EP3590617A1 - Method for manufacturing a support profile comprising a sheet and support profile manufactured using this process - Google Patents

Abstract

The invention relates to a method for producing a carrier profile from a sheet metal, the sheet having a first longitudinal edge and a second longitudinal edge, the first longitudinal edge and the second longitudinal edge being parallel to one another; the method comprising a step of bending the sheet into a carrier profile, the first longitudinal edge being bent into a first envelope with a first envelope edge and the second longitudinal edge into a second envelope with a second envelope edge, the first envelope edge and the second envelope edge being in direct To be in contact; further comprising a step of welding the first envelope edge and the second envelope edge to one another is formed by a step of fusion welding, which increases the resistance and area moment of inertia.

Description

The invention relates to a method for producing a carrier profile from a sheet metal, the sheet having a first longitudinal edge and a second longitudinal edge, the first longitudinal edge and the second longitudinal edge being parallel to one another.

The method comprises a step of bending, the sheet being bent into the shape of the support profile. The first longitudinal edge is bent into a first envelope with a first envelope edge and the second longitudinal edge into a second envelope with a second envelope edge, the first envelope edge and the second envelope edge being in direct contact.

The method further comprises a step of welding the first envelope edge and the second envelope edge to one another.

A method according to the preamble of independent claim 1 is among others FR 2 865 667 A1 known. Methods of this type are used for the production of support profiles with an integrated rail. However, the outwardly curved envelopes lead to an inhomogeneous outer surface with additional joints or edges, which make it difficult to use them for support profiles with a precise surface fit. The welding consumables used for this process can also contribute to the unevenness of the outer surface, but revising them can weaken the connection point and thus the strength of the support profile.

The object of the present invention is to provide a method for producing a carrier profile from a sheet metal, which has both a high strength and a high surface quality.

The object is achieved by the features of independent claim 1. Accordingly, in a method according to the preamble of independent claim 1, there is a solution to the object according to the invention if sheet metal is bent into the carrier profile in such a way that the first and the second longitudinal edge within the Support profile lie, wherein the welding is formed by a step of high-frequency welding or by a step of fusion welding.

The cover edges are preferably welded to one another by means of inductive high-frequency welding. By using a high frequency (HF) welding process a particularly good connection between the two envelopes can be achieved, the use of welding consumables being dispensed with. This process gives the weld a particularly high strength and enables its high stability without supporting the seam from the inside on the profile. The eddy currents generated by the induction coils also make it possible to limit the heat input to the edges to be welded.

As an alternative to an HF welding process, a fusion welding process such as a metal-active gas welding process or a carbon dioxide laser welding process can also be used.

The inward-curved envelopes also further reinforce the stability of the support profile in the area around the weld, since the support profile is double-walled in this area. As a result, the section modulus and the area moment of inertia of the carrier profile can be increased in this area without additional reinforcement elements having to be welded on in this area. The cover edge forms the fold edge of the cover. After bending, and before the two cover edges are welded together, it forms, so to speak, the new outer edge of the respective longitudinal edge.

Together with the HF welding process, a particularly high surface quality can be achieved by bending the envelopes inwards, so that carrier profiles which have been produced by a method according to the invention can be used as precision profiles.

The sheet metal is preferably formed in a process for cold rolling profiling.

The sheet is preferably a pure metal sheet without a plastic coating or the like. In any case, the base material of the sheet is shit. More preferably, the sheet is a steel sheet.

Advantageous embodiments of the present invention are the subject of the dependent claims.

According to a particularly preferred embodiment of the present invention, the carrier profile has a long side, the long side having an inner width, the welding running along the long side. By bending the envelopes On the inside, the stiffness of the long side can be increased, which in particular allows support profiles which are loaded on one side to be reinforced without increasing their external dimensions.

According to a further particularly preferred embodiment of the present invention, the carrier profile has a first width of the first envelope perpendicular to the longitudinal extent of the carrier profile and a second width of the second envelope perpendicular to the longitudinal extent of the carrier profile, the first envelope over the first length and the second envelope over the second length lie against an inside of the carrier profile. As a result, the rigidity and the area moment of inertia of the support profile can be further increased. In particular, the electrical contact between the envelopes and the inside of the carrier profile can improve the effect of the eddy currents and thus the heat input on the edges to be welded by the step of high-frequency welding.

According to a further embodiment of the present invention, the first width and the second width are each at least twice the thickness of the sheet. As a result, in particular the area of the carrier profile directly adjacent to the weld seam can be reinforced.

According to an alternative embodiment of the present invention, the sum of the first width and the second width covers at least 50% of the inside width of the long side.

According to a further preferred embodiment of the present invention, the sum of the first width and the second width essentially completely covers the inner width of the long side. As a result, a particularly stressed side wall of the support profile can be mechanically reinforced.

According to a further embodiment of the present invention, the first longitudinal edge and the second longitudinal edge abut one another. As a result, at least part of the carrier profile can be double-walled, so that its cross-sectional values can be improved without using a higher thickness of the sheet used for the production. In particular in the case of carrier profiles loaded on one side, at least a first cavity of the carrier profile can be doubled in its wall thickness. Furthermore, eddy currents flowing back on the inside of the carrier profile can, in addition to welding the edge of the first envelope to the edge of the second envelope, cause the first longitudinal edge to be welded to the second longitudinal edge.

According to a further particularly preferred embodiment of the present invention, the longitudinal edges are bent through 180 °, so that the envelopes each abut the later inside of the carrier profile, the longitudinal edges being bent such that the envelope edge, after the sheet has been formed into the carrier profile and before Welding of the two envelope edges, one end face facing the respective other envelope edge, which runs orthogonal to the respective envelope and with a first radius into an outside of the carrier profile, and with a second radius merges into the respective envelope, at least the first radius being smaller than the sheet thickness D of the sheet. The first radius is preferably less than half the sheet thickness D, more preferably less than 10% of the sheet thickness D, particularly preferably less than 2% of the sheet thickness, and very particularly preferably the first radius is so small that there is a sharp edge at this point consists. The second radius is preferably larger than the first radius and is preferably more than 30% of the sheet thickness D. In order to achieve such a geometry with a particularly small first radius and to be able to bend the longitudinal edges by as little damage as possible, in before or during the bending of the longitudinal edges, the sheet is rolled into a groove in the area of the later cover edge, in particular in the area of the first radius, the groove being introduced into the side of the sheet which is opposite the later first radius, and / or the longitudinal edge is up to thinned later envelope edge to a smaller thickness. The reduced thickness of the thinned-out longitudinal edge is preferably between 50% and 80% of the sheet thickness D. Further preferably, the end face runs straight between the first radius and the second radius, so that the end faces of the two cover edges can be brought into contact at least partially flat during welding ,

As already mentioned above, this embodiment has the advantage that the longitudinal edges can be bent through 180 ° with as little damage as possible. In addition, this makes it possible to compress the envelope edges with sharp edges on the outer circumference before welding and then to weld the envelope edges without breaking.

According to a further embodiment of the present invention, the production of the carrier profile comprises an additional step of reworking the weld, for example by grinding or planing. As a result, the quality of the surface of the weld seam can be further improved, so that particularly high surface tolerances can be achieved. During the welding, the cover edges are preferably pressed onto one another in such a way that a weld seam elevation occurs on the outside of the carrier profile, which is planed off immediately after the welding in the still hot state to achieve a high surface quality. The planing of the weld seam elevation is preferably carried out in the line at a distance of 500 mm to 700 mm from the welding point. This enables particularly economical production. This embodiment also contributes to rapid manufacture of the carrier profile. By compressing the cover edges before the welding process as described above, the cover edges do not have to be pressed or compressed as much during welding in order to achieve a clean weld seam, in particular on the outside of the carrier profile, and, after planing the weld seam overhang, to achieve a high surface quality. This also reduces the risk of cracks.

According to a further preferred embodiment of the present invention, the width of a weld seam formed by the welding is at least one times the thickness of the sheet, but is at most three times the thickness of the sheet.

More preferably, the step of high frequency welding comprises using an impedance core. In particular, a rod made of ferritic material is held in the area of the induction coil in the interior of the carrier profile, the heat input being able to be concentrated further on the edges to be welded.

The present invention also provides a carrier profile which is produced by the method according to the invention, in particular according to one of the embodiments described above.

Exemplary embodiments of the present invention are explained in more detail below with reference to drawings.

Figur 1:

einen Querschnitt eines durch ein erfindungsgemäßes Verfahren hergestellten Trägerprofils 10,

Figur 2:

eine Detailansicht eines der beiden Längsränder im Querschnitt vor dem Umbiegen mit einer eingewalzten Rille,

Figur 3:

die Detailansicht aus Figur 2 mit einem ausgedünnten Randbereich anstatt einer eingewalzten Rille,

Figur 4:

die Detailansicht aus Figur 3 nach dem Umbiegen des Längsrands,

Figur 5:

die Detailansicht aus Figur 4 nach dem Verscheißen der Umschlagkanten, und

Figur 6:

die Detailansicht aus Figur 5 nach dem Abhobeln der Schweißnahtüberhöhung.

Show it:

Figure 1:

3 shows a cross section of a carrier profile 10 produced by a method according to the invention,

Figure 2:

a detailed view of one of the two longitudinal edges in cross section before bending with a rolled-in groove,

Figure 3:

the detailed view Figure 2 with a thinned edge area instead of a rolled groove,

Figure 4:

the detailed view Figure 3 after bending the longitudinal edge,

Figure 5:

the detailed view Figure 4 after the envelope edges are wasted, and

Figure 6:

the detailed view Figure 5 after planing the weld seam overhang.

The carrier profile 10 is formed from a sheet metal 12, in particular a sheet metal strip, the sheet metal 12 having a first envelope 4 bent by 180 ° with a first envelope edge 6 and a second envelope 5 bent by 180 ° with a second envelope edge 7. By bending parallel to the longitudinal extent of the sheet 12, and thus parallel to the first longitudinal edge 2 and the second longitudinal edge 3, the sheet 12 is brought into the shape of the carrier profile 10, the first fold-over edge 6 and the second fold-over edge 7 of the formed sheet 12 lying against one another , The area of the sheet 12 lying between the first cover edge 6 and the second cover edge 7 thus forms a cladding sheet 13 of the carrier profile 10. The envelopes 4 and 5 are bent inwards in such a way that the first longitudinal edge 2 and the second longitudinal edge 3 are inside the carrier profile 10 lie. Bending and the means for carrying it out are known and are not described in detail here. The forming preferably takes place in a method for cold rolling profiling.

The carrier profile 10 encloses a first cavity 11 and a second cavity 17.

The envelopes 4 and 5 are pressed firmly against the cladding sheet 13 of the carrier profile 10 by the 180 ° bending, so that the envelopes 4 and 5 form a double-walled area of the carrier profile 10 with the cladding sheet 13. The first envelope 4 has a first width 14 and the second envelope 5 has a second width 15.

The shape of the envelopes 4 and 5 is chosen such that the point of contact of the first envelope edge 6 and the second envelope edge 7 lies in the middle of the long side 16. The sum of the first width 14 and the second width 15 essentially completely covers the inner width 9 of the long side 16.

In the welding step, the carrier profile 10 is continuously guided through at least one induction coil through which alternating current flows, a gap being present between the first cover edge 6 and the second cover edge 7, which after passing through the induction coil by pressing the first cover edge 6 and the second cover edge 7 together is closed. The side faces 8 each have a profile roll pressed together so that the material of the cover edges 6 and 7 heated to a welding temperature is welded together to form a weld seam 1. The width of the weld seam 1 is approximately twice the thickness of the sheet 12, so that the cover edges 6 and 7 are welded together over their entire thickness, but the covers 4 and 5 themselves are essentially not welded to the cover sheet 13. The means for performing high-frequency welding are already known and will not be described in detail.

By using an impedance core, which is held in the first cavity 11 enclosed by the carrier profile 10, a backflow of the eddy currents in the envelopes 4 and 5 is reduced, the heat input in the envelope edges 6 and 7 being improved, and particularly good welding being achieved ,

The surface quality of the carrier profile is further improved by a subsequent step of mechanical reworking of the weld seam 1, in particular by a step of scraping or planing.

Those skilled in the art will recognize that the invention is not limited to the above embodiment. In addition to the inner width 9 of the longitudinal side 16, the sum of the first width 14 and the second width 15 can cover the entire inner circumference of the first cavity 11, so that the first longitudinal edge 2 and the second longitudinal edge 3 lie directly against one another.

How Figure 2 shows, before or during the bending of the longitudinal edges into the sheet a groove 18 is preferably rolled in the area of the later cover edge in order to facilitate further shaping and to reduce the risk of cracks. Alternatively or additionally, the longitudinal edge is thinned to a smaller thickness up to the later cover edge, as it is Figure 3 shows. The smaller thickness is preferably between 50% and 80% of the original sheet thickness D of the sheet 12. The thinned edge area is then shaped as shown in FIG Figure 4 is shown. After the sheet metal has been formed into the carrier profile and before the two envelope edges have been welded, the resulting envelope edge 6 has one end face facing the respective other envelope edge 7, which is orthogonal to the respective envelope 4 and has a first radius R1 in an outside of the carrier profile , and with a second radius R2 merges into the envelope 4, the first radius R1 being significantly smaller than the sheet thickness D of the sheet and the second radius R2. Ideally, the edge of the cover is compressed in such a way that the first Radius R1 is particularly small and essentially forms a sharp edge. The end face facing the other envelope edge runs essentially straight between the first radius R1 and the second radius R2, so that the two envelope edges can be brought into contact at least partially over a wide area during welding, which considerably simplifies the welding process and a relatively low contact pressure during welding requires. This can reduce the risk of cracks.

How Figure 5 shows, when welding on the outer circumference there is nevertheless a certain weld seam elevation 19, which is also desirable since this weld seam elevation 19, such as Figure 6 shows, in a planing step immediately after the welding process, can be planed while still hot in order to achieve a particularly high degree of dimensional accuracy and surface quality. A certain elevation 20 also arises on the inner circumference, but due to the relatively large second radius R2 it does not protrude beyond the surface of the two envelopes 4 and 5 directed into the interior of the carrier profile.

Claims (15)

Method for producing a carrier profile (10) from a sheet (12), the sheet (12) having a first longitudinal edge (2) and a second longitudinal edge (3), the first longitudinal edge (2) and the second longitudinal edge (3) are parallel to one another, the method comprising: a. Bending the sheet (12) to the carrier profile (10), the first longitudinal edge (2) to a first envelope (4) with a first envelope edge (6) and the second longitudinal edge (3) to a second envelope (5) with a second envelope edge (7) is bent, the first envelope edge (6) and the second envelope edge (7) being in direct contact; b. Welding the first cover edge (6) and the second cover edge (7) to one another, characterized in that
the sheet (12) is bent to the carrier profile (10) such that the first (2) and the second (3) longitudinal edge lie within the carrier profile (10), the welding being carried out by a step of high-frequency welding or by a step of fusion welding is formed. A method according to claim 1, characterized in that the carrier profile (10) has a long side (16), the long side (16) having an inner width (9), and wherein the weld (1) runs along the long side (16). A method according to claim 1 or 2, characterized in that the carrier profile (10) has a first width (14) of the first envelope (4) perpendicular to the longitudinal extension of the carrier profile and a second width (15) of the second envelope (5) perpendicular to the longitudinal extension of the Carrier profile (10), wherein the first envelope (4) over the first length (14) and the second envelope (5) over the second length (15) bear against an inside of the carrier profile (10). A method according to claim 3, characterized in that the first width (14) and the second width (15) are each at least twice the thickness of the sheet (10). Method according to claims 2 and 3, characterized in that the sum of the first width (14) and the second width (15) covers at least 50% of the inside width (9) of the long side (16). A method according to claim 2 and 3, characterized in that the sum of the first width (14) and the second width (15) substantially completely covers the inner width (9) of the long side (16). Method according to one of claims 1 to 6, characterized in that the longitudinal edges (2, 3) are bent through 180 °, so that the envelopes (4, 5) each abut a later inside of the carrier profile (10), the longitudinal edges ( 2, 3) are bent over such that the cover edge (6, 7), after the sheet metal (12) has been formed into the carrier profile and before the two cover edges (6, 7) are welded, one of the other cover edge (6, 7) has facing end face, which is orthogonal to the respective envelope (4, 5) and with a first radius R1 in an outer side of the carrier profile, and with a second radius R2 in the respective envelope (4, 5), at least the first radius R1 is smaller than the sheet thickness D of the sheet (12). A method according to claim 7, characterized in that the first radius R1 is smaller than half the sheet thickness D, particularly preferably less than 10% of the sheet thickness D. A method according to claim 7 or 8, characterized in that the second radius R2 is larger than the first radius R1 and is preferably more than 30% of the sheet thickness D. Method according to one of claims 7 to 9, characterized in that a groove (18) in the area of the later cover edge (6, 7), in particular in the area , in the sheet (12) before or during the bending of the longitudinal edges (2, 3) of the first radius R1, is rolled in and / or the longitudinal edge (2, 3) is thinned to a smaller thickness up to the later turning edge (5, 6). A method according to claim 10, characterized in that the smaller thickness of the thinned longitudinal edge is between 50% and 80% of the sheet thickness D. Method according to one of claims 7 to 11, characterized in that the end face runs straight between the first radius R1 and the second radius R2, so that the end faces of the two cover edges (6, 7) can be brought at least partially into contact during welding , Method according to one of claims 1 to 12, characterized in that the cover edges (6, 7) are pressed against one another during welding in such a way that on the outside of the carrier profile (10) there is a weld seam elevation (19) which immediately after welding in the hot condition is planed. Method according to claim 13, characterized in that the planing of the weld seam elevation (19) takes place in the line at a distance of 500 mm to 700 mm from the welding point. Support profile (10) made from a sheet (12), the sheet (12) having a first longitudinal edge (2) and a second longitudinal edge (3), the first longitudinal edge (2) and the second longitudinal edge (3) being parallel to one another The sheet (12) is bent into the shape of the carrier profile (10), the first longitudinal edge (2) forming a first envelope (4) with a first envelope edge (6) and the second longitudinal edge (3) forming a second envelope (5) is bent with a second cover edge (7), the first cover edge (6) and the second cover edge (7) being in direct contact, the first cover edge (6) and the second cover edge (7) being welded to one another,
characterized in that
the first envelope (4) and the second envelope (5) are bent such that the first (2) and the second (3) longitudinal edge are inside the carrier profile (10), the first (6) and the second (7) Cover edge are high-frequency welded, the carrier profile (10) being produced in particular by a method according to one of claims 1 to 14.

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