EP3801940A1

EP3801940A1 - Facility for producing metal sheets or hollow chamber plates from extruded profiles

Info

Publication number: EP3801940A1
Application number: EP19736292.4A
Authority: EP
Inventors: Ulrich Bruhnke
Original assignee: Individual
Current assignee: Individual
Priority date: 2018-06-01
Filing date: 2019-05-24
Publication date: 2021-04-14
Anticipated expiration: 2039-05-24
Also published as: JP2021525653A; EP3801940B1; US11596992B2; US20210291246A1; JP7425752B2; DE102018004387A1; CA3106737A1; CN215998117U; DE102018004387B4; WO2019228579A1; KR20210018335A

Abstract

The invention relates to a facility for producing metal sheets (19) from extruded profiles (7) of low thickness or hollow chamber plates (20) consisting of a light metal, preferably magnesium or magnesium alloys, comprising an extruder (1) for producing an extruded profile (7) which is open along a generating line, a separating device (6) for cutting the extruded profile (7) to length according to the length of the metal sheet (19) or the hollow chamber plate (20) to be produced, a bending unit (4) for deforming the extruded profile (7) into a U-shaped profile (7), an expansion unit (3) for expanding the U-shaped profile (7) into a flat metal sheet (18) or a hollow chamber plate (20), and a stacking unit (5), wherein at least one expansion unit (3) is arranged parallel to the extrusion line and, as such, extrusion and expansion processes can be separated from each other.

Description

Plant for the production of metal sheets or hollow panels

Extrusions

The invention relates to a plant for the production of metal sheets from round or approximately round thin-walled extruded profiles or hollow panels, which are made in particular of magnesium or magnesium alloys, by means of an extrusion. As a hollow chamber plates are plate-shaped

Extruded profiles with attached to opposite profile walls

Inner webs and at least two mutually adjacent a common inner web having hollow chambers, which also called web or

Be named double-skin sheets.

Generally known is the production of sheets by casting liquid alloy between two rolls and subsequent numerous rolling and heat treatment processes. Due to the large number of rolling passes from coarse to thin sheet, this process is very costly. The steps are necessary in order to obtain a formable kneading structure from a cast structure. The high number of rolling passes is costly.

DE 43 33 500 C2 discloses a method for producing a im

Cross-sectionally stepped and solid profile sheet having different wall thickness, in which first a semi-finished product is produced, whose cross section is similar to the cross section of the sheet in the thickness direction, and in which of Semi-finished a sheet is rolled, wherein for the production of the semifinished product

Hollow profile with circumferentially distributed, the desired wall thickness profile of the semifinished product corresponding wall thickness profile is extruded, while the hollow profile is separated along a surface line and formed into the semifinished product. Furthermore, two complementary profiles are superimposed, wherein at least one of the profiled contact sides of the complementary profiles is provided with a release agent, and the two complementary profiles are rolled out simultaneously with cylindrical, that is unampled rolls. Before rolling, the two complementary profiles are separated on two opposite generatrices.

In each case two parts are produced by this method. Of the

Production process is discontinuous and only relatively narrow parts can be produced. A disadvantage is further that due to the manufacture of the finished with two different wall thicknesses semi-finished product and a stepped roller assembly of the manufacturing process is relatively expensive.

From DE 10 2008 048 Al a method for the production of sheet metal parts and a device for carrying out the method is known. The method comprises the steps of extruding or continuously casting a tubular body, cutting open the tubular body in its longitudinal direction, widening the tubular body into a flat body, rendering the flat body into a component that conforms to the drawing by means of production technologies known per se. The device essentially consists of a linking of a melting unit, a continuous casting or extrusion unit, a longitudinal cutting device, a rolling stand, one or more forming units.

From DE 10 2007 002 322 Al a process for the production of sheet metal or sheet metal parts made of light metal, preferably magnesium, is known, wherein in one or more preceding process steps an extruded in an open structure or a closed structure with subsequent slitting to one open structure is produced and this is then subjected in one or more steps a straightening and directional bending over several rolling and bending stages.

GB 2469 549 A describes a method for producing a support structure, preferably a support structure for a vehicle seat with at least one seat shell for the seat part and / or the backrest of the vehicle seat, with the method steps producing a metallic semifinished product and forming the same to a in the Substantially planar sheet metal, separating a sheet metal part from the sheet and deforming the sheet metal part, wherein the production of the metallic semifinished product is carried out by extrusion.

US 2,681,764 A describes a device for extruding wide sheets, comprising a die element with a base portion in the form of an elongated U-shaped slot for producing a profile in a U-shape, which is then flattened.

Describes the conversion of metal tubes into flat strips by separating the tubes in the longitudinal direction and widening means of a double flight and subsequent rolling.

US 3,002,255 A describes a process for the production of continuous metal strips and the like. Fabrication is accomplished by sequentially extruding a plurality of blocks in a shape other than flat, stepwise flattening following extrusion, and holding the mold under tension during the flattening step and winding the previously flattened strips during each extrusion step. GB 556 061 A describes an improvement in the production of iron and steel sheets from pipes which are continuously produced by casting. After leaving the die of the extruder these are cut longitudinally and widened by means of forming rollers and smoothed.

Describes a method and apparatus for the continuous production of metal strips, wherein a workpiece is a punch for forming a tube having a circular cross-section and a slot formed therein is opened and the tube by Nachaussenbiegen in opposite directions in the slot area and flattened.

EP 2996825 Bl describes a method and a plant for the production of metal sheets of rope-shaped profiles of small thickness, in particular of magnesium or magnesium alloys, wherein the emerging from the extrusion die is extruded profile is formed into a metal sheet. The plant consists of an extruder with a die producing the extrusion profile and a deformation unit adjoining the die, wherein the deformation unit consists of a separation unit for separating the extruded profile according to the length of the metal sheet to be produced, a Aufbiegeeinheit for U-shaped bending of the profile and a take-up unit for rolling up the U-shaped profile to a metal sheet.

The object of the invention is that a plant for the production of metal sheets of round or approximately round thin-walled extruded profiles or hollow panels, in particular magnesium or magnesium alloys, indicate, wherein emerging from an extrusion die, preferably open extruded profile to a metal sheet or a Hollow chamber plate is widened and the expansion process is decoupled from the extrusion process.

According to the invention this object is achieved by the specified embodiment of the characterizing features mentioned in claim 1. The emerging from the extrusion of an extruder open extruded profile is separated according to the length of the metal sheet or the hollow panel to be produced, the longitudinal gap of the open extruded profile extended, preferably to an approximately U-shaped profile, and then transferred to a Aufweiteinheit in which it is expanded to a flat sheet or plate and then in a stacking unit is filed. The system has at least one, preferably two, expansion units, which are arranged parallel to the extrusion direction. Are manufactured sheet plates with a thickness <5.0 mm, preferably with a thickness in the range <2.5 mm, in particular from 1.0 to 1.5 mm or hollow chamber plates.

In a first step, emerging from the die extrusion profile is separated according to the length of the metal sheet to be produced and in a second step, the longitudinal gap of the open extruded profile is expanded, preferably to an approximately U-shaped profile. In the subsequent third step, the U-shaped profile is placed in a Aufweiteinheit and detected by means of clamping devices on the longitudinal sides of the U-shaped profile and deformed by means of the outwardly moving clamping devices to a metal sheet or hollow panel.

The deformation of the open extruded profile to a metal sheet or hollow panel can also be done alternatively by at least one pair of rollers, which is retracted into the open extruded profile and by moving the individual roles each in the direction of the longitudinal edge areas.

Another possibility of forming the Aufweiteinheit is that the retractable from a combination of gripping elements and two movable in the U-shaped profile rollers is formed. To protect the surface of the metal sheet to be produced, the rollers can be provided with a heat-resistant elastic surface coating. The roles that are used here are designed so that they do not cause surface damage. One way to expand an open extruded profile to a metal sheet or a flat hollow panel is to reshape the open extruded profile by means of a 3-roll unit to a metal sheet or a hollow panel.

The 3-roll unit of Aufweiteinheit consists of two mutually parallel upper rollers and an adjustable in the longitudinal direction of the upper rollers lower rollers. For the transport of the profile through the 3-roller unit, a feed unit, preferably consisting of a pair of rollers, is provided.

Another way to expand the open extruded profile is that the profile is used with its opening up in the Aufweiteinheit and then the 3-roll unit is retracted, the upper rollers inside the profile and the lower roller outside the Profils are provided. Moving the 3-roll unit to the left and right widen the profile to a metal sheet or a hollow panel.

The deformation to the metal sheet or hollow chamber plate is preferably carried out in a temperature range above 200 ° C and in a dry, preferably an inert, atmosphere.

The plant for the production of a metal sheet from an extruded profile consists essentially of an oven for heating the extrusion billets on extrusion, an extruder with die for extruding a hollow profile open in the longitudinal direction, a separator for cutting the extruded profile and a Aufbiegeeinheit. Parallel to this Aufbiegeeinheit at least one expansion unit and an adjoining stacking unit are provided. For calibrating the expanded metal sheets or hollow panels can be provided between the Aufweiteinheit and the stacking unit, a calibration and embossing unit in which the metal sheet between two heated stamping plates warm embossed, that is leveled. The calibration and embossing unit can be designed in the form of a simple hydraulic press.

The deposition of the metal sheets in the stacking unit is preferably carried out by a robot, which receives the metal sheet or hollow chamber plates either from the expansion or the calibration and embossing unit with its suction cups and stores in the stacking unit.

As separating means for cutting the extruded profile according to the length of the metal sheet can be applied to machining or non-chipping means. For example, saws can be used as cutting separators, while jet nozzles, laser cutting devices or wedge cutting or biting are used as non-cutting dividing devices.

Advantageous developments and refinements of the invention can be seen from the remaining subclaims and from the embodiment described in principle below.

Reference to an embodiment of the invention will be described in more detail. Show it

Fig. 1 - prinzigmäßiger structure of the system

Fig. 2 - Detail of the plant

Fig. 3 a - b - cutting to length of the hollow profile

Fig. 4 - section A-A

Fig. 5, 5 a-c - expansion process of the U-shaped profile

Fig. 6 - U-shaped multi-chamber profile

Fig. 7 - Calibration and embossing unit Fig. 8 - embodiment of an expansion unit

Fig. 9 - Process of the manufacturing process

1 shows the basic structure of the plant for the production of metal sheets of extruded profiles. The plant consists essentially of an extruder 1 for producing an extruded profile 7 with an upstream furnace 2 for heating the extrusion billet 8 on extrusion, a Aufbiegeeinheit 4, which is arranged in the extrusion direction after the extruder 1, a separator 6 for cutting the extruded profile 7 - hereinafter referred to as hollow section 7 -, and two parallel to the extrusion direction Aufweiteinheit 3 with subsequent stacking unit. 5

All facilities of the system are concatenated with each other, wherein the transfer of the U-shaped profile 7 to the expansion unit 3 and the expanded profile 7 to the stacking unit 5 and optionally to the intermediate calibration and embossing unit by handling devices, preferably by industrial robots takes place , For this purpose, the handling devices are provided with mechanical or pneumatic gripping systems.

Figure 2 shows a section of the plant for the production of metal sheets of extruded profiles 7. The in the oven 2 to extrusion temperature between 200 and 520 ° C, preferably to 470 ° C, heated extrusion billet 8 is in the recipient 10 of the extruder 1 and pressurized by the die 9 to an open profile 7, d. H. the profile 7 is slotted in the longitudinal direction, pressed out. FIG. 4 shows a section A-A through the extruded profile 7.

After pressing a predetermined length of the profile 7, the extruder is stopped and the profile 7 cut to length by the separator 6 according to the length of the metal sheet to be produced. 3a shows a variant of the separating device 6 for cutting the open profile 7. The cutting of the hollow section 7 from the extruded strand is carried out by a wedge cutting device 14, in which one or several wedge cutting wheels 14 circumferentially separate the profile 7 from the strand. The wedge cutting wheel (s) separate the material that lies on a support and is forced apart by moving the wedge-shaped blades. The pad is formed by extending the piercer 12.

Another variant of the cutting of the hollow section 7 from the strand is shown in Figure 3b. On the outside of the profile 7 is an annular abutment. Into the interior, the wedge cutting device 14 is retracted. At the end of two opposite, hydraulically movable wedge cutting wheels are arranged and separate with simultaneous rotational movement of the material. The pressurization and the rotation of the wedge cutter 14 is carried out by the drive and hydraulic device 15th

The wedge or Beißschneiden has the advantage that it does not form chips or splinters as a chipless separation process that would otherwise have to be removed consuming in the cutting area of the surface.

After cutting to length of the profile 7 this is cleared in extruder, d. H. slotted in the longitudinal direction and placed on the angle rails 11 of the Aufbiegeeinheit 4 profile 7 is moved out of the range of the separator 6. Subsequently, the bending of the profile 7 in U-shape (Figure 5) by moving apart of the angle rails 11th

The U-shaped bent profile 7 is detected by means of a handling device, not shown, and spent in the expansion unit 3. Here the U-shaped profile 7 is completely widened. For this purpose, the profile 7 is inserted with its longitudinal sides in the rotatably mounted clamping units 16, wherein the profile 7 is deformed by moving apart of the clamping units 16 to form a flat sheet. FIGS. 5 a to 5 c show the individual sections of the widening of the profile 7 to form a flat metal sheet 19. The inserted into the clamping units 14 of the widening unit 3 U-shaped bent profile 7 is clamped by the clamping rail 18 in the clamping unit 16. The clamping takes place by pressurizing the clamping rail 18. For this purpose, at least two hydraulic cylinders 17 are arranged along the outer side of the clamping rails over the length thereof.

By driving the clamping units 16, the U-shaped profile 7 is expanded to a flat metal sheet 19 (Figure 5 c). Subsequently, the metal sheet 19 is detected by a handling device, preferably by means of suction pads, and stored in the stacking unit 5.

If the metal sheets 19 still have unevenness after the expansion process, these are transferred before depositing in the stacking unit 5 to a calibrating or embossing unit. For this purpose, the metal sheet 19 is tensioned on the transverse side and retracted by linear drive in the calibration and embossing station. In the calibration and embossing unit, the metal sheet 19 is embossed warm, eliminating any existing bumps.

The calibration and embossing unit is formed by two mutually movable heated stamping plates 24, wherein the stamping plates 24 can be opened and closed by a simple hydraulic press.

After the calibration and embossing process, the metal sheet is picked up by a handling device with suction gripper and stored in the stacking unit 5.

In a further embodiment, the production of hollow chamber plates 20 will be described. FIG. 6 shows the extruded profile 7 produced by means of the extruder 1, which forms the basis for a hollow comb plate 20. The extruded profile 7 is designed such that it assumes the shape of a flat hollow chamber plate 20 after the expansion. The bottom 22 of the hollow comb plate 20, the extruded profile 7 is formed such that the portions of the bottom 22 and top 21 between the inner webs 23 have the same length, whereby the portions of the bottom 22 between the inner webs 23 are arcuate. After the expansion process then have the sections between the inner webs 23 on the bottom 22 and the top 21 the same length.

The emerging in a first step from the die of the extruder 1 extruded profile 7 is separated according to the hollow chamber plate 20 to be produced. As a separator 6 is preferably a cutting separator, z. As a saw used. This is connected to a suction for the chips.

Subsequently, the extruded profile 7 is bent by means of the Aufbiegeeinheit 4 to a U-shaped profile 7 and further spent in a Aufweiteinheit 3. The bending to a U-shaped profile 7 takes place by moving apart the angle rails 11 of the Aufbiegeeinheit. 4

In the expansion unit 3, the U-shaped profile 7 is expanded to a flat hollow chamber plate 20. After the expansion process, the hollow chamber plate 20 is placed in a calibration and embossing unit.

The calibrating and embossing unit is shown schematically in FIG. It consists essentially of two mutually movable heated stamping plates 24 between which the hollow chamber plate 20 is disposed during the calibration and stamping process. As a result, the hollow comb plates 20 are brought to a uniform level with respect to the distance between the top and bottom 21, 22 and at the same time directed. FIG. 8 shows a further embodiment of the expansion unit. This consists essentially of a 3-roller unit 25, the two top rollers 26 and a top roller 26 movable bottom roller 27. Before the 3-roller unit 25, a pair of rollers 28 is arranged, with the help of the profile 7 in the 3-rollers Unit 25 and is transported by this.

After detecting the longitudinal side (front edge) of the profile 7 by the pair of rollers 28, this is pushed in the direction of the 3-roller unit. When the leading edge of the profile 7 reaches the second top roller 26, the bottom roller 27 is moved in the direction of the top rollers 26. With the further pushing through of the profile 7 by the 3-roller unit 25, this is converted into a flat metal sheet 19, d. h., It widened from the U-shaped profile 7 to the metal sheet 19. This can be followed by a calibration or embossing step or the metal sheet 19 can be stored immediately in the stacking unit 5.

In the figure 9, the flow of the manufacturing process is shown in simplified form. Starting from the extrusion pin 8, a tubular open extruded profile 7 is produced by means of an extruder 1 and separated by means of a separator 6 according to the length of the metal sheet 19 or the hollow chamber plate 20 from the strand. Subsequently, the extruded profile 7 is bent U-shaped. After transfer to a widening unit 3, the extrusion press profile 7 is expanded to a metal sheet 19 or a hollow comb plate 20.

All parts of the system, which come into contact with the U-shaped profile 7 or the metal sheet 19 and the hollow comb plate 20 are provided with a coating, preferably with a ceramic material, or of a magnesium-compatible material to a direct contact with an iron material to prevent exist.

The inventive plant for the production of metal sheets or hollow panels of extruded profiles has the advantage that the expansion process to a flat plate or to a hollow chamber plate is decoupled from the extrusion process, whereby the number of cycles for the production can be substantially increased.

The extrusion of magnesium sheets has the further advantage of being able to produce very low sheet thicknesses in a single process step and thus represents an alternative to rolling or casting rolls.

Here, not only very small sheet thicknesses can be realized, but also produce very wide sheets by the extrusion of hollow sections, for example of pipes. Likewise, it is also possible to produce very wide hollow chamber plates by means of the extrusion process. The width is given over the circumference of the

Extruded profiles according to the formula u = d * n. For example, with a pipe diameter of 300 mm, a sheet metal with a width of approx. 942 mm can be produced.

[0055] Reference symbol:

1 extruder

2 oven

3 expansion unit

4 bending unit

5 stacking unit

6 separating device

7 extruded profile / profile

8 extrusion bolts

9 matrix

10 recipient

11 angle rail

12 piercer

13 counter bearings

14 wedge cutting device

15 drive and hydraulic unit

16 clamping unit

17 hydraulic cylinders

18 clamping rail

19 metal sheet

20 hollow chamber plate

21 top

22 bottom

23 inner bridge

24 stamping plates

25 3-roller unit

26 top roller

27 lower roller

28 pair of rollers

Claims

protection claims

1.

Plant for the production of metal sheets (19) of extruded profiles of small thickness or of hollow-wall panels (20) of light metal, preferably of magnesium or magnesium alloys, comprising an extruder (1) for producing an extruded profile (7) open along its surface line, a separating device (6) for cutting the extruded profile (7) according to the length of the metal sheet (19) or the hollow chamber plate (20) to be produced, a bending unit (4) for widening the longitudinal gap of the open extruded profile (7), a widening unit (3) for widening the open extruded profile (7) in a flat metal sheet (18) or a hollow chamber plate (20) and a stacking unit (5), wherein at least one expansion unit (3) is arranged parallel to the extrusion line and thus extrusion and expansion process are decoupled from each other.

Second

Plant according to claim 1,

characterized in that

between the expansion unit (3) and the stacking device (5) a calibration or embossing device is arranged.

Third

Plant according to claim 1 and 2,

characterized in that

the calibration or embossing unit is formed from two mutually movable heated embossing plates (24), wherein the calibration or embossing unit is designed in the form of a simple hydraulic press.

4th

Plant according to claim 1 to 3,

characterized in that

the expansion unit (3) is formed by two divisible and rotatable clamping devices (16), this consisting of a U-shaped rail and arranged therein by at least two hydraulic cylinders (17) acted upon clamping rails (18).

5th

Plant according to claim 1 to 3,

characterized in that

the widening unit (3) is formed by a 3-roller unit (25), wherein the 3-roller unit (25) consists of two upper rollers (26) arranged parallel to one another and a lower roller (27) movable in the direction of the upper rollers (26) ), and the 3-roller unit is associated with a feed or transport unit.

6th

Plant according to claims 1 to 5,

characterized in that

all parts of the system which come into contact with the hollow section profile, the open extruded profile (7) or the metal sheet (19) are provided with a coating or consist of a material compatible with magnesium in order to prevent direct contact with a ferrous material.

7th

Plant according to claims 1 to 6,

characterized in that

the separating device (5) for the production of flat metal sheets (18) is designed as a non-splitting separating device, preferably as a wedge or bite cutting device.

8th.

Plant according to claims 1 to 6,

characterized in _/ that

the separating device (5) for producing planar hollow chamber profiles (20) is designed as a cutting separating device, preferably as a saw in combination with a suction device for the chips.

9th

Plant according to claim 1,

characterized in that

all facilities of the system are linked together, wherein the transfer of the u-shaped hollow profile (7) to the expansion unit (3) and the expanded flat sheet metal plate (19) to the stacking unit (5) and optionally to the intermediate calibrating and embossing device by handling equipment , which are provided with mechanical or pneumatic gripping systems takes place.