JP2004167572A

JP2004167572A - Steel transverse member, and method and system for manufacturing the same

Info

Publication number: JP2004167572A
Application number: JP2002337491A
Authority: JP
Inventors: Yoshiaki Harigai; 義昭針谷
Original assignee: Tsuka Kanamono KK
Current assignee: Tsuka Kanamono KK
Priority date: 2002-11-21
Filing date: 2002-11-21
Publication date: 2004-06-17
Anticipated expiration: 2022-11-21
Also published as: JP3944594B2

Abstract

PROBLEM TO BE SOLVED: To provide a lightweight steel transverse member with sufficient strength, and a method and a system for manufacturing the same. SOLUTION: A steel sleeper 10 comprising a first member B1 constituting one side and a second member B2 constituting the remaining side is manufactured by performing caulk-joining so that joined portion of the first member B1 with the second member B2 forms a self-reinforcing portion. A manufacturing system comprises a first member forming unit 40 to roll-form the first member B1 in a predetermined shape, a second member forming unit 50 to roll-form the second member B2 in a predetermined shape, and a joining unit 60 to caulk-join the first member B1 with the second member B2. COPYRIGHT: (C)2004,JPO

Description

【０００１】
【発明の属する技術分野】
本発明は、鋼製横材、その製造方法および製造システムに関する。さらに詳しくは、例えば鋼製大引や鋼製根太として適用される鋼製横材、その製造方法および製造システムに関する。
【０００２】
【従来の技術】
従来より、住宅の床支持部材として大引や根太が用いられている。この大引や根太の材質は、従来、木材とされていた。しかしながら、木製大引や木製根太には、次のような問題があった。
【０００３】
（１）いわゆる木やせによる問題がある。例えば、木やせにより床鳴りが生ずるという問題がある。
【０００４】
（２）防蟻対策や防腐対策のための薬剤処理が必要である。この薬剤処理の過程において環境汚染が生ずるおそれが大きい。また、薬剤処理に従事する作業者の健康を損なうおそれがあるので、その対策を講ずる必要がある。
【０００５】
（３）森林破壊による環境悪化を招来する。
【０００６】
かかる木製大引の問題を解消すべく、大引の材質を鋼製としたものが種々提案されかつ実施されている。
【０００７】
例えば、特開平８ー４２５３号公報には、図２４に示すように、鋼板を断面が略逆台形状となるように折り曲げ成形するとともに、両側面に補強リブ１１１を設けてなる鋼製大引１１０が提案されている。また、特開２０００−７３５２７号公報には、図２５に示すように、鋼板を断面が略長方形状となるように折り曲げ成形するとともに、両側面に補強リブ１２１を設けてなる鋼製大引１２０が提案されている。
【０００８】
前記各提案に係る鋼製大引１１０、１２０は、１枚の鋼板を折り曲げ成形してなるものとされているので、その軽量化には一定の限度がある。
【０００９】
すなわち、鋼板が１枚ものよりなる鋼製大引１１０、１２０における板厚は、荷重が最も集中する部分で所定の強度を充足するようにしなければなず、その結果この荷重集中面と反対側の分散荷重が作用する面では板厚が過剰、つまり過剰品質となるということになる。例えば、鋼製大引１１０がその上面における他部材との接触が面接触（全面接触）となって荷重分散が図られる一方、その下面がごく限られた範囲における面接触（局所接触）や点接触となって荷重集中が生じているような態様で使用される場合、鋼製大引１１０の板厚は集中荷重を受ける下面がその集中荷重に耐えるようにしなければならないため、上面では過剰品質となる。その結果、鋼製大引１１０、１２０の重量をいたずらに増加させているということになる。
【００１０】
このことは鋼製根太についても同様であり、集中荷重が作用する面の板厚によりその全体の板厚が決定されることになり、軽量化が困難であるといった問題がある。
【００１１】
【発明が解決しようとする課題】
本発明はかかる従来技術の課題に鑑みなされたものであって、充分な強度を有しながらより一層の軽量化がされてなる鋼製横材、その製造方法および製造システムを提供することを目的としている。
【００１２】
【課題を解決するための手段】
本発明の鋼製横材は、１面を形成する第１材と、残りの面を形成する第２材とを備えてなる鋼製横材であって、前記鋼製横材が自己補強型鋼製横材とされてなることを特徴とする。
【００１３】
本発明の鋼製横材においては、第１材と第２材とがかしめにより接合されてなるのが好ましい。
【００１４】
また、本発明の鋼製横材においては、第１材のかしめ部背後に対応する個所に係合外れ防止部および／または横滑り防止部が形成されてなるのが好ましい。
【００１５】
さらに、本発明の鋼製横材においては、第１材と第２材との板厚が異なっているのが好ましい。その場合、第１材の板厚が第２材の板厚より厚くされてなるのがさらに好ましい。
【００１６】
さらに、本発明の鋼製横材においては、第１材の材質と第２材の材質とが異なっているのが好ましい。
【００１７】
さらに、本発明の鋼製横材においては、第１材が所定間隔または適宜間隔で配設されてなるのが好ましい。
【００１８】
さらに、本発明の鋼製横材においては、補強リブ、位置決めビードなどが成形されてもよい。
【００１９】
さらに、本発明の鋼製横材においては、かしめ部内側にローレット加工がされてなるのが好ましい。
【００２０】
本発明の鋼製横材の製造方法は、１面を形成する第１材と、残りの面を形成する第２材とを備えてなる鋼製横材の製造方法であって、第１材と第２材との接合部を自己補強部とするよう接合する手順を含んでいることを特徴とする。
【００２１】
本発明の鋼製横材の製造方法は、具体的には、第１材の側端部を緩係合部に成形する手順と、第２材の側端部を緩係合部に成形する手順と、前記緩係合部が成形された第２材を溝状に成形する手順と、第１材の緩係合部と、第２材の緩係合部とを係合する手順と、第１材と第２材との係合部をかしめる手順とを含んでいることを特徴とする。
【００２２】
あるいは、本発明の鋼製横材の製造方法は、第１材の側端部を緩係合部に成形する手順と、第２材の側端部を緩係合部に成形する手順と、前記緩係合部が成形された第２材を溝状に成形する手順と、第１材を所定間隔または適宜間隔でその緩係合部を第２材の緩係合部に係合する手順と、第１材と第２材との係合部をかしめる手順とを含んでいることを特徴とする。
【００２３】
本発明の鋼製横材の製造方法においては、第１材と第２材との係合を、第２材の両側面が内側に倒された状態で第１材を係合位置まで降下させながら、第２材の両側面を起こすことによりなすのが好ましい。
【００２４】
また、本発明の鋼製横材の製造方法においては、かしめを数次にわたってなすのが好ましい。
【００２５】
さらに、本発明の鋼製横材の製造方法においては、第１材のかしめ部背後に対応する個所に係合外れ防止部および／または横滑り防止部を形成する手順が付加されているのが好ましい。
【００２６】
さらに、本発明の鋼製横材の製造方法においては、第１材および／または第２材の成形時に、補強リブ、位置決めビードなどの成形も併せてなすのが好ましい。
【００２７】
さらに、本発明の鋼製横材の製造方法においては、第１材の成形を平板を順送しながらなすのが好ましい。
【００２８】
さらに、本発明の鋼製横材の製造方法においては、第２材の成形を平板を順送しながらなすのが好ましい。
【００２９】
さらに、本発明の鋼製横材の製造方法においては、第１材と第２材の係合およびその係合部のかしめを第１材および第２材を同時に順送しながらなすのが好ましい。
【００３０】
さらに、本発明の鋼製横材の製造方法においては、かしめ部内側にローレット加工をなすのが好ましい。
【００３１】
さらに、本発明の鋼製横材の製造方法においては、第１材および／または第２材の成形をロール成形法によりなすのが好ましい。
【００３２】
本発明の鋼製横材の製造システムは、１面を形成する第１材と、残りの面を形成する第２材とを備えてなる鋼製横材の製造システムであって、前記製造システムは、第１材と第２材との接合部が自己補強部となるように接合するよう構成されてなることを特徴とする。
【００３３】
本発明の鋼製横材の製造システムは、具体的には、第１材を所定形状に成形する第１材成形部と、第２材を所定形状に成形する第２材成形部と、第１材と第２材とを接合する接合部とを備えなるものとされる。
【００３４】
本発明の鋼製横材の製造システムにおいては、第２材成形部と接合部とが直線状に配設されてなるのが好ましい。
【００３５】
また、本発明の鋼製横材の製造システムにおいては、第１材成形部が第２材成形部の上方に配設されてなるのが好ましい。
【００３６】
さらに、本発明の鋼製横材の製造システムにおいては、第１材成形部が第１材成形装置を備え、該第１材成形装置がロール成形により第１材の側端部を緩係合部に成形するよう構成されてなるのが好ましい。
【００３７】
さらに、本発明の鋼製横材の製造システムにおいては、第１材成形装置が、ロール成形により第１材のかしめ部背後に対応する位置個所に係合外れ防止部および／または横滑り防止部も併せて成形するよう構成されてなるのが好ましい。
【００３８】
さらに、本発明の鋼製横材の製造システムにおいては、第１材成形装置が、ロール成形により補強リブ、位置決めビードなども併せて成形するよう構成されてなるのが好ましい。
【００３９】
さらに、本発明の鋼製横材の製造システムにおいては、第２材成形部が第２材成形装置を備え、該第２材成形装置がロール成形により第２材の側端部を緩係合部に成形するよう構成されてなるのが好ましい。
【００４０】
さらに、本発明の鋼製横材の製造システムにおいては、第２材成形装置が、ロール成形により補強リブ、位置決めビードなども併せて成形するよう構成されてなるのが好ましい。
【００４１】
さらに、本発明の鋼製横材の製造システムにおいては、接合部が接合装置を備え、該接合装置が第１材と第２材とを所定の位置関係とする位置調整機構と、第１材と第２材とを係合させる係合機構と、係合された第１材と第２材とをかしめるかしめ機構とを備えてなるのが好ましい。
【００４２】
さらに、本発明の鋼製横材の製造システムにおいては、位置調整機構が、第２材を先細溝状に成形するロール成形部を有してなるのが好ましい。
【００４３】
さらに、本発明の鋼製横材の製造システムにおいては、係合機構が、先細溝状とされた第２材の側面を起こすロール成形部を有してなるのが好ましい。
【００４４】
さらに、本発明の鋼製横材の製造システムにおいては、かしめ機構が、少なくとも１次かしめロール成形部および仕上げかしめロール成形部を有してなるのが好ましい。
【００４５】
さらに、本発明の鋼製横材の製造システムにおいては、かしめロール成形部は、中通し部材に上下に配設された上側かしめロールと下側かしめロールとを有し、該上側かしめロール外周面と該下側かしめロール外周面とが接触させられてなるのが好ましい。
【００４６】
さらに、本発明の鋼製横材の製造システムにおいては、中通し部材が、上側かしめロールおよび下側かしめロールの前後にガイドロールを有してなるのが好ましい。
【００４７】
さらに、本発明の鋼製横材の製造システムにおいては、接合装置が、ローレット加工機構を有してなるのが好ましい。
【００４８】
ここで、鋼製横材は、例えば鋼製大引とされ、１面が上面とされたり、あるいは鋼製横材が鋼製根太とされ、１面が下面とされる。
【００４９】
【作用】
本発明の鋼製横材は、前記の如く構成されているので、所望強度を確保しながら鋼製大引や鋼製根太などの鋼製横材の一層の軽量化が図られる。
【００５０】
また、本発明の鋼製横材の製造方法および製造システムは、前記の如く構成されているので、所望強度が確保されかつ一層の軽量化が図られてなる鋼製大引や鋼製根太などの鋼製横材を製造できる。
【００５１】
【発明の実施の形態】
以下、添付図面を参照しながら本発明を実施形態に基づいて説明するが、本発明はかかる実施形態のみに限定されるものではない。
【００５２】
実施形態１
図１〜図３に、本発明の実施形態１に係る鋼製横材製造方法により製造される鋼製横材を示す。なお、この実施形態１においては、鋼製横材は、具体的には鋼製大引とされる。
【００５３】
鋼製大引１０は、図１に示すように、断面が正方形状あるいは長方形状とされてなるもの（図示例では７５ｍｍＷｘ７５ｍｍＨの正方形）であって、上面１１を形成する第１材Ｂ１と、両側面１２，１３および下面１４を形成する第２材Ｂ２との２材からなり、上面１１側端部と側面１２，１３上端部とをかしめにより接合してなるものである。このため、鋼製大引２０の上面角部は４層構造となって自己補強部が形成され、同一の板厚からなる通常の角パイプや１材により加工成形されてなる鋼製大引より強度が格段に上昇する。
【００５４】
鋼製大引１０は、具体的には図１に示すように、上面１１側端部を下方内側に折り曲げて横Ｕ字状の係合部１１ａとする一方、側面１２（１３）上端部を前記横Ｕ字状の係合部１１ａとは逆向きの横Ｕ字状の係合部１２ａ（１３ａ）とし、両係合部１１ａ，１２ａ（１１ａ，１３ａ）を係合させた後に、両者をかしめて接合してなるものである。また、図１に示すように、側面１２，１３上端部の係合部１２ａ，１３ａの背後に対応する個所上面部分がＶ状（またはＵ状）の陥没部１１ｂとされて、側面１２，１３上端部と上面１１側端部とにより形成されるかしめ部１５における係合外れや横滑りが生じないようにされている。つまり、陥没部１１ｂは、係合外れ防止部や横滑り防止部とされる。なお、かしめ部１５などの第１材Ｂ１と第２材Ｂ２との接合部が前掲したように補強部として機能する鋼製大引１０を、本明細書においては自己補強型鋼製大引ということにする。
【００５５】
また、大引１０の側面１２，１３には大引１０の縦圧縮剛性を向上させるように、リブ１２ｃ、１３ｃを設けてもよい。
【００５６】
ここで、第１材Ｂ１は、防錆処理がなされた鋼板（板厚：０．８ｍｍ）とされる。例えば、溶融亜鉛−５％アルミニウムめっき鋼板（板厚：０．８ｍｍ）、高耐食溶融亜鉛−６％アルミニウム−３％マグネシウムめっき鋼板（板厚：０．８ｍｍ）などとされる。また、第２材Ｂ２は、防錆処理がなされた鋼板（板厚：０．６ｍｍ）とされる。例えば、溶融亜鉛−５％アルミニウムめっき鋼板（板厚：０．６ｍｍ）、高耐食溶融亜鉛−６％アルミニウム−３％マグネシウムめっき鋼板（板厚：０．６ｍｍ）などとされる。
【００５７】
以下、かかる構成とされた鋼製大引１０の製造システムを説明する。
【００５８】
図４に、鋼製大引１０の製造システムＳの一例をブロック図で示す。同図に示すように、製造システムＳは、第１材Ｂ１の成形をなす第１材成形部４０と、第２材Ｂ２の成形をなす第２材成形部５０と、成形後の第１材Ｂ１および第２材Ｂ２の接合をなす接合部６０とを備えてなるものとされる。ここで、第２材成形部５０と接合部６０とは一直線状に配設され、また第１材成形部４０は第２材成形部５０の上方に配設されるものとされる。
【００５９】
第１材成形部４０は、第１材Ｂ１の素材となるプレートコイル４１を保持するコイル保持部４２と、プレートコイル４１からプレートを巻き出すアンコイラー４３と、第１材成形装置４５とを備えてなるものとされる。なお、第１材成形装置４５における成形方法に応じて、第１材成形装置４５の前段にレベラー４４を配設しプレートの巻きぐせを取るようにしても良い。
【００６０】
第１材成形装置４５は例えばロールフォーミング機械からなり、図５に横断面形状をフラワー図で示すように、プレートコイル４１から巻き出され、図示しないシャーウェルダにより所定長さに溶断されるプレート、すなわち第１材Ｂ１（同図（ａ）参照）を順送しながら、同図（ｂ）、（ｃ）、（ｄ）に示すよう段階的にロール成形し、係合部１１ａ、１１ａおよび陥没部１１ｂ、１１ｂを形成していくものとされる。また、係合部１１ａ、１１ａの成形に併せて、センター表示やビス位置を示す識別標識として利用されるビード１１ｃを成形するようにしても良い。このビード１１ｃの成形は、例えばロールのビード１１ｃ成形個所を所定形状に凸部とすることによりなし得る。
【００６１】
ここで、係合部１１ａ、１１ａは、接合部６０により第１材Ｂ１を第２材Ｂ２と接合する際に、係合部１１ａ、１１ａと、係合部１２ａ、１３ａとの係合が容易となるように、断面形状が最終的な断面形状（前掲図１参照）よりもやや開いたＵ字形となるように成形される、つまり緩係合部に成形される（図５（ｄ）参照）。
【００６２】
第２材成形部５０は、第２材Ｂ２の素材となるプレートコイル５１を保持するコイル保持部５２と、プレートコイル５１からプレートを巻き出すアンコイラー５３と、第２材成形装置５５とを備えてなるものとされる。なお、第２材成形装置５５における成形方法に応じて、第２材成形装置５５の前段にレベラー５４を配設しプレートの巻きぐせを取るようにしても良い。
【００６３】
第２材成形装置５５は例えばロールフォーミング機械からなり、プレートコイル５１から巻出され、シャーウェルダにより所定長さに溶断されるプレート、すなわち第２材Ｂ２（同図（ｅ）参照）を順送しながら、同図（ｆ）、（ｇ）、（ｈ）、（ｉ）、（ｊ）に示すよう段階的にロール成形し、係合部１２ａ、１３ａを形成するとともに、下面１４を残して両側を折り曲げるようにして側面１２、１３を形成して第２材Ｂ２を溝状に成形するものとされる。また、係合部１２ａ、１３ａの成形に併せて、センター表示やビス位置を示す識別標識としてリブ１２ｃ、１３ｃやビード１４ａを成形してもよい。なお、リブ１２ｃ、１３ｃやビード１４ａの成形は、例えばロールのリブ１２ｃ、１３ｃやビード１４ａに対応する個所を所定形状の凸部とすることによりなし得る。
【００６４】
ここで、係合部１２ａ、１３ａは第１材Ｂ１の係合部１１ａ、１１ａと同様に最終的な断面形状（前掲図１参照）よりもやや開いたＵ字形断面形状に成形される、つまり緩係合部に成形される。
【００６５】
接合部６０は、具体的には接合装置６１とされる。接合装置６１は、例えば第１材と第２材とを係合可能なように位置調整する位置調整機構と、位置調整された第１材と第２材とを係合する係合機構と、係合された第１材と第２材とをかしめるかしめ機構と、かしめ部内側にローレット加工をなすローレット加工機構とを備えたロールフォーミング機械からなり、第１材Ｂ１および第２材Ｂ２を同時に順送しながら、第１材成形装置４５によって図５（ｄ）の状態まで成形された第１材Ｂ１の係合部（緩係合部）１１ａ、１１ａと、第２材成形装置５５によって図５（ｊ）の状態まで成形された第２材Ｂ２の係合部（緩係合部）１２ａ、１３ａとを係合（緩係合）させ、その緩係合部かしめるようにして第１材Ｂ１と第２材Ｂ２とを本係合させて接合する。
【００６６】
以下、第１材成形装置４５、第２材成形装置５５および接合装置６１をより具体例に説明する。
【００６７】
図６および図７に、第２材成形装置５５および接合装置６１を構成するロールフォーミング機械を示す。なお、第１材成形装置４５は第２材成形装置５５と同様の構成とされ、別ラインとして第２材成形装置５５の上方に構成してもよく、また第１材成形装置４５および第２材成形装置５５は、例えば成形ロール８０（後掲する）およびスタンド７２を第１材成形装置４５のものと第２材成形装置５５のものとを交換するようにして構成してもよい。
【００６８】
図６に示すように、第２材成形装置５５は、エントリーガイド７１により幅方向の位置決めがなされた第２材Ｂ２を長手方向に送りながら、つまり順送しながら段階的に成形していくように、各段階に対応する所定形状とされた成形ロール８０（図７参照）を成形ロール支持スタンド（以下、単にスタンドという）７２、７２、…により個別に支持し、各スタンド７２、７２、…を水平かつタンデムに配列してなるものとされる。
【００６９】
ここで、成形ロール８０は、各成形ロール８０に対応して設けられ入力軸が相互に直列に接続されるウォーム減速機（不図示である）を介して図示しないメインモータにより駆動される。
【００７０】
図７に、第２材成形装置５５を構成する成形ロール８０の一例を示す。成形ロール８０は上側ロール８１および下側ロール８２からなる２段ロールとされる。なお、図示例の成形ロール８０は、側面１２、１３を形成するよう下面１４を残して第２材Ｂ２の両側を折り曲げていく工程（以下、側面形成工程ともいう）の１つに対応するものとされる。
【００７１】
この側面形成工程において、上側ロール８１は軸受８１ａにより軸支される、下面１４の幅と略等しい厚さの円板形状とされる。また、下側ロール８２は、上側ロール８１の外周面と対向するように配設される下面１４の幅と略等しい軸方向長さの小径部分８２ａと、小径部分８２ａの軸方向両側に所定の傾斜角度θで軸方向外側に向かって径が直線的に増大するように形成される径漸増部８２ｂ、８２ｃとを有する糸巻形状とされ、上側ロール８１と同様に軸受８２ｄにより軸支される。
【００７２】
しかして、第２材Ｂ２は上側ロール８１外周面と下側ロール８２の小径部分８２ａ外周面との間に下面１４実施部分が挟まれた状態で送られ、側面１２、１３が前掲傾斜角度θまで折り曲げられる。すなわち、第２材Ｂ２の送りの上流側から下流側に向かって上側ロール８１の傾斜角度θを段階的に大きくするよう各成形ロール８０を配列することによって、前掲図５に示すように側面１２、１３を段階的に折り曲げ成形することが可能となる。
【００７３】
接合装置６１は、図６に示すように、後掲する所定形状の各成形ロール８０を軸支するスタンド７２、７２、…を第２材成形装置５５の各スタンド７２と一直線に並べるようにして構成される。ここで、第２材成形装置５５と接合装置６１との接続部分には釣支機構７３により支持される角鋼材からなる中通し部材７４が下流側に向けて延伸させて配設されている。
【００７４】
以下、図８〜図１８を参照して、接合装置６１を詳細に説明する。図８は、位置調整機構により実施される、第２材Ｂ２と第１材Ｂ１とを接合する接合工程の第１段階（以下、第１接合工程という）を示す。図９は、接合装置６１を構成する実機の第１接合工程実施部分を示す写真図である。図１０は、係合機構により実施される第２接合工程を示す。図１１は、接合装置６１を構成する実機の第１接合工程実施部分と後続の各接合工程実施部分との配置を示す写真図である。図１２は、かしめ機構（１次かしめ機構）により実施される第３接合工程を示す。図１３は、第３接合工程の補足説明図である。図１４は、かしめ機構（２次かしめ機構）により実施される第４接合工程を示す。図１５は、ローレット加工機構により実施される第５接合工程を示す。図１６、図１７、図１８は、第５接合工程の補足説明図である。
【００７５】
第１接合工程
図８および図９に示すように、第１接合工程は、接合装置６１先端の成形ロール８０Ａ（図９、図１１参照）において、第２材成形装置５５により所定形状（図５（ｊ）参照）に成形された第２材Ｂ２と、第１材成形装置４５により所定形状（図５（ｄ）参照）に成形された第１材Ｂ１とを接合するために、所定の位置関係に調整する工程とされる。
【００７６】
第１接合工程の成形ロール８０Ａは、上側ロール８１Ａおよび下側ロール８２Ａを有するとともに、第２材Ｂ２の両側に配され、側面１２、１３の下面１４となす底外角θ_Ａ、θ_Ｂ（図８参照）が直角よりも大きい角度（例えば９３°）となるように側面１２、１３を内側に傾けるようにして押える横ロール８３、８３（図９参照）を有してなるものとされる。成形ロール８０Ａがかかる構成とされていることにより、第２材Ｂ２は側面１２，１３が内側に倒された先細溝状に成形される。
【００７７】
下側ロール８２Ａは、中空部分Ｄに中通し部材７４が通された第２材Ｂ２を下支えしつつ下流側に送るように回転する。一方、上側ロール８１Ａは中通し部材７４の上部板材７４ａ上面に載置されるようにして合流される第１材Ｂ１を上部板材７４ａとの間に挟みながら下流側に送るよう回転する。ここで、上部板材７４ａは例えば硬質樹脂製とされ、上面に載置された第１材Ｂ１との摩擦が小さくなるようされている。
【００７８】
また、この段階で第１材Ｂ１の係合部（緩係合部）１１ａ、１１ａと第２材Ｂ２の係合部（緩係合部）１２ａ、１３ａとを干渉させないように、上部板材７４ａは座金７４ｃを介装させて中通し部材７４の上面に設けられるものとされる。これにより、上部板材７４ａ上面が第２材Ｂ２の中空部分Ｄ開口面から所定高さ上方に位置するようされている（図８参照）。
【００７９】
また、図６に示すように、第１材Ｂ１は上面視で第２材Ｂ２と長手方向を一致させるようにして手前から斜めに差込まれ、ロール８３によって幅方向の位置決めがなされるようにして第２材Ｂ２に添えられる。
【００８０】
第２接合工程
図１０および図１１に示すように、第２接合工程は、第１接合工程の下流側に配される成形ロール８０Ｂにおいて実施される、第１材Ｂ１の係合部（緩係合部）１１ａ、１１ａと、第２材Ｂ２の係合部（緩係合部）１２ａ、１３ａとをかしめの実行が可能な状態に係合させる工程とされる。
【００８１】
すなわち、第２接合工程実施部分において中通し部材７４は、両側にカムフォロワ７５、７５が設けられ、これにより先細溝状に成形された側面１２、１３を底外角θ_Ａ、θ_Ｂが直角となるように内側から拡げると同時に、第１材Ｂ１を係合部１１ａ、１１ａが第２材Ｂ２の係合部１２ａ、１３ａと係合する所定位置（以下、係合位置という）に支持するように、座金を介装することなく直接に本体７４ｂ上面に設けられる上部板材７４ｄにより、１材Ｂ１を支持するようにしてなるものとされる。これにより、各係合部１１ａ、１１ａ、１２ａ、１３ａが係合するように側面１２、１３が拡げられる。
【００８２】
また、成形ロール８０Ｂの下側ロール（図示省略）は第２材Ｂ２を下支えしつつ下流側に送るように回転し、上側ロール（図示省略）は上部板材７４ｄとの間に第１材Ｂ１を挟んで下流側に送るように回転する。
【００８３】
第３接合工程
図１２および図１３に示すように、第３接合工程は、側面１２、１３の底外角θ_Ａ、θ_Ｂ（図８、図１０参照）を直角に保ちつつ係合部１１ａ、１１ａ、１２ａ、１３ａを緩やかにかしめる工程（１次かしめ工程）とされる。すなわち、図１３に片側のみを示すように、第３接合工程実施部分において中通し部材７４は、第２材Ｂ２の送りの方向に並べて配設されるカムフォロワ（ガイドロール機構）７５、７５と、各カムフォロワ７５、７５の中間位置に上下に並べて配設される、一対のかしめロール７６（７６Ａ、７６Ｂ）とが両側に配設されてなるものとされる。なお、図１２においては、中心線より右側がカムフォロワ７５、７５の配設位置における断面を示し、中心線より左側がかしめロール７６Ａ、７６Ｂの配設位置における断面を示す。
【００８４】
ここで、カムフォロワ（ガイドロール機構）７５、７５の外側面とかしめロール７６Ａ、７６Ｂの外側面とは一致するものとされる。これにより、かしめ中における側面１２，１３の移動や変形が抑制される。また、上側かしめロール７６Ａの外周面と下側かしめロール７６Ｂの外周面とは接するものとされる。
【００８５】
また、成形ロール８０Ｃの上側ロール８１Ｃおよび下側ロール８２Ｃと、上側かしめロール７６Ａおよび下側かしめロール７６Ｂとは軸心が１つの平面に含まれるように配設される。
【００８６】
しかして、第３接合工程においては、上流側のカムフォロワ７５によりガイドされて、第２材Ｂ２の中空部分にかしめロール７６Ａ、７６Ｂが通され、係合部（緩係合部）１１ａ、１１ａ、１２ａ、１３ａが上側かしめロール７６Ａと成形ロール８０Ｃの上側ロール８１Ｃとにより挟圧されて緩やかにかしめられる。つまり、１次かしめがなされる。
【００８７】
このとき上側かしめロール７６Ａに掛る荷重は軸７６ａにより受けられるとともに、下側かしめロール７６Ｂの軸７６ｂ、および第２材Ｂ２の下面１４を介して下側かしめロール７６Ｂの外周面と当接するようされた成形ロール８０Ｃの下側ロール８２Ｃにより受けられる。
【００８８】
これによって、大きな押圧力によって各係合部１１ａ、１１ａ、１２ａ、１３ａをかしめながら上側かしめロール７６Ａの軸７６ａに掛る荷重を小さくすることができ、例えばすべり軸受により軸支するようされた軸７６ａの焼き付きを防止することが可能となる。
【００８９】
第４接合工程
図１４に示すように、第４接合工程は、第３接合工程で緩やかにかしめられた係合部１１ａ、１１ａ、１２ａ、１３ａを成形ロール８０Ｄ（図１１参照）において強固にかしめる工程（２次かしめ工程、仕上げかしめ工程）とされる。すなわち、第４接合工程実施部分において中通し部材７４は、両側にそれぞれ一対のかしめロール７６Ｃ、７６Ｄおよび７６Ｅ、７６Ｆが設けられるものとされる。
【００９０】
ここで、第４接合工程実施部分における上側かしめロール７６Ｃ、７６Ｅは、第３接合工程実施部分における上側かしめロール７６Ａと同一形状、同一寸法とされる。また、４接合工程実施部分における下側かしめロール７６Ｄ、７６Ｆも、第３接合工程実施部分における下側かしめロール７６Ｂと同一形状、同一寸法とされる。また、中通し部材７４における上側かしめロール７６Ｃ、７６Ｅおよび下側かしめロール７６Ｄ、７６Ｆの配設の位置関係も第３接合工程実施部分におけるのと同一とされる。つまり、第３接合工程実施部分におけるかしめロール７６Ａ、７６Ｂ（ここでは片側のみが図示されている）と、第４接合工程実施部分におけるかしめロール７６Ｃ、７６Ｄ、７６Ｅ、７６Ｆとは全く同一の構成とされる。これによりツールの製造コストの上昇が抑えられる。
【００９１】
その一方で、上側かしめロール７６Ｃ、７６Ｅ外周面と成形ロール８０Ｄの上側ロール８１Ｄとの間隙は第３接合工程におけるよりも小さくされる。
【００９２】
しかして、第３接合工程において係合部１１ａ、１１ａ、１２ａ、１３ａが緩やかにかしめられた、第１材Ｂ１および第２材Ｂ２の中空部分にかしめロール７６Ｃ、７６Ｄ、７６Ｅ、７６Ｆが通され、上側かしめロール７６Ｃ、７６Ｅと成形ロール８０Ｄの上側ロール８１Ｄとにより挟圧されて係合部１１ａ、１１ａ、１２ａ、１３ａが強固にかしめられる。つまり、２次かしめ（仕上げかしめ）がなされる。
【００９３】
また、第４接合工程においても第３接合工程におけると同様に、かしめの際の荷重が軸７６ｃ、７６ｄおよび下側ロール８２Ｄにより受けられる。
【００９４】
第５接合工程
図１５、図１６、図１７および図１８に示すように、第５接合工程は、第４接合工程で強固にかしめられた、つまり仕上げかしめがなされた係合部１１ａ、１１ａ、１２ａ、１３ａを成形ロール８０Ｅ（図１１参照）において、係合部１１ａ、１１ａ、１２ａ、１３ａ間の滑りが生じないようにかしめる工程とされる。
【００９５】
すなわち、第５接合工程実施部分において中通し部材７４は両側にローレット７７、７７および支持ロール７８、７８、つまりローレット加工機構が設けられるものとされる。
【００９６】
ローレット７７は、図１８に示すように、係合部１１ａ、１１ａ、１２ａ、１３ａを上側ロール８１Ｅと挟圧する挟圧部分７７ａの外周面にダイヤモンド形の凹凸７７ｂ、７７ｂ、…が多数設けられてなるものとされ、これにより係合部１１ａ、１１ａの内側に数ミリ間隔で横溝を付けるようにしてかしめ部全体のかしめ強度を増強し、それにより係合部１１ａ、１１ａ、１２ａ、１３ａ間に滑りが生じないようにすることが可能となる。なお、図１８中、符号７７ｃはローレット軸を示す。
【００９７】
図１６に示すように、支持ロール７８、７８はローレット７７、７７の上流側および下流側にそれぞれ配設されており、ベース８４に立設される支柱８５、８５により軸支されるロールフォロワ７９、７９と第２材Ｂ２下面１４を間に挟んで当接し、これにローレット加工の際に中通し部材７４に掛る荷重を受けるものとされる。
【００９８】
このように、この実施形態１の横材製造システムＳは、荷重の集中する鋼製大引１０の上面１１を厚めの第１材Ｂ１から構成し、それ以外の面１２、１３、１４を薄めの第２材Ｂ２から構成するように、係合部１１ａ、１１ａ、１２ａ、１３ａの係合が容易にできる状態に各材Ｂ１、Ｂ２をそれぞれロール成形し、各材Ｂ１、Ｂ２の成形と連続的にロール成形により係合部１１ａ、１１ａ、１２ａ、１３ａをかしめるようにして、第１材Ｂ１と第２材Ｂ２とを接合するものとされる。なお、第１材Ｂ１は予め図５（ｄ）にまで成形しておき、第２材Ｂ２の接合部６０への順送に同期させて接合部６０に順送するようにしてもよい。
【００９９】
これにより、従来は加工の困難性や寸法管理の困難さに起因して試みられることさえなかった、２材のかしめ接合による横材の製造が実現される。この結果、充分な強度を有しながらより一層の軽量化が図られてなる鋼製大引１０を製造することが可能となる。
【０１００】
実施形態２
図１９〜図２１に、本発明の実施形態２に係る鋼製横材を示す。なお、この実施形態２では鋼製横材は、具体的には鋼製根太とされる。
【０１０１】
鋼製根太２０は、図１９に示すように、断面が略長方形（図示例では４５ｍｍＷｘ５０ｍｍＨ）とされてなるものであって、下面２１を形成する第１材Ｂ３と、両側面２２，２３および上面２４を形成する第２材Ｂ４との２材からなり、下面２１側端部と側面２２，２３下端部とをかしめにより接合してなるものである。
【０１０２】
すなわち、図１９に示すように、下面２１側端部を上方内側に折り曲げて横Ｕ字状の係合部２１ａとする一方、側面２２（２３）下端部を前記横Ｕ字状の係合部２１ａとは逆向きの横Ｕ字状の係合部２２ａ（２３ａ）とし、両係合部２１ａ，２２ａ（２１ａ，２３ａ）を係合させた後に、両者をかしめて接合してなるものである。また、図１９に示すように、側面２２（２３）下端部の係合部２２ａ（２３ａ）の背後に位置する下面部分がＶ状（またはＵ状）の陥没部２１ｂとされて、側面２２（２３）下端部と下面２１側端部とにより形成されるかしめ部２５における係合外れや横滑りが生じないようにされている。つまり、陥没部２１ｂは係合外れ防止部あるいは横滑り防止部とされる。
【０１０３】
ここで、第１材Ｂ３は、防錆処理がなされた鋼板（板厚：０．６ｍｍ）とされる。例えば、溶融亜鉛−５％アルミニウムめっき鋼板（板厚：０．６ｍｍ）、高耐食溶融亜鉛−６％アルミニウム−３％マグネシウムめっき鋼板（板厚：０．６ｍｍ）などとされる。また、第２材Ｂ４は防錆処理がなされた鋼板（板厚：０．４ｍｍ）とされる。例えば、溶融亜鉛−５％アルミニウムめっき鋼板（板厚：０．４ｍｍ）、高耐食溶融亜鉛−６％アルミニウム−３％マグネシウムめっき鋼板（板厚：０．４ｍｍ）などとされる。
【０１０４】
また、この鋼製根太２０においては、かしめ部２５が下面２１側端部に位置するようにされているので、かしめ部２５は鋼製根太２０が鋼製大引１０に載置された際に補強部（自己補強部）として機能する。
【０１０５】
なお、このようにかしめ部２５などの第１材Ｂ３と第２材Ｂ４との接合部が補強部材あるいは補強部として機能する鋼製根太２０を、本明細書においては自己補強型鋼製根太ということにする。
【０１０６】
しかして、かかる構成とされている鋼製根太２０は、実施形態１の鋼製大引１０と同様に製造される。これにより、充分な強度を有しながらより一層の軽量化が図られてなる鋼製根太の製造が可能となる。
【０１０７】
実施形態３
図２２に、本発明の実施形態３に係る鋼製横材を示す。この実施形態３の鋼製横材は、実施形態１の鋼製大引１０を改変してなるものであって、図２２に示すように、第１材Ｂ１Ａを所定ピッチ（間隔）あるいは適宜ピッチ（間隔）で配設して鋼製大引１０Ａとしてなるものである。例えば、根太が載置される個所にのみ第１材Ｂ１Ａを配設して上面１１Ａを形成してなるものである。この場合、第１材Ｂ１Ａの板厚を実施形態１の第１材Ｂ１の板厚よりも厚くしても鋼製大引の軽量化の妨げにはならない。
【０１０８】
なお、この実施形態３の鋼製大引１０Ａのその余の構成は、実施形態１の鋼製大引１０と同様とされている。
【０１０９】
このように、この実施形態３の鋼製大引１０Ａは、第１材Ｂ１Ａを所定ピッチあるいは適宜ピッチで配設してなるものであるから、所望強度を確保しながら鋼製大引の軽量化が一層促進される。
【０１１０】
実施形態４
図２３に、本発明の実施形態４に係る鋼製横材を示す。この実施形態４の鋼製横材は、実施形態２の鋼製根太２０を改変してなるものであって、図２３に示すように、第１材Ｂ３Ａを所定ピッチあるいは適宜ピッチで配設して鋼製根太２０Ａとしてなるものである。例えば、鋼製根太２０Ａの鋼製大引１０に載置される個所にのみ第１材Ｂ３Ａを配設して下面２１Ａを形成してなるものである。この場合、第１材Ｂ３Ａの板厚を実施形態２の第１材Ｂ３の板厚よりも厚くしても鋼製根太の軽量化の妨げにはならない。
【０１１１】
なお、この実施形態４の鋼製根太２０Ａのその余の構成は、実施形態２の鋼製根太２０と同様とされている。
【０１１２】
このように、この実施形態４の鋼製根太２０Ａは、第１材Ｂ３Ａを所定ピッチあるいは適宜ピッチで配設してなるものであるから、所望強度を確保しながら鋼製根太の軽量化が一層促進される。
【０１１３】
以上、本発明を実施形態に基づいて説明してきたが、本発明はかかる実施形態のみに限定されるものではなく、種々改変が可能である。例えば、実施形態では第１材と第２材とは同材質とされているが、第１材と第２材とは異種材質されてもよい。例えば、第１材をステンレス鋼板とし、第２材を通常鋼板とすることもできる。また、板厚の組合せもその使用態様に応じて適宜とできる。そして、こうすることにより、所望強度を確保しながら、一層の軽量化が図られる。
【０１１４】
さらに、実施形態ではかしめは１次かしめおよび２次かしめの２回かしめとされているが、材質および板厚に応じて３次かしめ、４次かしめの多数回かしめとされてもよい。
【０１１５】
【発明の効果】
以上詳述したように、本発明の鋼製横材によれば、鋼製大引や鋼製根太などの鋼製横材を所望強度を確保しながら一層の軽量化が図られるという優れた効果が得られる。
【０１１６】
また、本発明の鋼製横材の製造方法および製造システムによれば、所望強度を確保しながら一層の軽量化が図られてなる鋼製横材を製造できるという優れた効果が得られる。
【図面の簡単な説明】
【図１】本発明の実施形態１に係る横材製造方法により製造される鋼製大引を示す横断面図である。
【図２】同鋼製大引の側面図である。
【図３】同鋼製大引の上面図である。
【図４】本発明の第１実施形態に係る横材製造方法が適用された製造システムの概略構成を示すブロック図である。
【図５】鋼製大引を構成する各材の各成形段階における横断面形状を一覧可能に表したフラワー図である。
【図６】成形装置を構成する実機としてのロールフォーミング機械の概略構成を示す側面図である。
【図７】同ロールフォーミング機械を構成する成形ロールの一例を示す２面図であって、同（ａ）は正面図を示し、同（ｂ）は側面図を示す。
【図８】接合装置における第１接合工程実施部分を示す断面図である。
【図９】同第１接合工程実施部分を示す写真図である。
【図１０】接合装置における第２接合工程実施部分を示す断面図である。
【図１１】接合装置における各接合工程実施部分の配置を示す写真図である。
【図１２】接合装置における第３接合工程実施部分を示す断面図である。
【図１３】第３接合工程実施部分の側面図である。
【図１４】接合装置における第４接合工程実施部分を示す断面図である。
【図１５】接合装置における第５接合工程実施部分を示す断面図である。
【図１６】第５接合工程実施部分の側面図である。
【図１７】第５接合工程実施部分全体を示す断面図である。
【図１８】ローレットの形状を示す部分断面図である。
【図１９】本発明の実施形態２に係る横材製造方法により製造される鋼製根太を示す横断面図である。
【図２０】同鋼製根太の側面図である。
【図２１】同鋼製根太の上面図である。
【図２２】本発明の実施形態３に係る横材製造方法により製造される鋼製大引を示す斜視図である。
【図２３】本発明の実施形態４に係る横材製造方法により製造される鋼製根太を示す斜視図である。
【図２４】特開平８ー４２５３号公報に提案されている鋼製大引の断面図である。
【図２５】特開２０００ー７３５２７号公報に提案されている鋼製大引の断面図である。
【符号の説明】
１０鋼製大引
１１上面
１２，１３側面
１５かしめ部
２０鋼製根太
２１下面
２２，２３側面
２５かしめ部
２０鋼製根太
４０第１材成形部
４５第１材成形装置
５０第２材成形部
５５第２材成形装置
６０接合部
６１接合装置
８０成形ロール
Ｓ製造システム
Ｂ１，Ｂ３第１材
Ｂ２，Ｂ４第２材[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a steel cross member, a method for manufacturing the same, and a manufacturing system. More specifically, the present invention relates to a steel cross member applied as, for example, a steel pulling bar or a steel joist, a method of manufacturing the same, and a manufacturing system thereof.
[0002]
[Prior art]
Conventionally, pulling and joists have been used as floor support members for houses. The material of the pulling and joist was conventionally wood. However, wooden pulling and wooden joists have the following problems.
[0003]
(1) There is a problem due to so-called thin wood. For example, there is a problem that the floor noise is caused by a thin tree.
[0004]
(2) Chemical treatment is required for termite control and antiseptic measures. There is a great possibility that environmental pollution will occur in the course of this chemical treatment. In addition, there is a risk that the health of workers engaged in chemical treatment may be impaired, so it is necessary to take countermeasures.
[0005]
(3) Environmental degradation due to deforestation is caused.
[0006]
In order to solve the problem of wooden pulling, various types of pulling made of steel have been proposed and implemented.
[0007]
For example, Japanese Unexamined Patent Publication No. Hei 8-4253 discloses a steel pulley formed by bending a steel sheet so that its cross section has a substantially inverted trapezoidal shape and providing reinforcing ribs 111 on both sides as shown in FIG. 110 have been proposed. Japanese Patent Application Laid-Open No. 2000-73527 discloses a steel pulley 120 formed by bending a steel sheet so as to have a substantially rectangular cross section and providing reinforcing ribs 121 on both side surfaces, as shown in FIG. Has been proposed.
[0008]
Since the steel pullers 110 and 120 according to the above proposals are formed by bending a single steel plate, there is a certain limit in weight reduction.
[0009]
That is, the thickness of the steel pulleys 110 and 120 made of one steel plate must satisfy a predetermined strength at the portion where the load is concentrated most, and as a result, the opposite side of this load concentration surface Means that the plate thickness is excessive, that is, the quality is excessive. For example, while the steel pulley 110 is in surface contact (overall contact) with other members on its upper surface, load distribution is achieved, while surface contact (local contact) or point in a very limited range on its lower surface. When used in such a manner that load concentration occurs due to contact, the thickness of the steel pulley 110 must be such that the lower surface receiving the concentrated load can withstand the concentrated load. It becomes. As a result, the weight of the steel pulleys 110 and 120 is unnecessarily increased.
[0010]
This is the same for steel joists, and the overall thickness is determined by the thickness of the surface on which the concentrated load acts, and there is a problem that it is difficult to reduce the weight.
[0011]
[Problems to be solved by the invention]
The present invention has been made in view of the problems of the related art, and has an object to provide a steel cross member having a sufficient strength and further reduced weight, a method of manufacturing the same, and a manufacturing system thereof. And
[0012]
[Means for Solving the Problems]
The steel cross member of the present invention is a steel cross member including a first member forming one surface and a second member forming the remaining surface, wherein the steel cross member is a self-reinforcing type. It is characterized by being made of a steel cross member.
[0013]
In the steel cross member of the present invention, it is preferable that the first member and the second member are joined by caulking.
[0014]
Further, in the steel cross member of the present invention, it is preferable that a disengagement prevention portion and / or a side slip prevention portion are formed at a position corresponding to the back of the caulked portion of the first material.
[0015]
Furthermore, in the steel cross member of the present invention, it is preferable that the first member and the second member have different plate thicknesses. In this case, it is more preferable that the thickness of the first material is made larger than the thickness of the second material.
[0016]
Further, in the steel cross member of the present invention, it is preferable that the material of the first material and the material of the second material are different.
[0017]
Further, in the steel horizontal member according to the present invention, it is preferable that the first members are arranged at predetermined intervals or at appropriate intervals.
[0018]
Further, in the steel cross member of the present invention, a reinforcing rib, a positioning bead, or the like may be formed.
[0019]
Further, in the steel cross member of the present invention, it is preferable that the inner side of the caulked portion is knurled.
[0020]
The method for producing a steel cross member according to the present invention is a method for producing a steel cross member comprising a first material forming one surface and a second material forming the remaining surface, wherein the first material is provided. And a step of joining the joint between the first member and the second material so as to form a self-reinforcing portion.
[0021]
Specifically, in the method of manufacturing a steel cross member according to the present invention, the procedure of forming the side end of the first material into the loosely engaging portion and the step of forming the side end of the second material into the loosely engaging portion are provided. A procedure, a step of forming the second material having the loosely-engaged portion formed into a groove, a procedure of engaging the loosely-engaged portion of the first material, and the loosely-engaged portion of the second material, Caulking the engaging portion between the first material and the second material.
[0022]
Alternatively, the method for manufacturing a steel cross member according to the present invention includes a step of forming a side end of the first material into a loosely engaging portion, a step of forming a side end of the second material into a loosely engaging portion, A procedure of forming the second material having the loosely-engaged portion into a groove shape, and a procedure of engaging the first material with the loosely-engaged portion of the second material at predetermined intervals or at appropriate intervals. And a step of caulking the engaging portion between the first material and the second material.
[0023]
In the method for manufacturing a steel cross member according to the present invention, the engagement between the first member and the second member is performed by lowering the first member to the engagement position in a state where both side surfaces of the second member are turned inward. However, it is preferable to raise by raising both side surfaces of the second material.
[0024]
In the method for manufacturing a steel cross member according to the present invention, it is preferable to perform caulking several times.
[0025]
Further, in the method of manufacturing a steel cross member according to the present invention, it is preferable that a procedure for forming a disengagement prevention portion and / or a side slip prevention portion is added at a position corresponding to a position behind the caulked portion of the first material. .
[0026]
Furthermore, in the method for manufacturing a steel cross member according to the present invention, it is preferable to form a reinforcing rib, a positioning bead, and the like at the time of forming the first material and / or the second material.
[0027]
Further, in the method for manufacturing a steel cross member according to the present invention, it is preferable that the forming of the first member is performed while progressively feeding the flat plate.
[0028]
Furthermore, in the method for manufacturing a steel cross member according to the present invention, it is preferable that the forming of the second material is performed while the flat plate is being fed in order.
[0029]
Further, in the method for manufacturing a steel cross member according to the present invention, it is preferable that the engagement between the first member and the second member and the caulking of the engagement portion be performed while simultaneously feeding the first member and the second member simultaneously. .
[0030]
Further, in the method for producing a steel cross member according to the present invention, it is preferable to perform knurling on the inside of the caulked portion.
[0031]
Further, in the method for producing a steel cross member according to the present invention, it is preferable that the forming of the first material and / or the second material is performed by a roll forming method.
[0032]
A manufacturing system for a steel cross member according to the present invention is a steel cross member manufacturing system including a first material forming one surface and a second material forming the remaining surface, wherein the manufacturing system Is characterized in that it is configured such that a joint between the first material and the second material is joined so as to be a self-reinforcing portion.
[0033]
Specifically, the steel horizontal member manufacturing system of the present invention includes a first material forming unit that forms a first material into a predetermined shape, a second material forming unit that forms a second material into a predetermined shape, It is provided with a joining portion for joining the first material and the second material.
[0034]
In the steel horizontal member manufacturing system of the present invention, it is preferable that the second material forming part and the joining part are arranged linearly.
[0035]
Further, in the steel horizontal member manufacturing system of the present invention, it is preferable that the first material forming part is disposed above the second material forming part.
[0036]
Further, in the steel cross bar manufacturing system of the present invention, the first material forming section includes a first material forming device, and the first material forming device loosely engages the side end of the first material by roll forming. Preferably, it is configured to be formed into a part.
[0037]
Further, in the system for manufacturing a steel cross member according to the present invention, the first material forming device may include a disengagement prevention portion and / or a side slip prevention portion at a position corresponding to a position behind the caulked portion of the first material by roll forming. It is preferable that it is configured to be molded together.
[0038]
Further, in the steel horizontal member manufacturing system of the present invention, it is preferable that the first material forming device is configured to also form the reinforcing rib, the positioning bead, and the like by roll forming.
[0039]
Further, in the steel horizontal member manufacturing system according to the present invention, the second material forming unit includes a second material forming device, and the second material forming device loosely engages the side end of the second material by roll forming. Preferably, it is configured to be formed into a part.
[0040]
Further, in the steel horizontal member manufacturing system of the present invention, it is preferable that the second material forming device is configured to also form the reinforcing rib, the positioning bead, and the like by roll forming.
[0041]
Further, in the steel horizontal member manufacturing system according to the present invention, the joining portion includes a joining device, and the joining device has a position adjusting mechanism for bringing the first material and the second material into a predetermined positional relationship; It is preferable to include an engagement mechanism for engaging the first material and the second material, and a caulking mechanism for caulking the engaged first material and the second material.
[0042]
Further, in the steel horizontal member manufacturing system of the present invention, it is preferable that the position adjusting mechanism has a roll forming part that forms the second member into a tapered groove shape.
[0043]
Further, in the steel horizontal member manufacturing system of the present invention, it is preferable that the engagement mechanism has a roll forming portion that raises the side surface of the tapered groove-shaped second member.
[0044]
Further, in the steel horizontal member manufacturing system of the present invention, it is preferable that the caulking mechanism has at least a primary caulking roll forming part and a finish caulking roll forming part.
[0045]
Further, in the steel horizontal member manufacturing system of the present invention, the caulking roll forming unit has an upper caulking roll and a lower caulking roll disposed vertically on the through member, and the upper caulking roll outer peripheral surface. It is preferable that the lower caulking roll is brought into contact with the outer peripheral surface thereof.
[0046]
Further, in the steel horizontal member manufacturing system of the present invention, it is preferable that the intermediate member has guide rolls before and after the upper caulking roll and the lower caulking roll.
[0047]
Further, in the steel horizontal member manufacturing system according to the present invention, it is preferable that the joining device has a knurling mechanism.
[0048]
Here, the steel horizontal member is, for example, a steel bar, and one surface is an upper surface, or the steel horizontal member is a steel joist and one surface is a lower surface.
[0049]
[Action]
Since the steel cross member of the present invention is configured as described above, it is possible to further reduce the weight of a steel cross member such as a steel bar and a steel joist while maintaining a desired strength.
[0050]
In addition, since the method and system for manufacturing a steel cross member according to the present invention are configured as described above, a steel pulling bar, a steel joist, and the like, in which desired strength is secured and weight is further reduced. Can be manufactured.
[0051]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, the present invention will be described based on embodiments with reference to the accompanying drawings, but the present invention is not limited to only such embodiments.
[0052]
Embodiment 1
1 to 3 show a steel cross member manufactured by the steel cross member manufacturing method according to the first embodiment of the present invention. In the first embodiment, the steel cross member is specifically a steel bar.
[0053]
As shown in FIG. 1, the steel puller 10 has a square or rectangular cross section (75 mmW × 75 mmH square in the illustrated example), and includes a first material B1 forming the upper surface 11 and both sides. It is made of two materials, the surface 12 and the second material B2 forming the lower surface 14, and the upper end of the upper surface 11 and the upper end of the side surfaces 12 and 13 are joined by caulking. For this reason, the upper corner portion of the steel pulley 20 has a four-layer structure to form a self-reinforcing portion, and is formed by a normal square pipe having the same thickness and a steel pulley formed by one material. The strength increases significantly.
[0054]
Specifically, as shown in FIG. 1, the steel puller 10 bends the upper end of the upper surface 11 inward to form a horizontal U-shaped engaging portion 11 a, while forming the upper end of the side surface 12 (13). After making the horizontal U-shaped engaging portion 11a the opposite direction to the horizontal U-shaped engaging portion 12a (13a), and engaging the two engaging portions 11a, 12a (11a, 13a), It is formed by caulking. Also, as shown in FIG. 1, the upper surface portion corresponding to the upper part of the side surfaces 12, 13 behind the engaging portions 12a, 13a is a V-shaped (or U-shaped) recessed portion 11b, and the side surfaces 12, 13 are formed. The crimping portion 15 formed by the upper end portion and the end portion on the upper surface 11 side is prevented from being disengaged or slipping. That is, the depressed portion 11b is a disengagement prevention portion or a side slip prevention portion. In addition, the steel pulley 10 in which the joint between the first material B1 and the second material B2 such as the caulked portion 15 functions as a reinforcing portion as described above is referred to as a self-reinforcing steel pulley in this specification. I will.
[0055]
Further, ribs 12 c and 13 c may be provided on the side surfaces 12 and 13 of the large pull 10 so as to improve the vertical compression rigidity of the large pull 10.
[0056]
Here, the first material B1 is a steel plate (plate thickness: 0.8 mm) that has been subjected to rust prevention treatment. For example, a hot-dip zinc-5% aluminum-plated steel sheet (sheet thickness: 0.8 mm), a high corrosion-resistant hot-dip zinc-6% aluminum-3% magnesium-plated steel sheet (sheet thickness: 0.8 mm), etc. In addition, the second material B2 is a steel plate (plate thickness: 0.6 mm) that has been subjected to rust prevention treatment. For example, a hot-dip zinc-5% aluminum-plated steel sheet (sheet thickness: 0.6 mm), a highly corrosion-resistant hot-dip zinc-6% aluminum-3% magnesium-plated steel sheet (sheet thickness: 0.6 mm), etc. are used.
[0057]
Hereinafter, a manufacturing system of the steel pulley 10 having such a configuration will be described.
[0058]
FIG. 4 is a block diagram showing an example of the manufacturing system S for the steel pulley 10. As shown in the figure, the manufacturing system S includes a first material forming section 40 for forming the first material B1, a second material forming section 50 for forming the second material B2, and a first material after forming. And a joining portion 60 for joining B1 and the second material B2. Here, the second material forming portion 50 and the joining portion 60 are disposed in a straight line, and the first material forming portion 40 is disposed above the second material forming portion 50.
[0059]
The first material forming unit 40 includes a coil holding unit 42 that holds a plate coil 41 serving as a material of the first material B1, an uncoiler 43 that unwinds a plate from the plate coil 41, and a first material forming device 45. It will be. Note that, depending on the forming method in the first material forming apparatus 45, a leveler 44 may be provided in a stage preceding the first material forming apparatus 45 to take up the plate.
[0060]
The first material forming device 45 is formed of, for example, a roll forming machine, and is a plate which is unwound from a plate coil 41 and blown to a predetermined length by a shear welder (not shown) as shown in a flower diagram in a cross section in FIG. That is, while progressively feeding the first material B1 (see (a) in the figure), roll forming is performed stepwise as shown in (b), (c) and (d) of the figure, and the engaging portions 11a and 11a and the depression The portions 11b, 11b are formed. In addition, a bead 11c used as an identification mark indicating a center display or a screw position may be formed together with the formation of the engagement portions 11a. The bead 11c can be formed by, for example, forming a bead 11c forming part of a roll into a convex shape in a predetermined shape.
[0061]
Here, when the first material B1 is joined to the second material B2 by the joining portion 60, the engaging portions 11a and 11a can easily engage with the engaging portions 11a and 11a and the engaging portions 12a and 13a. Is formed so that the cross-sectional shape becomes a slightly open U-shape from the final cross-sectional shape (see FIG. 1 described above), that is, is formed into a loosely engaging portion (see FIG. 5D). ).
[0062]
The second material forming unit 50 includes a coil holding unit 52 that holds a plate coil 51 that is a material of the second material B2, an uncoiler 53 that unwinds a plate from the plate coil 51, and a second material forming device 55. It will be. Note that, depending on the forming method in the second material forming device 55, the leveler 54 may be disposed at the preceding stage of the second material forming device 55 so as to take up the plate.
[0063]
The second material forming apparatus 55 is, for example, a roll forming machine, and sequentially feeds a plate unwound from the plate coil 51 and blown to a predetermined length by a shear welder, that is, a second material B2 (see FIG. 9E). While forming the engaging portions 12a and 13a, the lower surface 14 is left while forming the engaging portions 12a and 13a in a stepwise manner as shown in FIGS. (F), (g), (h), (i) and (j). The side surfaces 12 and 13 are formed by bending both sides, and the second material B2 is formed into a groove shape. In addition to the formation of the engaging portions 12a and 13a, the ribs 12c and 13c and the beads 14a may be formed as center marks and identification marks indicating screw positions. The ribs 12c, 13c and the bead 14a can be formed by, for example, forming portions of the roll corresponding to the ribs 12c, 13c and the bead 14a into convex portions having a predetermined shape.
[0064]
Here, the engaging portions 12a and 13a are formed into a U-shaped cross-sectional shape that is slightly more open than the final cross-sectional shape (see FIG. 1 described above), similarly to the engaging portions 11a and 11a of the first material B1. It is formed into a loose engagement portion.
[0065]
The joining section 60 is specifically a joining device 61. The joining device 61 includes, for example, a position adjustment mechanism that adjusts the position so that the first material and the second material can be engaged, an engagement mechanism that engages the position-adjusted first material and the second material, A roll forming machine having a caulking mechanism for caulking the engaged first and second materials and a knurling mechanism for performing knurling on the inside of the caulked portion, and comprises a first material B1 and a second material B2. At the same time, the engaging portions (loosely engaging portions) 11a and 11a of the first material B1 formed by the first material forming device 45 to the state shown in FIG. The engaging portion (loosely engaging portion) 12a, 13a of the second material B2 formed up to the state of FIG. 5 (j) is engaged (loosely engaged), and the loosely engaging portion is swaged so as to be crimped. The first material B1 and the second material B2 are fully engaged and joined.
[0066]
Hereinafter, the first material forming device 45, the second material forming device 55, and the joining device 61 will be described more specifically.
[0067]
6 and 7 show a roll forming machine constituting the second material forming device 55 and the joining device 61. FIG. The first material forming apparatus 45 has the same configuration as the second material forming apparatus 55, and may be configured as a separate line above the second material forming apparatus 55. The material forming apparatus 55 may be configured such that, for example, the forming roll 80 (described later) and the stand 72 are exchanged between those of the first material forming apparatus 45 and those of the second material forming apparatus 55.
[0068]
As shown in FIG. 6, the second material forming device 55 gradually forms the second material B2 positioned in the width direction by the entry guide 71 while feeding the second material B2 in the longitudinal direction, that is, sequentially feeding. In addition, forming rolls 80 (see FIG. 7) each having a predetermined shape corresponding to each stage are individually supported by forming roll support stands (hereinafter simply referred to as stands) 72, 72,. Are arranged horizontally and in tandem.
[0069]
Here, the forming rolls 80 are driven by a main motor (not shown) via a worm speed reducer (not shown) provided corresponding to each forming roll 80 and having input shafts connected in series with each other.
[0070]
FIG. 7 shows an example of a forming roll 80 constituting the second material forming apparatus 55. The forming roll 80 is a two-stage roll including an upper roll 81 and a lower roll 82. The forming roll 80 in the illustrated example corresponds to one of the processes of bending both sides of the second material B2 while leaving the lower surface 14 to form the side surfaces 12 and 13 (hereinafter, also referred to as a side surface forming process). It is said.
[0071]
In this side surface forming step, the upper roll 81 is formed into a disk shape having a thickness substantially equal to the width of the lower surface 14 and supported by the bearing 81a. The lower roll 82 has a small-diameter portion 82a having an axial length substantially equal to the width of the lower surface 14 disposed to face the outer peripheral surface of the upper roll 81, and a predetermined diameter on both sides in the axial direction of the small-diameter portion 82a. It has a thread winding shape having gradually increasing diameter portions 82b and 82c formed so that the diameter increases linearly outward in the axial direction at an inclination angle θ, and is supported by a bearing 82d similarly to the upper roll 81.
[0072]
Thus, the second material B2 is sent with the lower surface 14 implemented portion sandwiched between the outer peripheral surface of the upper roll 81 and the outer peripheral surface of the small-diameter portion 82a of the lower roll 82, and the side surfaces 12, 13 are inclined at the above-mentioned inclination angle θ. Can be folded up. That is, by arranging the forming rolls 80 so as to gradually increase the inclination angle θ of the upper roll 81 from the upstream side to the downstream side of the feeding of the second material B2, the side surfaces 12 are arranged as shown in FIG. , 13 can be bent in a stepwise manner.
[0073]
As shown in FIG. 6, the joining device 61 is configured such that stands 72, 72,... That support respective forming rolls 80 having a predetermined shape described later are aligned with the respective stands 72 of the second material forming device 55. Be composed. Here, a through member 74 made of a square steel material supported by the fishing support mechanism 73 is provided at a connection portion between the second material forming device 55 and the joining device 61 so as to extend toward the downstream side.
[0074]
Hereinafter, the joining device 61 will be described in detail with reference to FIGS. FIG. 8 shows a first step (hereinafter, referred to as a first joining step) of a joining step of joining the second material B2 and the first material B1, which is performed by the position adjusting mechanism. FIG. 9 is a photograph showing a part of the actual apparatus constituting the bonding apparatus 61 where the first bonding step is performed. FIG. 10 shows a second joining step performed by the engagement mechanism. FIG. 11 is a photographic view showing the arrangement of the first joining step execution part and the subsequent joining step execution parts of the actual machine that constitutes the joining device 61. FIG. 12 shows a third joining step performed by the caulking mechanism (primary caulking mechanism). FIG. 13 is a supplementary explanatory diagram of the third joining step. FIG. 14 shows a fourth joining step performed by the caulking mechanism (secondary caulking mechanism). FIG. 15 shows a fifth joining step performed by the knurling mechanism. FIGS. 16, 17, and 18 are supplementary explanatory diagrams of the fifth bonding step.
[0075]
1st joining process
As shown in FIGS. 8 and 9, in the first joining step, the second material forming apparatus 55 forms a predetermined shape (see FIG. 5 (j)) on the forming roll 80A at the tip of the joining apparatus 61 (see FIGS. 9 and 11). ) Is adjusted to a predetermined positional relationship in order to join the second material B2 formed into a predetermined shape (see FIG. 5D) by the first material forming device 45 to the first material B1. Process.
[0076]
The forming roll 80A in the first joining step has an upper roll 81A and a lower roll 82A, is disposed on both sides of the second material B2, and forms a bottom outer angle θ with the lower surface 14 of the side surfaces 12, 13. _A , Θ _B (See FIG. 8). Lateral rolls 83, 83 (see FIG. 9) that press the side surfaces 12, 13 inward so as to make the angle (for example, 93 °) larger than the right angle (see, for example, 93 °). You. With this configuration of the forming roll 80A, the second material B2 is formed into a tapered groove shape in which the side surfaces 12, 13 are turned inward.
[0077]
The lower roll 82A rotates so as to feed the second material B2 having the hollow portion D, through which the through member 74 is passed, to the downstream side while supporting the second material B2. On the other hand, the upper roll 81A rotates so as to feed the first material B1, which is placed on the upper surface of the upper plate material 74a of the intermediate passing member 74 and merged, to the downstream side while sandwiching the first material B1 with the upper plate material 74a. Here, the upper plate member 74a is made of, for example, a hard resin so that friction with the first member B1 placed on the upper surface is reduced.
[0078]
At this stage, the upper plate member 74a does not interfere with the engaging portions (loosely engaging portions) 11a, 11a of the first material B1 and the engaging portions (loosely engaging portions) 12a, 13a of the second material B2. Is provided on the upper surface of the through member 74 with the washer 74c interposed therebetween. Thus, the upper surface of the upper plate member 74a is located at a predetermined height above the opening surface of the hollow portion D of the second member B2 (see FIG. 8).
[0079]
As shown in FIG. 6, the first material B1 is obliquely inserted from the near side so that the longitudinal direction of the first material B1 matches the longitudinal direction of the second material B2 when viewed from above, and positioning in the width direction is performed by the roll 83. To the second material B2.
[0080]
2nd joining process
As shown in FIGS. 10 and 11, the second joining step is performed on the forming roll 80 B arranged downstream of the first joining step, and the engaging portion (loose engaging portion) 11 a of the first material B 1 is used. , 11a and the engaging portions (loose engaging portions) 12a, 13a of the second material B2 are engaged with each other so that caulking can be performed.
[0081]
That is, the cam followers 75, 75 are provided on both sides of the intermediate member 74 in the portion where the second joining step is performed, whereby the side surfaces 12, 13 formed into a tapered groove shape can be used to form the outer angle θ at the bottom. _A , Θ _B At the same time, the first material B1 is moved to a predetermined position (hereinafter, referred to as an engagement position) where the engaging portions 11a and 11a engage with the engaging portions 12a and 13a of the second material B2. The first member B1 is supported by an upper plate member 74d provided directly on the upper surface of the main body 74b without interposing a washer so as to support it. Thereby, the side surfaces 12, 13 are expanded so that the engaging portions 11a, 11a, 12a, 13a are engaged.
[0082]
A lower roll (not shown) of the forming roll 80B rotates so as to feed the second material B2 downstream while supporting the second material B2, and an upper roll (not shown) places the first material B1 between the upper roll 74d and the upper material 74d. Rotate so that it is sandwiched and sent downstream.
[0083]
Third bonding step
As shown in FIGS. 12 and 13, the third joining step is performed by using the outer bottom angles θ of the side surfaces 12 and 13. _A , Θ _B (See FIGS. 8 and 10) is a step of gently caulking the engaging portions 11a, 11a, 12a, and 13a while maintaining the right angle (first caulking step). That is, as shown in FIG. 13 only on one side, in the third joining step execution part, the intermediate member 74 includes cam followers (guide roll mechanisms) 75, 75 arranged side by side in the feed direction of the second material B2, A pair of caulking rolls 76 (76A, 76B), which are vertically arranged at an intermediate position between the cam followers 75, 75, are arranged on both sides. In FIG. 12, the right side from the center line shows a cross section at the position where the cam followers 75 and 75 are provided, and the left side from the center line shows a cross section at the position where the caulking rolls 76A and 76B are provided.
[0084]
Here, the outer surfaces of the cam followers (guide roll mechanisms) 75, 75 and the outer surfaces of the caulking rolls 76A, 76B match. Thereby, movement and deformation of the side surfaces 12 and 13 during caulking are suppressed. The outer peripheral surface of the upper caulking roll 76A is in contact with the outer peripheral surface of the lower caulking roll 76B.
[0085]
Further, the upper roll 81C and the lower roll 82C of the forming roll 80C, and the upper caulking roll 76A and the lower caulking roll 76B are disposed such that their axes are included in one plane.
[0086]
Thus, in the third joining step, the caulking rolls 76A and 76B are passed through the hollow portion of the second material B2 while being guided by the upstream cam follower 75, and the engaging portions (loosely engaging portions) 11a, 11a, 12a and 13a are sandwiched between the upper caulking roll 76A and the upper roll 81C of the forming roll 80C and are caulked gently. That is, primary caulking is performed.
[0087]
At this time, the load applied to the upper caulking roll 76A is received by the shaft 76a, and is brought into contact with the shaft 76b of the lower caulking roll 76B and the outer peripheral surface of the lower caulking roll 76B via the lower surface 14 of the second material B2. It is received by the lower roll 82C of the formed forming roll 80C.
[0088]
This makes it possible to reduce the load applied to the shaft 76a of the upper caulking roll 76A while caulking each of the engaging portions 11a, 11a, 12a, 13a with a large pressing force. For example, the shaft 76a supported by a slide bearing Can be prevented from burning.
[0089]
4th joining process
As shown in FIG. 14, in the fourth joining step, the engaging portions 11a, 11a, 12a, 13a gently swaged in the third joining step are firmly swaged with the forming roll 80D (see FIG. 11) (2). Next caulking process, finish caulking process). That is, in the part where the fourth bonding step is performed, the through member 74 is provided with a pair of caulking rolls 76C, 76D and 76E, 76F on both sides.
[0090]
Here, the upper caulking rolls 76C and 76E in the fourth bonding step execution part have the same shape and the same dimensions as the upper caulking roll 76A in the third bonding step execution part. Also, the lower caulking rolls 76D and 76F in the part where the four bonding steps are performed have the same shape and dimensions as the lower caulking roll 76B in the part where the third bonding step is performed. Further, the positional relationship of the arrangement of the upper caulking rolls 76C and 76E and the lower caulking rolls 76D and 76F in the through-hole member 74 is the same as that in the third bonding step execution part. In other words, the caulking rolls 76A and 76B (only one side is shown here) in the third bonding step execution part and the caulking rolls 76C, 76D, 76E and 76F in the fourth bonding step execution part have exactly the same configuration. Is done. This suppresses an increase in tool manufacturing cost.
[0091]
On the other hand, the gap between the outer peripheral surfaces of the upper caulking rolls 76C and 76E and the upper roll 81D of the forming roll 80D is made smaller than in the third joining step.
[0092]
Thus, the caulking rolls 76C, 76D, 76E, 76F are passed through the hollow portions of the first material B1 and the second material B2 in which the engaging portions 11a, 11a, 12a, 13a are gently caulked in the third joining step. The engaging portions 11a, 11a, 12a, and 13a are firmly caulked by being pressed between the upper caulking rolls 76C and 76E and the upper roll 81D of the forming roll 80D. That is, secondary caulking (finish caulking) is performed.
[0093]
Also, in the fourth joining step, similarly to the third joining step, the load at the time of caulking is received by the shafts 76c and 76d and the lower roll 82D.
[0094]
Fifth bonding step
As shown in FIG. 15, FIG. 16, FIG. 17, and FIG. 18, in the fifth joining step, the engaging portions 11a, 11a, 12a, 13a firmly crimped in the fourth joining step, that is, the finished crimps are performed. In the forming roll 80E (see FIG. 11), a step of caulking is performed so that slippage between the engaging portions 11a, 11a, 12a, and 13a does not occur.
[0095]
That is, in the part where the fifth joining step is performed, the piercing member 74 is provided with knurls 77 and 77 and support rolls 78 and 78 on both sides, that is, a knurling mechanism.
[0096]
As shown in FIG. 18, the knurl 77 has a large number of diamond-shaped irregularities 77b, 77b,... Provided on the outer peripheral surface of a pressing portion 77a for pressing the engaging portions 11a, 11a, 12a, 13a with the upper roll 81E. Thereby, a lateral groove is provided at several millimeter intervals inside the engaging portions 11a, 11a to increase the caulking strength of the entire caulking portion, and thereby, between the engaging portions 11a, 11a, 12a, 13a. It is possible to prevent slippage from occurring. In FIG. 18, reference numeral 77c indicates a knurl shaft.
[0097]
As shown in FIG. 16, the support rolls 78, 78 are disposed on the upstream and downstream sides of the knurls 77, 77, respectively. , 79 and the lower surface 14 of the second material B2 are interposed therebetween, and receive a load applied to the intermediate member 74 during knurling.
[0098]
As described above, in the cross member manufacturing system S of the first embodiment, the upper surface 11 of the steel pulley 10 on which a load is concentrated is formed from the thick first material B1, and the other surfaces 12, 13, and 14 are thinned. Each of the materials B1 and B2 is roll-formed so that the engaging portions 11a, 11a, 12a, and 13a can be easily engaged with each other so as to form the second material B2. The first material B1 and the second material B2 are joined by caulking the engaging portions 11a, 11a, 12a, and 13a by roll forming. The first material B1 may be formed beforehand as shown in FIG. 5D, and may be sequentially fed to the joint 60 in synchronization with the sequential feeding of the second material B2 to the joint 60.
[0099]
As a result, the production of a cross member by caulking and joining two members, which has not been attempted even due to the difficulty of processing and the difficulty of dimensional control in the past, is realized. As a result, it becomes possible to manufacture a steel pulley 10 having sufficient strength and further weight reduction.
[0100]
Embodiment 2
19 to 21 show a steel cross member according to the second embodiment of the present invention. In the second embodiment, the steel cross member is specifically a steel joist.
[0101]
As shown in FIG. 19, the steel joist 20 has a substantially rectangular cross section (45 mmW × 50 mmH in the illustrated example), and includes a first material B 3 forming the lower surface 21, both side surfaces 22 and 23, and an upper surface. 24, and is formed by joining the lower end of the lower surface 21 and the lower ends of the side surfaces 22 and 23 by caulking.
[0102]
In other words, as shown in FIG. 19, the lower end of the lower surface 21 is bent inward to form a horizontal U-shaped engaging portion 21a, and the lower end of the side surface 22 (23) is formed of the horizontal U-shaped engaging portion. The U-shaped engaging portion 22a (23a) is formed in a direction opposite to that of the engaging portion 21a. After the engaging portions 21a, 22a (21a, 23a) are engaged, the two are caulked and joined. . As shown in FIG. 19, the lower surface portion located behind the engaging portion 22 a (23 a) at the lower end of the side surface 22 (23) is formed as a V-shaped (or U-shaped) recessed portion 21 b, and the side surface 22 (23) is formed. 23) The crimping portion 25 formed by the lower end portion and the lower surface 21 side end is prevented from being disengaged or side-sliding. That is, the depressed portion 21b is a disengagement prevention portion or a side slip prevention portion.
[0103]
Here, the first material B3 is a steel plate (plate thickness: 0.6 mm) that has been subjected to rust prevention treatment. For example, a hot-dip zinc-5% aluminum-plated steel sheet (sheet thickness: 0.6 mm), a highly corrosion-resistant hot-dip zinc-6% aluminum-3% magnesium-plated steel sheet (sheet thickness: 0.6 mm), etc. are used. In addition, the second material B4 is a steel plate (plate thickness: 0.4 mm) that has been subjected to rust prevention treatment. For example, a hot-dip zinc-5% aluminum-plated steel sheet (sheet thickness: 0.4 mm), a highly corrosion-resistant hot-dip zinc-6% aluminum-3% magnesium-plated steel sheet (sheet thickness: 0.4 mm), etc.
[0104]
Also, in this steel joist 20, the caulked portion 25 is located at the end on the lower surface 21 side, so that when the steel joist 20 is placed on the steel pulley 10, Functions as a reinforcing part (self-reinforcing part).
[0105]
In addition, the steel joist 20 in which the joining portion between the first material B3 and the second material B4 such as the caulked portion 25 functions as a reinforcing member or a reinforcing portion is referred to as a self-reinforced steel joist in this specification. I will.
[0106]
The steel joist 20 having such a configuration is manufactured in the same manner as the steel pulley 10 of the first embodiment. As a result, it is possible to manufacture a steel joist which has sufficient strength and is further reduced in weight.
[0107]
Embodiment 3
FIG. 22 shows a steel cross member according to Embodiment 3 of the present invention. The steel cross member of the third embodiment is obtained by modifying the steel pulley 10 of the first embodiment, and as shown in FIG. 22, the first material B1A is provided at a predetermined pitch (interval) or at an appropriate pitch. (Interval) to form a steel pulley 10A. For example, the upper surface 11A is formed by disposing the first material B1A only at the position where the joist is placed. In this case, even if the thickness of the first material B1A is larger than the thickness of the first material B1 of the first embodiment, it does not hinder the weight reduction of the steel pulling.
[0108]
The remaining configuration of the steel pulley 10A of the third embodiment is the same as that of the steel pulley 10 of the first embodiment.
[0109]
As described above, since the steel puller 10A of the third embodiment is formed by arranging the first materials B1A at a predetermined pitch or at an appropriate pitch, the weight of the steel pulley can be reduced while ensuring the desired strength. Is further promoted.
[0110]
Embodiment 4
FIG. 23 shows a steel cross member according to Embodiment 4 of the present invention. The steel cross member of the fourth embodiment is obtained by modifying the steel joist 20 of the second embodiment. As shown in FIG. 23, the first members B3A are arranged at a predetermined pitch or an appropriate pitch. 20A. For example, the lower surface 21A is formed by disposing the first material B3A only at the place where the steel joist 20A is placed on the steel pulley 10. In this case, even if the thickness of the first material B3A is larger than the thickness of the first material B3 of the second embodiment, it does not hinder the weight reduction of the steel joists.
[0111]
The remaining configuration of the steel joist 20A of the fourth embodiment is the same as that of the steel joist 20 of the second embodiment.
[0112]
As described above, since the steel joists 20A of the fourth embodiment are formed by arranging the first materials B3A at a predetermined pitch or an appropriate pitch, the weight of the steel joists can be further reduced while ensuring the desired strength. Promoted.
[0113]
As described above, the present invention has been described based on the embodiments, but the present invention is not limited to only such embodiments, and various modifications are possible. For example, in the embodiment, the first material and the second material are made of the same material, but the first material and the second material may be made of different materials. For example, the first material may be a stainless steel plate and the second material may be a normal steel plate. Further, the combination of the plate thicknesses can be appropriately determined according to the usage mode. By doing so, it is possible to further reduce the weight while securing the desired strength.
[0114]
Further, in the embodiment, the caulking is performed twice, that is, the first caulking and the second caulking. However, the caulking may be performed a plurality of times, such as a third caulking or a fourth caulking, depending on the material and the thickness of the plate.
[0115]
【The invention's effect】
As described in detail above, according to the steel cross member of the present invention, an excellent effect that the steel cross member such as a steel bar and a steel joist can be further reduced in weight while securing desired strength. Is obtained.
[0116]
Further, according to the method and system for manufacturing a steel cross member according to the present invention, an excellent effect that a steel cross member that is further reduced in weight while ensuring desired strength can be manufactured can be obtained.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view showing a steel pulley manufactured by a cross member manufacturing method according to a first embodiment of the present invention.
FIG. 2 is a side view of the steel puller.
FIG. 3 is a top view of the steel puller.
FIG. 4 is a block diagram illustrating a schematic configuration of a manufacturing system to which the cross member manufacturing method according to the first embodiment of the present invention is applied.
FIG. 5 is a flower diagram showing a cross-sectional shape of each material constituting a steel pulley at each molding stage in a listable manner.
FIG. 6 is a side view showing a schematic configuration of a roll forming machine as an actual machine constituting the forming apparatus.
FIGS. 7A and 7B are two views showing an example of a forming roll constituting the roll forming machine, wherein FIG. 7A shows a front view and FIG. 7B shows a side view.
FIG. 8 is a cross-sectional view showing a portion where a first bonding step is performed in the bonding apparatus.
FIG. 9 is a photograph showing a part where the first bonding step is performed.
FIG. 10 is a cross-sectional view illustrating a portion where a second bonding step is performed in the bonding apparatus.
FIG. 11 is a photographic view showing an arrangement of a portion where each bonding step is performed in the bonding apparatus.
FIG. 12 is a cross-sectional view illustrating a portion where a third bonding step is performed in the bonding apparatus.
FIG. 13 is a side view of a portion where a third bonding step is performed.
FIG. 14 is a cross-sectional view illustrating a part where a fourth bonding step is performed in the bonding apparatus.
FIG. 15 is a cross-sectional view illustrating a portion where a fifth bonding step is performed in the bonding apparatus.
FIG. 16 is a side view of a portion where a fifth bonding step is performed.
FIG. 17 is a cross-sectional view showing the entire part where the fifth bonding step is performed.
FIG. 18 is a partial sectional view showing the shape of a knurl.
FIG. 19 is a cross-sectional view showing a steel joist manufactured by the method for manufacturing a cross member according to the second embodiment of the present invention.
FIG. 20 is a side view of the steel joist.
FIG. 21 is a top view of the steel joist.
FIG. 22 is a perspective view showing a steel pulley manufactured by the cross member manufacturing method according to the third embodiment of the present invention.
FIG. 23 is a perspective view showing a steel joist manufactured by the cross member manufacturing method according to the fourth embodiment of the present invention.
FIG. 24 is a sectional view of a steel pulley proposed in Japanese Patent Application Laid-Open No. 8-4253.
FIG. 25 is a sectional view of a steel puller proposed in Japanese Patent Application Laid-Open No. 2000-73527.
[Explanation of symbols]
10 Steel pulling
11 Top
12,13 side
15 Caulking part
20 Steel joists
21 Lower surface
22,23 side
25 Caulking part
20 Steel joists
40 1st material forming part
45 1st material forming device
50 2nd material forming part
55 Second material forming device
60 joint
61 Joining equipment
80 Forming roll
S manufacturing system
B1, B3 1st material
B2, B4 2nd material

Claims

A steel cross member comprising a first material forming one surface and a second material forming a remaining surface,
A steel cross member, wherein the steel cross member is a self-reinforced steel cross member.

The steel cross member according to claim 1, wherein the first member and the second member are joined by caulking.

The steel cross member according to claim 2, wherein a disengagement prevention part and / or a side slip prevention part is formed at a position corresponding to a position behind the caulked part of the first material.

The steel cross member according to claim 1, wherein the first member and the second member have different plate thicknesses.

The steel crosspiece according to claim 4, wherein the thickness of the first material is greater than the thickness of the second material.

2. The steel cross member according to claim 1, wherein the material of the first member is different from the material of the second member.

The steel cross member according to claim 1, wherein the first members are arranged at predetermined intervals or at appropriate intervals.

The steel cross member according to claim 1, wherein a reinforcing rib, a positioning bead, or the like is formed.

3. The steel cross member according to claim 2, wherein the inside of the caulked portion is knurled.

The steel cross member according to claim 1, 2, 3, 4, 5, 6, 7, 8, or 9, wherein the steel cross member is made of steel and one surface is an upper surface. .

The steel cross member according to claim 1, 2, 3, 4, 5, 6, 7, 8, or 9, wherein the steel cross member is a steel joist and one surface is a lower surface.

A method of manufacturing a steel cross member comprising a first material forming one surface and a second material forming a remaining surface,
A method for manufacturing a steel cross member, comprising a step of joining a joint between a first material and a second material so as to be a self-reinforcing portion.

A method of manufacturing a steel cross member comprising a first material forming one surface and a second material forming a remaining surface,
Forming a side end of the first material into a loose engagement portion;
Forming a side end of the second material into a loose engagement portion;
Forming the second material having the loosely-engaged portion into a groove shape,
A procedure for engaging the loosely engaging portion of the first material with the loosely engaging portion of the second material;
The method for manufacturing a steel cross member according to claim 12, further comprising a step of caulking an engagement portion between the first material and the second material.

A method of manufacturing a steel cross member comprising a first material forming one surface and a second material forming a remaining surface,
Forming a side end of the first material into a loose engagement portion;
Forming a side end of the second material into a loose engagement portion;
Forming the second material having the loosely-engaged portion into a groove shape,
A procedure for engaging the loosely engaging portion of the first material at predetermined or appropriate intervals with the loosely engaging portion of the second material;
The method for manufacturing a steel cross member according to claim 12, further comprising a step of caulking an engagement portion between the first material and the second material.

Engagement of the first material and the second material is performed by raising both sides of the second material while lowering the first material to the engagement position in a state where both sides of the second material are turned inward. The method for producing a steel cross member according to claim 13 or 14, wherein:

The method for producing a steel cross member according to claim 13 or 14, wherein caulking is performed for several orders.

15. The method according to claim 13, further comprising a step of forming a disengagement prevention part and / or a side slip prevention part at a position corresponding to a position behind the caulking part of the first material. Method.

15. The method for manufacturing a steel cross member according to claim 13, wherein forming the first material and / or the second material includes forming a reinforcing rib, a positioning bead, and the like.

19. The method for producing a steel cross member according to claim 13, wherein the forming of the first material is performed while feeding the flat plate.

The method for producing a steel cross member according to claim 13, 14, or 18, wherein the forming of the second material is performed while feeding the flat plate in order.

17. The steel according to claim 13, 14, 15 or 16, wherein the engagement between the first material and the second material and the caulking of the engagement portion are performed while simultaneously feeding the first material and the second material simultaneously. A method of manufacturing cross members.

22. The method for manufacturing a steel cross member according to claim 13, wherein knurling is performed on an inner side of the caulking portion.

The method for producing a steel cross member according to any one of claims 12 to 22, wherein the forming of the first material and / or the second material is performed by a roll forming method.

A system for manufacturing a steel cross member comprising a first material forming one surface and a second material forming a remaining surface,
The said manufacturing system is a structure which joins so that the joining part of a 1st material and a 2nd material may become a self-reinforcement part, The manufacturing system of the steel cross member characterized by the above-mentioned.

A first material forming unit configured to form the first material into a predetermined shape, a second material forming unit configured to form the second material into a predetermined shape, and a joining unit configured to join the first material and the second material. The system for producing a steel cross member according to claim 24, comprising:

26. The manufacturing system for a steel cross member according to claim 25, wherein the second material forming portion and the joining portion are arranged linearly.

The system for manufacturing a steel cross member according to claim 26, wherein the first material forming part is disposed above the second material forming part.

The first material forming part includes a first material forming device, and the first material forming device is configured to form a side end portion of the first material into a loosely engaging portion by roll forming. Item 30. A system for producing a steel cross member according to Item 25.

The first material forming apparatus is characterized in that the first material forming device is configured to also form a disengagement prevention portion and / or a side slip prevention portion at a position corresponding to a position behind the caulking portion of the first material by roll forming. Item 29. The system for manufacturing a steel cross member according to Item 28.

30. The steel cross member manufacturing system according to claim 28, wherein the first material forming device is configured to also form the reinforcing rib, the positioning bead, and the like by roll forming.

The second material forming unit includes a second material forming device, and the second material forming device is configured to form the side end of the second material into a loosely engaging portion by roll forming. Item 30. A system for producing a steel cross member according to Item 25.

32. The steel cross member manufacturing system according to claim 31, wherein the second material forming device is configured to also form the reinforcing rib, the positioning bead, and the like by roll forming.

A joining unit including a joining device, the joining device having a position adjusting mechanism for bringing the first material and the second material into a predetermined positional relationship, an engaging mechanism for engaging the first material and the second material, The steel cross member manufacturing system according to claim 25, further comprising a caulking mechanism for caulking the combined first and second members.

34. The manufacturing system of a steel cross member according to claim 33, wherein the position adjusting mechanism has a roll forming portion that forms the second material into a tapered groove shape.

The steel cross member manufacturing system according to claim 33, wherein the engagement mechanism has a roll forming portion that raises a side surface of the tapered groove-shaped second material.

34. The steel cross member manufacturing system according to claim 33, wherein the caulking mechanism has at least a primary caulking roll forming part and a finish caulking roll forming part.

The caulking roll forming part has an upper caulking roll and a lower caulking roll disposed vertically on the through-through member, and the upper caulking roll outer peripheral surface and the lower caulking roll outer peripheral surface are brought into contact with each other. 37. The system for manufacturing a steel cross member according to claim 36.

38. The steel cross member manufacturing system according to claim 37, wherein the through member has guide rolls before and after the upper caulking roll and the lower caulking roll.

26. The manufacturing system for a steel cross member according to claim 25, wherein the joining device has a knurling mechanism.