EP3515629B1 - Method and device for expanding a metal element - Google Patents

Description

The present invention relates to a method for expanding an elongated and at least regionally flat metal element, which in each case has two opposite edge regions extending in the longitudinal direction and a central region arranged between them and provided with cuts, the edge regions of the metal element being transverse to the longitudinal direction and parallel to Surface extension of the metal element are moved apart, so that connecting sections of the central region formed by the cuts and connecting the edge regions to one another are folded.

With the method according to the invention and the device according to the invention in particular flat metal elements, as they are in the DE 102 59 307 A1 are described, are expanded.

Elongated and at least regionally flat metal elements are used, for example, to produce profile elements for construction, in particular upright or plaster profiles. Folding over or folding the connecting sections results in a widening of the metal element with the same amount of material. As a result of the folding, wider metal elements can thus be produced with reduced material consumption and reduced weight. A particular advantage of the folding method is that no time-consuming punching is required to produce the corresponding cutouts and, in particular, there is no waste of material.

The cutting patterns required for the folding process can be of various types. A variety of such different cutting patterns are mentioned in the above DE 102 59 307 A1 described and illustrated. For a better understanding of the present application, the disclosure content of DE 102 59 307 A1 , in particular with regard to the specifically described and illustrated cutting patterns, expressly included in the content of the present application.

In the context of the present invention, the metal elements are flat at least in the area of the cutting patterns. In other areas, for example also in the area of the longitudinal sides of the metal elements, the metal elements can also deviate from the flat shape. In particular, thickenings, attachments or bent areas can be formed on the longitudinal sides. For example, the metal elements can already be pre-formed as U- or C-shaped profiles. Furthermore, the metal elements can be manufactured from roll material that is bent in different ways during manufacture. The term “surface extension of the metal element” accordingly means the plane of local expansion at the point where the pulling apart and folding takes place. It should also be pointed out that when the edge areas are moved apart, parts of the central section are generally also moved.

The edge areas are preferably pulled apart automatically in a continuous process, as is the case, for example, in FIG DE 10 2006 010 795 A1 is described. Here, the edge areas are gripped by suitable clamping holding devices and pulled apart in opposite directions. Although this method has proven itself in practice, there is a desire to reduce the force required to pull it apart and to have more precisely defined folding edges. A particular challenge here is that profile elements of the type mentioned at the beginning are mass-produced articles represent, which is manufactured at a very high speed, for example 100 to 150 m / min, and which is subject to high cost pressure.

It is an object of the invention to enable a simpler and more reliable widening of elongated, at least regionally flat metal elements.

The invention provides that after the cuts have been made in the central area, the edge areas are offset against one another in a first process step before moving apart by targeted application of force in a direction transverse to the surface extension of the metal element and in a subsequent second process step in the offset state are moved apart. In other words, the edge areas and possibly also parts of the central area are moved at least locally in two planes offset parallel to one another. The connecting sections to be folded, which are each in direct or indirect connection with both edge areas, are set up, that is, after being moved, they run obliquely from one of the two parallel planes to the other plane. This is advantageous in that when the edge areas are subsequently pulled apart, there is a favorable leverage effect, so that the force required for folding is reduced. In addition, during the relocation process, the kinks or folds are already formed exactly at the points provided for them, so that inaccurate kinks or incorrect kinks are reliably avoided. Due to the advantages achieved by the transverse offset before folding, it is possible to expand thicker and stiffer metal parts than was previously possible in an economical manner.

To offset the edge areas, a pressing or rolling tool, the pressing surface of which has a step defining the offset, can be pressed against the metal element. The step can be designed as a one-sided flank between two essentially smooth sections of the pressing surface, which at least locally define two planes offset parallel to one another. Using a A corresponding pressing or rolling tool enables the relocation process to be carried out particularly easily and quickly.

When the pressing or rolling tool is pressed against the metal element, the step is preferably located in the area of the central section, so that the edge areas are accordingly pressed into the two planes offset parallel to one another.

One embodiment of the invention provides that the metal element is passed between two rotatable rollers, the outer surfaces of which have respective circumferential steps with oppositely aligned flanks. In this way it is possible to move the edge areas in one continuous pass.

The rollers can be rotated in opposite directions when the metal element is passed through and, in particular, driven in opposite directions.

The edge areas are preferably offset from one another by a directional offset which corresponds to at least 3 times and at most 7 times the thickness of the metal element. Such an offset has proven to be particularly favorable in practice.

According to a special embodiment of the invention, an embossed pattern is embossed in the central section before or during the displacement of the edge regions. Such an embossed pattern causes a stiffening of the expanded metal element and accordingly an increase in stability in the profile element produced. The embossing pattern can in particular comprise reinforcing beads which define depressions. The cuts of the central area are preferably arranged completely in the depressions of the embossed pattern.

The metal element is preferably moved in the longitudinal direction during the displacement of the edge regions and / or while the edge regions are moving apart, so that the corresponding method steps are carried out in one continuous pass.

The invention also relates to a device for expanding an elongated and at least regionally flat metal element, which has two opposite edge regions extending in the longitudinal direction and a central region arranged between them and provided with cuts, in particular a device for carrying out a method as described above, with a stretching unit which is designed to hold the edge regions of the metal element and to move them apart transversely to the longitudinal direction and parallel to the surface extension of the metal element, so that connecting sections of the central region formed by the cuts and connecting the edge regions to one another are folded.

According to the invention, the device comprises a straightening unit connected upstream of the stretching unit, which is designed to offset the edge regions against one another by applying force in a direction transverse to the surface extension of the metal element, transversely to the surface extension of the metal element. As described above, the transverse displacement of the edge areas by means of the straightening unit results in a favorable leverage effect for the subsequent step of pulling the edge areas apart. In addition, the straightening unit ensures that inaccurate kinks or incorrect kinks are avoided.

The straightening unit can comprise a pressing or rolling tool, the pressure surface of which has a step that defines the offset. This enables a particularly simple construction.

The pressing surface can have two at least substantially smooth outer sections which are arranged on both sides of the step and which form the edge regions of the metal element are assigned and, viewed at least locally, extend in two mutually offset planes. The step here forms one or more flanks running between the levels.

The pressing or rolling tool preferably has at least one rotatable roller, on the outer surface of which the step is designed to run around. Such a straightening unit can process roll material in motion.

A special embodiment provides that the pressing or rolling tool comprises two rotatable rollers, between which the metal element can be passed, the outer surfaces of the rollers having respective circumferential steps with oppositely aligned flanks. The edge areas and possibly parts of the central area are thus each clamped between the rollers and fixed in a reliable manner in the mutually offset planes.

An embossed pattern, which preferably extends over the step, can be formed on the pressing surface. As described above, an embossed pattern has a stiffening effect. The embossing pattern can in particular comprise reinforcing beads which define depressions. The cuts of the central area are preferably arranged completely in the depressions of the embossed pattern.

The device can comprise a feed unit, by means of which the metal element can be moved in the longitudinal direction during the displacement of the edge regions and / or during the moving apart of the edge regions. The feed unit can in particular comprise a drive roller or an arrangement of several drive rollers.

The metal element can be made of galvanized steel, aluminum or copper, depending on the application.

Furthermore, the metal element can have a thickness of more than 0.5 mm, preferably of more than 0.6 mm. Such thick metal elements can at best be expanded with great difficulty using current methods and devices. Due to the reduction in force and increase in reliability made possible by the displacement, thicker and more rigid metal elements can also be processed with a device according to the invention.

The stretching unit can have at least two clamping sections for holding clamping of the edge areas and a device for automatically moving the clamping sections apart. This enables the expansion process to be carried out easily and quickly. The clamping sections can be designed as shown in FIG DE 10 2006 010 795 A1 is described.

According to a further embodiment of the invention, the device comprises a pressing or rolling unit connected downstream of the stretching unit for pressing or rolling the expanded metal element flat. The folds or kinks produced during folding can be leveled out in this way.

A device according to the invention can comprise an embossing unit connected upstream of the straightening unit for embossing an embossing pattern in the central section.

Alternatively, the straightening unit can have a combined embossing / offset roller or roller, by means of which both the edge areas can be displaced transversely to the surface extension of the metal element and an embossing pattern can be embossed in the central section. The offset of the edge areas and the creation of the embossing pattern can therefore be carried out in combination at a single work station. A separate embossing unit is then not required.

Further advantageous embodiments of the invention are specified in the subclaims, the description and the accompanying drawings.

Fig. 1

zeigt einen Teil eines flächigen Metallelements mit einem Schnittmuster.

Fig. 2 bis 4

zeigen drei unterschiedliche Zustände beim Aufweiten eines Metallelements mit dem Schnittmuster nach Fig. 1.

Fig. 5 bis 8

zeigen einen Zustand eines Metallelements nach dem Versetzen zweier Randbereiche des Metallelements quer zu dessen Flächenerstreckung und vor dem Aufweiten des Metallelements.

Fig. 9

ist eine perspektivische Ansicht einer Richteinheit einer erfindungsgemäßen Vorrichtung zum Aufweiten eines Metallelements.

Fig. 10

ist eine Seitenansicht der Richteinheit nach Fig. 9.

Fig. 11

zeigt einen Schnitt entlang der Linie A-A in Fig. 10.

Fig. 12

ist eine vergrößerte Darstellung des Ausschnitts B in Fig. 11.

Fig. 13

ist eine vergrößerte Darstellung des Ausschnitts C in Fig. 10.

Fig. 14

ist eine Draufsicht auf eine Presswalze der Richteinheit nach Fig. 9 einschließlich eines von der Presswalze beaufschlagten Metallelements.

The invention is described in more detail below using an exemplary embodiment with reference to the drawings.

Fig. 1

shows part of a flat metal element with a cutting pattern.

Figs. 2 to 4

show three different states when expanding a metal element with the cutting pattern Fig. 1 .

Figures 5 to 8

show a state of a metal element after the displacement of two edge regions of the metal element transversely to its surface extension and before the metal element is expanded.

Fig. 9

is a perspective view of a straightening unit of a device according to the invention for expanding a metal element.

Fig. 10

FIG. 13 is a side view of the straightening unit according to FIG Fig. 9 .

Fig. 11

shows a section along the line AA in Fig. 10 .

Fig. 12

FIG. 11 is an enlarged view of section B in FIG Fig. 11 .

Fig. 13

FIG. 11 is an enlarged view of section C in FIG Fig. 10 .

Fig. 14

FIG. 13 is a plan view of a press roll of the straightening unit of FIG Fig. 9 including a metal element acted upon by the press roll.

Fig. 1 shows a detail from a flat metal element 11, which has two opposite edge regions 13 extending along a longitudinal axis L and a central region 17 arranged between them and provided with interlocking cuts 15. The edge areas 13 are free of cuts, which is preferred but not mandatory. The in Fig. 1 The section shown is clearly shortened compared to the actual length of the metal element 11. In fact, the metal element 11 forms a long metal strip which, for example, can have a length of several 100 m.

The metal element 11 is already in the DE 102 59 307 A1 which are explicitly referred to.

The cuts 15 are arranged such that the edge regions 13 of the metal element 11 can be pulled apart at right angles to the longitudinal axis L, as in FIG Fig. 1 indicated by arrows. When the edge regions 13 are pulled apart, connecting sections 19 formed by the cuts 15 are folded in the form of narrow webs along kink lines 21, so that a resulting metal element 11 with an enlarged width is produced. A corresponding folding process is in the Figs. 2 to 4 shown in detail.

Correspondingly expanded metal elements can be used, for example, for the production of profiles, as they are, for. B. as edge protection or as stand profiles for drywall, z. B. in the form of U and C profiles can be used.

To the known metal elements 11 at high speed as in the Figs. 2 to 4 shown to be able to expand, for example, a device can be used as in the DE 10 2006 010 795 A1 is described.

In a method according to the invention for expanding the in Fig. 1 the metal element 11 shown, the edge regions 13 are not starting from the in Fig. 1 The basic state shown is drawn apart at right angles to the longitudinal axis L, but rather offset from one another at right angles to the surface extension of the metal element 11 in a preceding method step. The shifted state is in the Figures 5 to 8 shown, where Fig. 5 a side view transverse to the longitudinal axis L, Fig. 6 a side view in the direction of the longitudinal axis L, Fig. 7 a perspective view and Fig. 8 an enlarged view of the area A in Fig. 7 is. It can be seen that the two edge regions 13 and parts of the central region 17 adjoining them run in planes 25, 26 that are parallel and spaced apart from one another, while the connecting sections 19 are oriented obliquely to these planes 25, 26. In the central area 17 there is an embossed pattern 27, the creation of which will be described in more detail below.

The shape of the cuts 15 of the in Figures 5 to 8 The metal element 11 shown differs slightly from the shape of the metal element 11 shown in FIG Figs. 1 to 4 Sections 15 shown, but this is not important with regard to the relocation process.

Based on the in Figures 5 to 8 The intermediate state shown, the edge areas 13 are pulled apart in opposite directions, wherein the connecting sections 19 are folded. Since the folding lines 21 are already formed in the intermediate state and the connecting sections 19 are inclined, the pulling apart can be carried out easily and with reduced tensile force. In addition, there cannot be a faulty formation of fold lines 21 come. A method according to the invention can therefore also be carried out for metal elements 11 with a thickness of more than 0.6 mm and for hard types of metal.

In a conventional method for expanding a metal element 11, in the course of the folding there is also an offset of the edge areas 13 transversely to the surface extension of the metal element 11, since the folding connecting sections 19 press the adjoining sections of the metal element 11 apart, as in FIG Figs. 2 and 3 can be seen. However, this is an extremely short-lived transition state, and it inevitably occurs due to the folding process. The invention, on the other hand, provides that the edge areas 13 are displaced by the application of targeted force in a direction pointing transversely to the extent of the surface and that the edge areas 13 are only pulled apart after this targeted displacement step.

Moving can be done with an in the Figures 9-14 shown straightening unit 29 are carried out. A device according to the invention for expanding a metal element 11 has, in addition to the straightening unit 29, a stretching unit connected downstream of the straightening unit 29, which, however, is shown in FIG Figures 9-14 is not shown. The stretching unit serves to hold the edge regions 13 of the metal element 11 and to pull them apart transversely to the longitudinal axis L and parallel to the surface extension of the metal element 11. In particular, the stretching unit can have clamping sections engaging the edge regions 13, as shown in FIG DE 10 2006 010 795 A1 are disclosed.

A device according to the invention for expanding a metal element 11 can also comprise a pressing or rolling unit downstream of the stretching unit for flattening or flat rolling the expanded metal element 11 and / or a feed unit for moving the metal element 11 along its longitudinal axis L in a feed direction R, which is shown in FIG Figures 9-14 is also not shown. Furthermore, a device according to the invention for expanding of a metal element 11 comprise an embossing unit (not shown) connected upstream of the straightening unit 29 for generating the embossing pattern 27.

The straightening unit 29 comprises two rotatable press rollers 30, 31, between which the metal element 11 is passed. During the passage, the press rollers 30, 31 are rotated in opposite directions, either passively or by means of a drive.

The press rollers 30, 31 are preferably made of steel and have respective pressure surfaces 33 which have two smooth outer sections 35, 36 and an embossing section 39 arranged between them. The embossing sections 39 of the two press rollers 30, 31 are shaped complementarily and aligned with one another so that the embossing pattern 27 is not impaired when the metal element 11 is passed through the press rollers 30, 31.

Furthermore, the smooth outer sections 35, 36 of a pressure surface 33 run at different distances from the axis of rotation D ( Fig. 10 ) so that they are offset radially. A step 45 is thus formed between the smooth outer sections 35, 36 and is arranged completely circumferentially on the pressure surface 33. Like in particular from Fig. 12 As can be seen, the step 45 in the illustrated embodiment is overlaid with the embossed section 39 and accordingly has a plurality of flanks 47. Instead of the embossed section 39, however, a further smooth section could also be provided, in which case the step 45 would preferably be designed as a single, one-sided flank. It goes without saying that the steps 45 of the two press rollers 30, 31 are designed to be complementary, so that when the metal element 11 is passed through the press rollers 30, 31, the opposite edge regions 13 are moved apart as desired across the surface extension. The offset defined by the steps 45 in the illustrated straightening unit 29 is five times the thickness of the metal element 11, which has proven to be beneficial in practice. With the exemplary The straightening unit 29 described above, the press rollers 30, 31 are spaced from one another in such a way that the metal element 11 is not or not significantly pressed ( Fig. 13 ).

In Fig. 14 the deformation of the metal element 11 by the pressing surface 33 of a press roller 31 can be seen.

In principle, it is possible not to produce the embossed pattern 27 on the one hand and to move the edge regions 13 on the other hand, as described above, in different work stations, but in a single work station. Such a work station can have a combined embossing / offset roller or roller which, due to its shape, accomplishes the offset of the two edge regions 13 and the formation of the stiffening embossed pattern 27 in one and the same work step.

The invention enables the connecting sections 19 to be folded with reduced expenditure of force and with more precisely defined folding edges, as a result of which the expansion of metal elements 11 is significantly simplified.

List of reference symbols

11

Metal element

13th

Edge area

15th

cut

17th

Central area

19th

Connection section

21

Kink line

25.26

level

27

Embossing pattern

29

Straightening unit

30.31

Press roll

33

Contact surface

35.36

Outer section

39

Embossing section

45

step

L.

Longitudinal axis

D.

Axis of rotation

R.

Feed direction

Claims (15)

1. A method of expanding an elongated and at least regionally planar metal element (11) which has two respective marginal regions (13), which are oppositely disposed and which extend in the longitudinal direction (L), and a central region (17) which is arranged therebetween and which is provided with cuts (15), wherein the marginal regions (13) of the metal element (11) are moved apart transversely to the longitudinal direction (L) and in parallel with the planar extent of the metal element (11) such that connection sections (19) of the central region (17) formed by the cuts (15) and connecting the marginal regions (13) to one another are folded,
   characterized in that,
   in a first method step before the moving apart, the marginal regions (13) are displaced with respect to one another transversely to the planar extent of the metal element (11) by a targeted exertion of force in a direction facing transversely to the planar extent of the metal element (11) and, in a subsequent second method step, said marginal regions (13) are moved apart in the displaced state.
2. A method in accordance with claim 1,
   characterized in that
   a pressing tool or rolling tool (30, 31) whose pressing surface (33) has a step (45) defining the displacement is pressed against the metal element (11) to displace the marginal regions (13).
3. A method in accordance with claim 2,
   characterized in that
   the step (45) is located in the region of the central section (17) during the pressing of the pressing tool or rolling tool (30, 31) against the metal element (11).
4. A method in accordance with claim 2 or claim 3,
   characterized in that
   the metal element (11) is led between two rotatable rollers (30, 31) whose jacket surfaces (33) have respective peripheral steps (45) having oppositely aligned flanks, in particular with the rollers (30, 31) being rotated in opposite directions on the leading through of the metal element (11) and in particular being driven in opposite directions.
5. A method in accordance with at least one of the preceding claims,
   characterized in that
   the marginal regions (13) are displaced with respect to one another by a dressing displacement which corresponds to at least 3 times, and at most 7 times, the thickness of the metal element (11).
6. A method in accordance with at least one of the preceding claims, characterized in that
   an embossed pattern (27) is embossed in the central section (17) before or during the displacement of the marginal regions (13); and/or in that the metal element (11) is moved in the longitudinal direction (L) during the displacement of the marginal regions (13) and/or during the moving apart of the marginal regions (13).
7. An apparatus for expanding an elongated and at least regionally planar metal element (11) which has two respective marginal regions (13), which are oppositely disposed and which extend in the longitudinal direction (L), and a central region (17) which is arranged therebetween and which is provided with cuts (15), in particular an apparatus for carrying out a method in accordance with any one of the preceding claims, comprising a stretching unit which is configured to hold the marginal regions (13) of the metal element (11) and to move them apart transversely to the longitudinal direction (L) and in parallel with the planar extent of the metal element (11) such that connection sections (19) of the central region (17) formed by the cuts (15) and connecting the marginal regions (13) to one another are folded,
   characterized in that
   the apparatus comprises a dressing unit (29) which is connected upstream of the stretching unit and which is configured to displace the marginal regions (13) with respect to one another transversely to the planar extent of the metal element (11) by a targeted exertion of force in a direction facing transversely to the planar extent of the metal element (11).
8. An apparatus in accordance with claim 7,
   characterized in that
   the dressing unit (29) comprises a pressing tool or rolling tool (30, 31) whose pressing surface (33) has a step (45) defining the displacement.
9. An apparatus in accordance with claim 8,
   characterized in that
   the pressing surface (33) has two at least substantially smooth outer sections (35, 36) which are arranged at both sides of the step (45) and which are associated with the marginal regions (13) of the metal element (11).
10. An apparatus in accordance with claim 8 or claim 9,
    characterized in that
    the pressing tool or rolling tool has at least one rotatable roller (30, 31) on whose jacket surface (33) the step (45) is peripherally formed, in particular with the pressing tool or rolling tool comprising two rotatable rollers (30, 31) between which the metal element (11) can be led, and with the jacket surfaces (33) of the rollers (30, 31) having respective peripheral steps (45) having oppositely aligned flanks.
11. An apparatus in accordance with at least one of the claims 8 to 10,
    characterized in that
    an embossed pattern (27) which preferably extends beyond the step (45) is formed on the pressing surface (33).
12. An apparatus in accordance with at least one of the claims 7 to 11,
    characterized in that
    the apparatus comprises a feed unit through which the metal element (11) is movable in the longitudinal direction (L) during the displacement of the marginal regions (13) and/or during the moving apart of the marginal regions (13).
13. An apparatus in accordance with at least one of the claims 7 to 12,
    characterized in that
    the metal element (11) is composed of galvanized steel, aluminum or copper; and/or in that
    the metal element (11) has a thickness of more than 0.5 mm, preferably of more than 0.6 mm.
14. An apparatus in accordance with at least one of the claims 7 to 13,
    characterized in that
    the stretching unit has at least two clamping sections for a holding clamping of the marginal regions (13) and an apparatus for an automatic moving apart of the clamping sections; and/or in that
    the apparatus comprises a pressing unit or rolling unit connected downstream of the stretching unit for flat pressing or flat rolling the expanded metal element (11).
15. An apparatus in accordance with at least one of the claims 7 to 14,
    characterized in that
    the apparatus comprises an embossing unit connected upstream of the dressing unit (29) for embossing an embossed pattern (27) in the central section (17); and/or in that
    the dressing unit (29) has a combined embossing/displacement roller or roll by means of which both the marginal regions (13) can be displaced transversely to the planar extent of the metal element (11) and an embossed pattern (27) can be embossed in the central section (17).

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