17 is adjustable in a plane perpendicular to the track 3. In the embodiments it is envisaged that such pivoting of the roller 17 is either possible by hand or while the roller 17 rolls on the plate and adjusts its angular position by itself. If necessary, but also a separate drive for

Pivoting the roller 17 may be provided in a plane perpendicular to the web 13.

In a first profiling step, the roller 17 is in the position shown, in which it is located approximately at the level of the semifinished product 8 and is only slightly inclined to the plane of the platform 11. In this position, the carriage 10 is moved along the path 13 over its entire length along the Verstellgerüstes 14, wherein the roller 17 to the roller 17 projecting portion of the semifinished product 8 z. B. Bends down by 5 ° or 10 ° while it rolls freely on it. This is the

Formleistenseitige end of the roller 17 is always kept close to the bending point. For this purpose, the roller 17 is moved by means of the Verstellgerüstes 14 in the vertical direction, while it is passed from the bent portions of the moldings 6 and 7.

After a passage, when the carriage 10 has moved from one end to the other end of the platform 11, the base 5 and thus the roller 7 from

Adjustment frame 14 down a small piece, and the procedure described above is carried out in the opposite direction.

All this is repeated until the one leg 2 of the profile shown in Fig. 1 is finished rolled. In each passage, the roller 17 automatically adjusts itself to the required angle because its formleistenseitiges end is always close to the bending point, or the roll angle is adjusted and fixed each time by hand.

Subsequently, the moldings 6, 7 together with the in between

clamped semifinished product 8 are reversed on the carriage 10, or it is the entire carriage 10 is reversed to roll in the same manner as described above, the other leg 3 of the profile roll. Alternatively, on the the

Verstellgerüst 14 opposite side of the web 13 another Verstellgerüst of the same kind as the Verstellgerüst 14 may be mounted on the platform 11 in order to roll-profile the two legs 2, 3 at the same time.

The above-described further Walzprofilierschritte for the leg 3 or two adjusting frames 14 are of course not necessary if an L-profile is produced, whose legs are formed by the bottom 1 and the one leg 2 of the profile shown in Fig. 1.

Instead of by reciprocating the carriage 10 on the platform 11 with successive adjustment can be roll profiled with fewer passes or with only one passage when several identical adjusting frames 14, 14 ', 14 "and 14"' behind the other along the track 13 on the Platform 11 are fixed, as shown in Fig. 7, which otherwise corresponds to FIG. 6. That is, Fig. 7 also shows an apparatus for producing profiles with variable height and constant width top left as a side view, top right as an end view, bottom left as a top view and bottom right perspective, with an enlarged view of one of the adjusting frameworks in the middle.

A similar device is shown in just such a way in Fig. 8, with the only differences that the four Verstellgerüste 24, 24 ', 24 "and 24"' no

Monopods are like the adjusting frames 14, 14 ', 14 "and 14"' in Fig. 7, but bipods, as described in DE 10 2007 01 849 B4, and that the roller is not cylindrical, but a tapered roller 27 with a relatively small cone angle of z. B. 20 °. The bipod allows movement of the base, which is here a round disk 25, both vertically and in its central axis. This makes it possible to always position the tapered roller 27 so that unwanted deformations are avoided as possible, which can occur especially in the curved profile sections, and the slightly tapered shape of the tapered roller 27 also contributes to.

In order to be able to produce profiles of variable height and width with the device described above, the roller 17 or 27 must not only be movable vertically to the platform 11, but also transversely to the profile longitudinal direction or the web 13. This can be achieved, for example, by mounting the roller 17 or 27 on a monopod or bipod, which is mounted on the base of a monopod or bipod arranged perpendicular thereto, which is mounted on the platform 11. Alternatively, one can use one or more adjusting stands with more than two degrees of freedom, as shown schematically in FIGS. 2c and 2d of DE 10 2007 011 849 B4.

Fig. 9 shows a molding strip 30 for a U-profile with variable over its length Bend radii 31 and 32, which also represents a profile with not everywhere flat legs. The molding strip 30 may, for. B. in place of the lower mold bar 6 in the

Device of Fig. 6 are used. The upper molding can also be complementary to the lower molding 30 in this case. In the case of relatively small variable bending radii 31 and 32 as in Fig. 9, the upper mold bar

but maybe just be flat.

Fig. 10 shows two perspective views of another device for producing profiles with variable height and constant width, which differs from the

A further distinction is made in the preceding embodiments, which is arranged on the left and right of the carriage 10, which is similar to the previously described carriage 10 and is located on a platform 41, which is similar to the previously described platform 11, a respective adjusting frame 44 in the form of a hexapod or hexaglide ,

On the adjusting frame 44, a roller 47 is mounted in each case, and each roller 47 can be displaced by means of its Verstellgerüstes 44 in all three spatial directions and solid angles. Therefore, the rollers 47 do not pivot on their

Verstellgerüsten 44 be attached, as in the previous

Embodiments of the case

The two adjusting frames 44 are each supported by an auxiliary platform 48 which extends along one of the two longitudinal edges of the platform 41. each

Auxiliary platform 48 has a surface on which one of the Verstellgerüste 44 is fixed, and this surface extends obliquely to the surface portion of the platform 41, on which the carriage 10 is located, namely at an angle of approximately 45 ° with respect to the plane of the auxiliary platform 48 diagonally outwards and upwards. Such a support of Verstellgerüste 44 obliquely to the surface of the platform 41 is particularly advantageous in that on the one hand, the rollers 47 can be easily brought in all directions and angles, which are necessary for processing the semifinished product 8, and that on the other hand, the adjusting frames 44 from all directions are easily accessible ₍ eg for reel change and maintenance.

The device shown in Fig. 10 operates similarly to the devices of the previously described embodiments. During a passage of the carriage 10, the rollers 47 remain fixed to the angle and are only where the profile height changes, moved perpendicular to the platform 42, and for the next pass, the rollers 47 are slightly pivoted by means of Verstellgerüste 44. For example, the rear roller of Fig. 10 can be pivoted from the position shown in the sketch at the top right to the position shown at the bottom left in the diagram.

Another advantage of the device shown in Fig. 10 is that because of the

Mobility of Verstellgerüste 44 in all three spatial directions and solid angles easily profiles with variable width can be made. It must be designed according to the trained only by the carriage 10 moldings.

The skilled artisan recognizes that with the described devices not only profiles with variable height and / or width can be made, but also those with constant height and width, d. h., with a constant over their length

Cross-section. In this case, one uses planar moldings for clamping the profile, and the at least one roller is not moved vertically during a passage, but remains stationary.

Normally, other processes are used to mass-produce profiles with a constant cross-section, but it is an additional advantage that profiles with a constant cross-section can be produced quickly if you need them.

Another advantage of the invention, which is for both constant cross-section profiles and variable cross-section profiles, is that the process leaves very little machining marks on the sheet so as to obtain profiles with particularly high surface quality.

Claims

claims:

1. Apparatus for producing a profile from a sheet metal semifinished product (8), namely a profile having at least two limbs (1, 1 ', 2', 3 ', 3', 3 ', 3', 3 ') running in its longitudinal direction and in its cross-sectional plane. 3 "), the device having a desired profile predetermining lower mold strip (6) for full-surface supporting one of the legs (1, 1 ') and at least one roller (7, 27) for roll profiling of the mold strip (6) supported semifinished product ( 8) to the desired profile,

characterized in that

the device further comprises an upper mold bar (7) adapted to form a part of the first leg (1, 1 ') of the desired profile

Semifinished product (8) firmly clamped between itself and the lower mold strip (6), wherein the mutually facing surfaces of the two moldings (6, 7) are complementary to each other and have the same shape as the first leg (1, 1 ') of the desired profile.

2. Device according to claim 1, characterized in that the profile has a variable height and / or width, that at least a first leg (1, 1 ') of the profile has a not always flat shape that the facing each other

Surfaces of the two moldings (6, 7) are not flat, and that the at least one roller (17, 27) is rotatably mounted on a vertically movable base (15, 25).

3. A device according to claim 2, characterized in that at least the lower mold strip (6) on a carriage (10) is fixed, which is horizontally movable on a platform (1 1) along a straight path (13), and that at least on one side of the web (13) an adjusting frame (14, 24) on the platform (1 1) is fixed, which adjusting frame (14) contains the base (15, 25) on which the at least one roller (17, 27) is stored.

4. Apparatus according to claim 3, characterized in that on at least one side of the web (13) or on both sides of the web (13) has a number of

Adjusting stands (14, 14 ', 14 ", 14'", 24, 24 ', 24 ", 24"') are fastened at intervals on the platform (11), each of which contains a vertically movable base (15, 25), on which a roller (17, 27) is mounted.

5. Device according to one or more of the preceding claims 2 to 4, characterized in that the at least one roller (17, 27) is freely rotatably mounted on its base (15, 25).

6. Device according to one or more of the preceding claims 2 to 5, characterized in that the at least one roller (7, 27) as a whole is pivotally mounted on its base (15, 25),

7. Device according to one or more of the preceding claims 2 to 6, characterized in that the at least one roller (17, 27) or each roller (17, 27) is either cylindrical or relatively pointed cone.

8. Device according to one or more of the preceding claims 2 to 7, characterized in that the or each base (15, 25) is also horizontally movable transversely to the longitudinal direction of the profile.

9. Device according to one or more of the preceding of claims 2 to 8, characterized by a mechanical positive control of the position of the or each base (15, 25) by the moldings (6, 7) during their movement on the carriage (10) over the Platform (11).

10. The device according to claim 1, characterized in that it comprises a horizontal platform (41) from which the moldings (6, 7) are supported, and that the base on which the at least one roller (47) is mounted part an adjustment frame (44) carried by an auxiliary platform (48), wherein a flat surface on which the adjustment frame (44) is attached to the auxiliary platform (48) is at an oblique angle to a flat surface of the horizontal platform (48); 41) adjoins.

11. A method for producing a profile of a semifinished product (8) made of sheet metal, namely a profile having at least two legs (1, 1 ', 2', 2 ', 2', 3 ', 3', 3 ', 3') extending in its longitudinal direction and having a cross-sectional plane ', 3 "), wherein one of the two legs (1, 1') is supported over its entire length and width by a lower profile strip (6) which predetermines the desired profile, and then the semifinished product (8) supported by the molding strip (6). to the desired profile is roll profiled,

characterized in that

a part of the semifinished product (8) forming the first leg (1, 1 ') of the desired profile, firmly between the lower molding (6) and an upper molding (7)

is trapped, wherein the facing surfaces of the two

Moldings (6, 7) are complementary to each other and have the same shape as the first leg (1, 1 ') of the desired profile, whereupon the between the two moldings (6, 7) clamped semi-finished product (8) is roll-profiled to the desired profile.

12. The method according to claim 11, characterized in that the profile has a variable height and / or width, that at least one first leg (1, 1 ') of the profile has a not always flat shape that the facing each other

Surfaces of the two moldings (6, 7) are not flat, and that at least one roller (17, 27) according to the shape of the first leg (1, 1 ') is moved vertically.

13. The method according to claim 11 or 12, characterized in that a U- or hat profile is produced, the bottom of which is formed by the first leg (1, 1 ').

14. The method according to one or more of the preceding of claims 11 to 13, characterized in that a profile with variable height and constant width is produced.

15. The method according to one or more of the preceding of claims 11 to 14, characterized in that the semi-finished product (8) in a plane state between the two moldings (6, 7) brought and that the first leg (1, 1 ') of the desired profile is formed while the semi-finished product (8) between the two moldings (6, 7) is clamped.

16. The method according to one or more of the preceding of claims 11 to 15, characterized in that the semi-finished product (8) is brought in a state between the two moldings (6, 7) in which it is preformed such that the first Leg (1, 1 ') of the desired profile forming part of the semifinished product (8) in Essentially already has the desired not everywhere flat shape.