EP3453467B1

EP3453467B1 - Variable roll-forming machine

Info

Publication number: EP3453467B1
Application number: EP18184162.8A
Authority: EP
Inventors: Isabel GARCÍA GALDÓN; Álvaro JIMÉNEZ GRADILLAS
Original assignee: CQLT SaarGummi Technologies SARL
Current assignee: CQLT SaarGummi Technologies SARL
Priority date: 2017-09-07
Filing date: 2018-07-18
Publication date: 2020-04-01
Anticipated expiration: 2038-07-18
Also published as: ES1200335Y; ES2795296T3; ES1200335U; EP3453467A1

Description

Object of the Invention

The present invention belongs to the field of industry, primarily to the automotive field. In manufacturing extruded gum and rubber profiles for sealing the doors and windows, grooved, steel sheet metal U-shaped profiles are introduced to provide rigidity. Tools for each profile model are used today for bending these steel profiles.
The object of the present invention is a machine that bends these profiles with the base width, angles of the flanges, and length thereof being variable, such that different tools are not required for a large number of profile types, since the machine can be reconfigured to make several possible models. This regulation is done automatically and precisely by means of mechanisms moved by servo motors.

Background of the Invention

Tools for each profile model are used today for bending these steel profiles (strips) . A machine for manufacturing and bending metal profiles is known from published patent application US 2016/023254 A1 .

Description of the Invention

The machine is made up of a compendium of mechanisms and modules which together form what is referred to as the machine for the variable bending of U-shaped profiles.
In a first inventive aspect, the present invention provides a machine for manufacturing metal profiles by means of rollers, comprising:

i) an inlet station configured for receiving and straightening a planar sheet metal, wherein the inlet station in turn comprises
- a straightening and guiding system for the planar sheet comprising a plurality of rollers arranged in two offset rows and assembled with their rotation shafts in the vertical position on a carriage that can be moved transversely with respect to the forward movement direction of the sheet, a spindle configured for moving the carriage, and a servomotor configured for operating the spindle, regulating the distance between the rows of rollers, and
- an asymmetry system configured for transversely moving the assembly of the straightening system, comprising a carriage on which the straightening system is assembled, a spindle configured for moving the carriage and a servomotor configured for operating the spindle, such that it allows moving the straightening system with respect to the center of the machine, thereby regulating the profile flange length;
ii) a bending station configured for bending the profile flanges in a symmetrical manner, comprising
- a profile width regulation system comprising one or more profile width regulation stages, wherein each stage comprises at least one pair of plates arranged coaxially and assembled on drive shafts,
  - wherein each stage of the profile width regulation system further comprises a transverse carriage, assembled in a sliding manner on transverse shafts and configured for pushing the plates along the drive shafts such that the plates move closer to or farther away from one another, and a spindle configured for moving the carriage,
  - wherein each stage of the profile width regulation system comprises a plurality of springs arranged between each pair of plates and configured for reducing clearances between the plates and the profile,
  - wherein the spindles of each stage of the profile width regulation system are operated by means of gear rings meshing with a worm screw, which is attached to a shaft common to all the stages of the profile width regulation system,
- a defined-angle bending system arranged above the profile width regulation system, comprising one or more defined-angle bending stages, wherein each stage comprises a central plate and a pair of side plates arranged on each side of the central plate and assembled coaxially on a rotating shaft,
  - wherein each stage of the defined-angle bending system comprises a plurality of springs arranged between each pair of side plates and friction discs,
  - wherein each stage of the defined-angle bending system comprises pushing elements configured for pushing the side plates such that the plates move closer to or farther away from one another, and spindles configured for moving the pushing elements,
  - wherein the spindles of each stage of the defined-angle bending system are attached by means of an elastic coupling,
iii) a profile web creasing station, comprising a profile web M-shape creasing system, in turn comprising a first roller and a second roller arranged below the first roller, wherein the distance between the first roller and the second roller can be regulated by means of a set of spindles and gear rings operated by a servomotor;
characterized in that the machine further comprises
iv) a profile flange asymmetrical bending station, in turn comprising
- a profile width regulation system comprising at least the same elements as the profile width regulation system of the bending station,
- a variable-angle bending system arranged above the profile width regulation system, comprising a central plate and a pair of forming plates arranged on each side of the central plate and assembled coaxially on a rotating shaft,
  - wherein the variable-angle bending system comprises a plurality of springs arranged between each pair of forming plates, and friction discs,
  - wherein the variable-angle bending system comprises pushing elements configured for pushing the forming plates such that the plates move closer to or farther away from one another, and spindles configured for moving the pushing elements,
  - wherein the spindles are operated independently by means of servomotors, such that the angle of each profile flange can be independently adjusted.

In a particular embodiment, the machine further comprises a side guiding system with side strip guides assembled on carriages, wherein the carriages are moved by means of spindles operated by servomotors.
In a particular embodiment, the machine further comprises a hinged attachment configured for attaching an upper part of the machine and a lower part of the machine, wherein

the upper part of the machine comprises at least the defined bending system, the variable-angle bending system, and the first roller of the profile web creasing station, and
the lower part of the machine comprises at least the profile width regulation system, the profile width regulation system of the station for the asymmetrical bending, and the second roller of the profile web creasing station.

In a particular embodiment, the profile web creasing station comprises after the M-shape creasing system a profile width regulation system and a variable-angle bending system for correcting the shape of the profile after passing through the profile web creasing station.
In a particular embodiment, the machine comprises a control system which can be operated by means of a control panel.
In a particular embodiment, the machine comprises a power supply system.
In a particular embodiment, the machine comprises a drive mechanism comprising extendable universal drives operated by a geared motor.
In a particular embodiment, the machine comprises intermediate guiding means arranged between the bending station and the profile flange asymmetrical bending station.
In a particular embodiment, the plurality of rollers of the straightening and guiding system for the planar sheet are arranged in two rows, the rollers facing one another and their rotation shafts being aligned according to a transverse direction with respect to the forward movement direction of the sheet, and assembled with their rotation shafts in the vertical position on a carriage that can be moved transversely with respect to the forward movement direction of the sheet.
The elements comprising the machine are described below:
Strip inlet, guiding, and straightening module. This module is formed by two rows of rollers. One row is offset with respect to the other by a distance equal to half the distance between rollers. The distance between these rows of rollers marks the width of the strip and is variable by means of right- and left-handed threaded spindles attached by a coupling. The movement is performed by means of a servomotor. These rows of rollers are assembled on carriages sliding on linear guides.
Profile asymmetry module. The profiles can be symmetrical or asymmetrical. To that end, the strip straightening module is assembled on a carriage which moves transversely to the strip movement direction. If this carriage is moved with respect to the center of the machine, the longitudinal axis, the profile will be asymmetrical and one flange of the U-shape will be longer than the other one. The movement of this carriage is performed by means of a spindle and a servomotor.
Profile width regulation module. Facing pairs of plates assembled on drive shafts are used to determine the width of the profiles. The number of these pairs depends on the thickness and the strength of the strip. A higher strip bending strength will necessitate there being more pairs of rollers. The transverse distance between these plates is variable by means of right- and left-handed threaded spindles. The spindles are assembled on transverse carriages guided on shafts with linear bushings, referred to as pushing elements (Figure 8). Said pushing elements will act on bearings with respect to the plates. Springs are incorporated between the plates to prevent clearances. All these spindles are attached to one another by means of gear rings and worm screws so as to be moved by a servomotor. All these worm screws are on a single shaft. All the plates of this module therefore open and close at the same time, maintaining the same width. These plates are in the lower part of the formation. The U-shape will be manufactured in an inverted position.
Side strip guiding system. Side strip guides are installed between the first rollers, from the first to the third. These guides prevent the strip, which is not yet altogether formed, from moving laterally. These guides are assembled on carriages which move by means of spindles moved by a servomotor on either side.
Defined-angle bending module. The sheet bending systems are assembled on the first lower plates which determine the width of the U-shape. This system is formed by a central plate pressing and holding the sheet. It is attached to the rotating shaft by means of a cotter pin and is placed in the longitudinal center of the machine. Two plates are arranged symmetrically on the sides thereof. These plates are driven by means of springs with friction discs. These plates impart the angle to the sheet according to the angle of each plate. The number of plates also depends on the thickness and the strength of the strip. The distance between these plates depends on the width of the base of the U-shape and it is considered the same as the distance of the lower plates. Regulation is likewise performed with the same system of pushing elements and right- and left-handed threaded spindles. These spindles are attached to one another by an elastic coupling and are moved by a servomotor, all at the same time.
Variable-angle bending modules. These modules are assembled on the lower plates defining the width of the profiles. They are formed by a central plate just like those that are assembled in the previous defined angle modules, which plate is also attached to the rotating shafts by means of a cotter pin and placed in the longitudinal center of the machine. The plates imparting the angle to the profiles are arranged on the sides of this plate. In this case, these plates do not have an angle, as the angle is imparted by moving these side plates closer to or farther away from the central plate, more or less pressing the profile against the lower plates. These side plates are driven by means of friction discs, clutches, and springs. These springs are driven by the central plate. The transverse movement of these plates is performed by the pushing elements by means of threaded spindles which are operated by servomotors. These spindles and motors are independent for each plate. The angle of the flanges of the U-shape can therefore be different.
M-shape creasing module. This module bends the web of the U-shape by means of a V-shaped roller acting against the lower rollers, which also together form a V-shape. The vertical movement of this roller is carried out by means of spindles and gear rings moved by a servomotor. When carrying out this shaping, the flanges of the U-shape open, so after this module there is a final bending module which uses a pair of variable bending pulleys.
The structure of these modules is split into two parts along the machine, such that the bending modules, which are in the upper part, are independent of the other modules. The structures of the two modules are attached to one another by means of hinges. The upper structure rotates with respect to the lower structure, and they are left separated for a possible intervention. This system is very practical in the event of maintenance and possible jams.
Drive module. All the shafts of the pulleys are moved by a gearbox and chain sprocket. The shafts of the drive box and the shafts of the pulleys are attached by extendable universal joints. The movement of this gearbox is operated by a variable speed geared motor.
There are arranged a distribution board and a control panel to control all the movements.
The present invention is a machine bending these profiles with the base width, angles of the flanges, and length thereof being variable, such that different tools are not required for a large number of profile types, since the machine can be reconfigured for making several possible models. This regulation takes place automatically and precisely by means of mechanisms moved by servomotors.

Description of the Drawings

Figure 1 shows a plan view of the machine.
Figure 2 shows an outer elevational view of the machine.
Figure 3 shows an internal view of the plan arrangement of the machine.
Figure 4 shows an inner elevational view of the arrangement.
Figure 5 shows a plan view of the strip straightening and guiding module.
Figure 6 shows an elevational view the strip straightening and guiding module.
Figure 7 shows the profile width regulation module.
Figure 8 shows the pushing element of plates.
Figure 9 shows the side strip guiding system.
Figure 10 shows the bending module with defined angle rollers.
Figure 11 shows the variable-angle bending module.
Figures 12 and 13 shows the M-shape bending module.
Figure 14 shows the upper roller opening system.

Detailed Description of the Invention

A particular example of a machine for the variable bending of U-shaped profiles for transforming a grooved steel strip into a profile is described below.
The machine is made up of a compendium of mechanisms and modules and grouped in four stations: inlet station (3.1), bending station (3.2), profile flange asymmetrical bending station (3.3) and profile web creasing station (3.4).

Inlet station (3.1):

The machine has at the inlet a strip inlet, guiding, and straightening module (Figures 3, 5 and 6). It is formed by two rows of rollers (5.1). One row is offset with respect to the other by a distance equal to half the distance between rollers. The distance between these rows of rollers marks the width of the strip and is variable by means of right- and left-handed threaded spindles (5.2) attached by a coupling (6.4). The movement is performed by means of a servomotor (5.4). These rows of rollers are assembled on carriages (5.3) sliding on linear guides.
Profile asymmetry module. The profiles can be symmetrical or asymmetrical. To that end, the strip straightening module is assembled on a carriage (6.1) which moves transversely to the strip movement direction. If this carriage is moved with respect to the center of the machine, i.e., the longitudinal axis, the profile will be asymmetrical and one flange of the U-shape will be longer than the other one. The movement of this carriage is performed by means of a spindle (6.2) and a servomotor (6.3).

Bending station (3.2):

The next module through which the strip passes is the profile width regulation module to determine the width of the profiles (Figures 7 and 8). Facing pairs of plates (7.1) assembled on drive shafts (7.2) are used to determine the width of the profiles. The number of these pairs depends on the thickness and the strength of the strip, as a higher bending strength of the strip will necessitate there being more pairs of rollers. The transverse distance between these plates is variable by means of right- and left-handed threaded spindles (7.3). The spindles are assembled on transverse carriages (7.5) guided on shafts (8.1) with linear bushings, referred to as pushing elements (Figure 8). Said pushing elements will act on bearings with respect to the plates. Springs are incorporated between the plates (7.4) to prevent clearances. All these spindles are attached to one another by means of gear rings (7.6) and worm screws (7.7) so as to be moved by a servomotor. All these worm screws are arranged on a single shaft (7.8). All the plates of this module thereby open and close at the same time, maintaining the same width. These plates are in the lower part of the arrangement. The U-shape will be manufactured in an inverted position.
The machine has a side strip guiding system (Figure 9). Side strip guides (9.1) are installed between the first rollers, from the first to the third. These guides prevent the strip (9.2), which is not yet altogether formed, from moving laterally. These guides are assembled on carriages (9.3) which move by means of spindles (9.4) moved by a servomotor on each side (9.5).
The machine integrates several plates forming the defined-angle bending module on the first lower plates which determine the width of the U-shape (Figure 10). This is the sheet bending system. This system is formed by a central plate (10.1) pressing and holding the sheet. It is attached to the rotating shaft (10.3) by means of a cotter pin and is placed in the longitudinal center of the machine. Two plates (10.2) are arranged symmetrically on the sides thereof. These plates are driven by means of springs (10.4) with friction discs (10.5). These plates impart the angle to the sheet according to the angle of each plate. The number of plates also depends on the thickness and the strength of the strip. The distance between these plates depends on the width of the base of the U-shape and it is considered the same as the distance of the lower plates. Regulation is likewise performed with the same system of pushing elements (10.6) and right- and left-handed threaded spindles (10.7). These spindles are attached to one another by an elastic coupling (10.8) and are moved by a servomotor, all at the same time.

Profile flange asymmetrical bending station (3.3):

The next modules through which the profile passes are the variable-angle bending modules (Figure 11). Like with the defined-angle bending (10.1), the central plate (11.1) is in charge of driving the strip attached to the rotating shaft (11.3). Variable angle forming plates (11.2) are arranged on both sides of this plate by means of the friction discs (11.5) and the springs (11.4), which are driven by the central plate. These plates form the angle by pushing the strip against the lower plates by means of the pushing elements (11.6) moved by the spindles (11.7), with the latter being operated by the servomotors (11.8) and (11.9). In this case, the spindles of the pushing elements are not attached and are operated by different servomotors. The profiles can thereby have different flange angles.

Profile web creasing station (3.4):

The profile finally passes through the M-shape creasing module (Figures 3, 12 and 13). This module bends the web of the U-shape by means of a V-shaped roller (12.1) acting against the lower rollers, which also together form a V-shape (12.2) . The vertical movement of this roller is carried out by means of spindles (12.4) and gear rings (12.3) moved by a servomotor (12.5). When carrying out this shaping, the flanges of the U-shape open, so after this module there is a final bending module which uses a pair of variable bending pulleys.
The structure of these modules is split into two parts along the machine, such that the bending modules, which are in the upper part (14.1), are independent of the other lower modules (14.2). The structures of the two modules are attached to one another by means of hinges (14.3). The upper structure rotates with respect to the lower structure, and they are left separated for a possible intervention. This system is very practical in the event of maintenance and possible jams. See Figure 14. All the shafts of the pulleys are moved by a gearbox and chain sprocket. The shafts of the drive box and the shafts of the pulleys are attached by extendable universal joints (1.1). The movement of this gearbox is operated by a variable speed geared motor. See Figure 1. This module is referred to as a drive module (1.2).
The stations (3.1, 3.2, 3.3, 3.4) defined above can be deactivated or disabled, such that they do not act on the profile by conventional means that are not shown.
There are arranged a distribution board and a control panel to control all the movements.
Taking into account the specific needs of a possible client, this machine could have slight modifications or additional modules, but always having the systems herein described. The modules are built with commercially available and specifically machined parts made of steel, aluminum, and bronze.

Claims

A machine (1) for manufacturing metal profiles by means of rollers, comprising:
i) an inlet station (3.1) configured for receiving and straightening a planar metal sheet, wherein the inlet station in turn comprises
- a straightening and guiding system (5) for the planar sheet comprising a plurality of rollers (5.1) arranged in two offset rows and assembled with their rotation shafts in the vertical position on a carriage (5.3) that can be moved transversely with respect to the sheet forward movement direction, a spindle (5.2) configured for moving the carriage (5.3), and a servomotor (5.4) configured for operating the spindle (5.2), regulating the distance between the rows of rollers (5.1), and

- an asymmetry system (6) configured for transversely moving the assembly of the straightening system (5), comprising a carriage (6.1) on which the straightening system (5) is assembled, a spindle (6.2) configured for moving the carriage (6.1), and a servomotor (6.3) configured for operating the spindle (6.2), such that it allows moving the straightening system (5) with respect to the center of the machine (1), thereby regulating the profile flange length;

ii) a bending station (3.2) configured for bending the profile flanges in a symmetrical manner, comprising
- a profile width regulation system (7) comprising one or more profile width regulation stages, wherein each stage comprises at least one pair of plates (7.1) arranged coaxially and assembled on drive shafts (7.2),
• wherein each stage of the profile width regulation system (7) further comprises a transverse carriage (7.5), assembled in a sliding manner on transverse shafts (8.1) and configured for pushing the plates (7.1) along the drive shafts (7.2) such that the plates (7.1) move closer to or farther away from one another, and a spindle (7.3) configured for moving the carriage (7.5),

• wherein each stage of the profile width regulation system (7) comprises a plurality of springs (7.4) arranged between each pair of plates (7.1) and configured for reducing clearances between the plates (7.1) and the profile,

• wherein the spindles (7.3) of each stage of the profile width regulation system (7) are operated by means of gear rings (7.6) meshing with a worm screw (7.7), which is attached to a shaft (7.8) common to all the stages of the profile width regulation system (7),

- a defined-angle bending system (10) arranged above the profile width regulation system (7), comprising one or more defined-angle bending stages, wherein each stage comprises a central plate (10.1) and a pair of side plates (10.2) arranged on each side of the central plate (10.1) and assembled coaxially on a rotating shaft (10.3),
• wherein each stage of the defined-angle bending system (10) comprises a plurality of springs (10.4) arranged between each pair of side plates (10.2) and friction discs (10.5),

• wherein each stage of the defined-angle bending system (10) comprises pushing elements (10.6) configured for pushing the side plates (10.2) such that the plates (10.2) move closer to or farther away from one another, and spindles (10.7) configured for moving the pushing elements (10.6),

• wherein the spindles (10.7) of each stage of the defined-angle bending system (10) are attached by means of an elastic coupling (10.8),

iii) a profile web creasing station (3.4), comprising a profile web M-shape creasing system (12), in turn comprising a first roller (12.1) and a second roller (12.2) arranged below the first roller (12.1), wherein the distance between the first roller (12.1) and the second roller (12.2) can be regulated by means of a set of spindles (12.4) and gear rings (12.3) operated by a servomotor (12.5); ch
aracterized in that the machine (1) further comprises

iv) a profile flange asymmetrical bending station (3.3), in turn comprising
- a profile width regulation system comprising at least the same elements as the profile width regulation system (7) of the bending station,

- a variable-angle bending system (11) arranged above the profile width regulation system, comprising a central plate (11.1) and a pair of forming plates (11.2) arranged on each side of the central plate (11.1) and assembled coaxially on a rotating shaft (11.3),
• wherein the variable-angle bending system (11) comprises a plurality of springs (11.4) arranged between each pair of forming plates (11.2), and friction discs (11.5),

• wherein the variable-angle bending system (11) comprises pushing elements (11.6) configured for pushing the forming plates (11.2) such that the plates (11.2) move closer to or farther away from one another, and spindles (11.7) configured for moving the pushing elements (11.6),

• wherein the spindles (11.7) are operated independently by means of servomotors (11.8, 11.9), such that the angle of each profile flange can be independently adjusted.
The machine (1) for manufacturing metal profiles according to the preceding claim, characterized in that it further comprises a side guiding system (9) with side strip guides (9.1) assembled on carriages (9.3), wherein the carriages (9.3) are moved by means of spindles (9.4) operated by servomotors (9.5).
The machine (1) for manufacturing metal profiles according to any of the preceding claims, characterized in that the machine (1) further comprises a hinged attachment (14) configured for attaching an upper part of the machine and a lower part of the machine, wherein
- the upper part of the machine comprises at least the defined bending system (10), the variable-angle bending system (11), and the first roller (12.1) of the profile web creasing station, and

- the lower part of the machine comprises at least the profile width regulation system (7), the profile width regulation system of the station for the asymmetrical bending, and the second roller (12.2) of the profile web creasing station.
The machine (1) for manufacturing metal profiles according to any of the preceding claims, characterized in that the profile web creasing station comprises after the M-shape creasing system (12) a profile width regulation system and a variable-angle bending system (11) for correcting the shape of the profile after passing through the profile web creasing station.
The machine (1) for manufacturing metal profiles according to any of the preceding claims, characterized in that the machine (1) comprises a control system which can be operated by means of a control panel.
The machine (1) for manufacturing metal profiles according to any of the preceding claims, characterized in that the machine (1) comprises a power supply system.
The machine (1) for manufacturing metal profiles according to any of the preceding claims, characterized in that the machine (1) comprises a drive mechanism comprising extendable universal drives (1.1) operated by a geared motor.
The machine (1) for manufacturing metal profiles according to any of the preceding claims, characterized in that it comprises intermediate guiding means arranged between the bending station (3.2) and the profile flange asymmetrical bending station (3.3).