JP3622837B2

JP3622837B2 - Heat transfer part forming method

Info

Publication number: JP3622837B2
Application number: JP2000232124A
Authority: JP
Inventors: 豊明松崎
Original assignee: Xenesys Inc
Current assignee: Xenesys Inc
Priority date: 2000-07-31
Filing date: 2000-07-31
Publication date: 2005-02-23
Anticipated expiration: 2020-07-31
Also published as: JP2002035871A; TW514570B

Description

【０００１】
【発明の属する技術分野】
本発明は被加工材をプレス成型して熱交換器の伝熱部を形成する伝熱部形成方法に関し、特に被加工材に複数回プレス成型を行って凹凸形状パターンが複数並んだ状態とする伝熱部形成方法に関する。
【０００２】
【従来の技術】
熱交換器における伝熱部は、一般に金属薄板からなり、プレス加工により所定形状に成型されて使用に供されている。プレス装置による伝熱部の成型には、従来から一組の金型が用いられ、組をなす型間に被加工材を配置し、型に互いに接近する関係運動を行わせることで、被加工材である金属薄板に伝熱部としての凹凸形状パターンを形成していた。
【０００３】
【発明が解決しようとする課題】
従来の伝熱部のプレス成型は以上のように行われていたことから、伝熱部全体の凹凸形状パターンを一組の型で成型しており、型の大きさより大きな凹凸形状パターンを形成することはできなかった。このため、型の大きさで伝熱部の大きさが制限されてしまい、型の寸法面での限界から大面積の伝熱部を製作できないという課題を有していた。
【０００４】
また、伝熱部の材料となるコイル状に巻取られた金属薄板は、圧延成形する際に応力分布及び伸延の不均一性から、両側端部が平行な直線性を有さず、緩やかに湾曲する所謂バナナシェープ状態にある。このバナナシェープ状態の金属薄板で長尺物の伝熱部を形成しようとすると、複数のプレス加工位置が両側端部からでは正確に決定できず、正確なプレス加工ができないという課題を有していた。
【０００５】
本発明は前記課題を解消するためになされたもので、被加工材に対しプレス装置で複数回プレスを行って所定の凹凸形状パターンを複数並べて形成でき、長尺の被加工材に対してももれなく凹凸形状を形成して金型より大きい伝熱面を容易に形成できる伝熱部形成方法を提供することを目的とする。
【０００６】
【課題を解決するための手段】
本発明に係る伝熱部形成方法は、金属薄板からなる被加工材をプレス装置の上型及び下型で所定の凹凸形状にプレス成型して熱交換器用の伝熱部を形成する伝熱部形成方法において、長手方向と平行な単一の送り方向に移送される長尺の被加工材に対し、当該被加工材より短い型を有するプレス装置が、被加工材に長手方向へ所定間隔で複数設定される所定箇所をそれぞれプレスし、前記伝熱部を所定の凹凸形状パターンが長手方向に複数並んだ形状として形成し、少なくとも前記被加工材を前記プレス装置でプレス成型する前に、所定のマーク付与装置で前記被加工材表面に対して被加工材へのプレス位置を規定する所定のマークを被加工材長手方向へ所定間隔で複数付与し、前記被加工材長手方向へ所定間隔でマーキングされた複数個のマークを結ぶ仮想の中心線を演算し、前記仮想の中心線上にプレス位置の間隔に相当する間隔で仮想の中心点及び／又は当該仮想の中心点の両側所定距離に仮想の側端点を特定し、前記被加工材の搬送方向に順次特定される仮想の中心点又は仮想の側端点から前記被加工材の側端縁までの各端縁距離を算出し、前記各端縁距離の変化の推移に基づいて前記マーク付与装置が増加傾向側へ補正距離だけスライド移動させて被加工材表面に複数個のマークを搬送方向に複数付与し、前記付与されたマークを所定のマーク検知手段で検知すると、マークで規定される被加工材の所定位置に対してプレスを行うものである。このように本発明においては、長尺の被加工材における長手方向にマーキングされた複数個のマークを結ぶ仮想の中心線を演算し、この仮想の中心線上の仮想の中心点及び／又はこの仮想の中心点から所定距離の仮想の側端点を特定し、この特定された仮想の中心点又は仮想の側端点から被加工材の側端縁までの端縁距離を算出し、この端縁距離の変化推移に基づいて増加傾向側へ補正距離だけスライド移動させて新たなマークを複数付与し、この新たなマークで規定される被加工材の所定位置に対し所定のプレス装置でプレス位置をずらしながらプレスを複数回行い、被加工材に所定の凹凸形状パターンを複数並んだ状態として形成することにより、湾曲形態を有する長尺の被加工材に対しても先端部分の端縁距離の変化推移で被加工材の湾曲状態を類推できることとなり、この類推された湾曲状態を有する被加工材の最適位置にプレス加工の位置を選択できる。また、プレス装置がマークに合わせて被加工材のプレスを行い、被加工材のマークを付けられた複数箇所に凹凸形状パターンがそれぞれ形成されることにより、プレス装置が被加工材のプレスを行うべき位置を正しく取得して該当する位置をプレスすることができ、厳密にプレス位置合わせが行え、被加工材における加工後の形状精度を向上させられる。さらに、凹凸形状パターンを全体にわたって適切にプレス成型できることとなり、金型より大きい長尺の伝熱部を確実に成型でき、伝熱部一つあたりの大きさを大きくして熱交換能力を高めた熱交換器を製作できるようになる。
【０００７】
また、本発明に係る伝熱部形成方法は必要に応じて、前記プレス装置の前記被加工材送り方向の前後に、被加工材より短い型を有する別のプレス装置を複数並設し、当該別のプレス装置のいずれかが、前記プレス装置による被加工材複数箇所へのプレスの前及び後に、被加工材の長手方向一端側所定範囲及び他端側所定範囲をそれぞれプレスし、前記伝熱部を少なくとも二種類以上の凹凸形状パターンが長手方向に複数並んだ形状として形成するものである。このように本発明においては、被加工材の長手方向両端部に対し複数並設したプレス装置のいずれかでそれぞれプレスを行い、被加工材の両端部に長手方向中間部分とは少なくとも異なる凹凸形状パターンを他の凹凸形状パターンと並んだ状態として形成することにより、長尺の被加工材両端部に伝熱部として最適となる凹凸形状パターンを適切にプレス成型できることとなり、長手方向中間部分と条件が異なる両端部についても熱交換能力が最適化された伝熱部を形成できると共に、複数並設したプレス装置で被加工材の各成型工程を連続的に行え、成型作業能率を大幅に向上させられる。
【０００８】
また、本発明に係る伝熱部形成方法は必要に応じて、前記プレス装置が、前記被加工材の幅方向両端部に、幅方向中央部分に対して段違いとなる段差部分を被加工材長手方向へ連続させて形成するものである。このように本発明においては、プレス装置が被加工材の幅方向端部に長手方向へ連続させて段差部分を形成し、被加工材に長手方向の曲げに対する所定の強度を与えることにより、被加工材が長尺であっても曲がりにくくなることとなり、被加工材の加工後の形状を維持させて後工程での加工を容易にすると共に、伝熱部としての強度を高めることができる。
【０００９】
また、本発明に係る伝熱部形成方法は必要に応じて、前記プレス装置が、前記被加工材の幅方向両端部に所定幅の平坦部分を形成すると共に、当該平坦部分に所定の凹部又は凸部を被加工材長手方向へ所定間隔で複数形成するものである。このように本発明においては、プレス装置が被加工材の幅方向端部に所定の平坦部分と複数の凹部又は凸部を形成し、平坦部分を被加工材における所定の加工代とすることにより、プレス後に被加工材を伝熱部として最終的に溶接加工する場合に、平坦部分を溶接代として用いて溶接作業を容易に行えると共に、被加工材を幅方向両側から把持可能となり、被加工材の搬送も容易に行える。さらに、平坦部分に複数の凹部又は凸部で被加工材幅方向の曲げに対する所定の強度を与えることにより、平坦部分が被加工材幅方向に曲りにくくなり、平坦部分を把持して被加工材を支持する場合における被加工材の幅方向のたわみを防ぐことができる。
【００１０】
また、本発明に係る伝熱部形成方法は必要に応じて、少なくとも前記被加工材を前記プレス装置でプレス成型する前に、所定の検出装置で被加工材の表面状態又は内部構造を検出し、得られた検出データを所定のデータ解析手段で解析して被加工材の表面又は内部の欠陥を判別し、被加工材に欠陥がある場合には被加工材のプレス装置への送りを停止して、前記欠陥部分を欠陥部分の送り方向前後方側の各部分に対して除去し、新たに欠陥部分の送り方向後方側部分を前記検出装置で検出しつつプレス装置へ向けて送ることものである。このように本発明においては、プレス成型前にあらかじめ撮像装置で被加工材を撮像して被加工材表面の欠陥の有無をチェックし、欠陥がある場合には欠陥部分を除去して被加工材の欠陥のない部分をプレス装置に送ることにより、プレス装置で欠陥のある被加工材を加工した後に欠陥判明による不良品化で被加工材が無駄になるのを防ぐと共に、確実に欠陥部分を除いた上で被加工材をプレス装置に送ることで、誤ってプレス成型後の伝熱部に欠陥が残ったままとなるのを防止でき、安全性を確保できる。
【００１２】
【発明の実施の形態】
（本発明の第１の実施形態）
以下、本発明の第１の実施形態に係る伝熱部形成方法を図１ないし図５に基づいて説明する。図１は本実施形態に係る伝熱部形成方法を適用するプレス装置の概略構成図、図２は本実施形態に係る伝熱部形成方法による被加工材供給状態説明図、図３は本実施形態に係る伝熱部形成方法による被加工材マーク状態説明図、図４は本実施形態に係る伝熱部形成方法による被加工材成型工程説明図、図５は本実施形態に係る伝熱部形成方法による被加工材成型後状態説明図である。
【００１３】
前記各図において本実施形態に係る伝熱部形成方法は、長尺の金属薄板からなる被加工材１００に対し、この被加工材１００の送り方向に並設した三つのプレス装置のうち端の二つのプレス装置１０、３０が、被加工材１００の長手方向両端に対しそれぞれ所定のプレス加工を行うと共に、中間のプレス装置２０が、所定長さずつ送られる被加工材１００に対し長手方向所定間隔でプレスを複数回行い、被加工材１００に所定の凹凸形状パターンを被加工材長手方向へ複数並べて成型して熱交換器用の伝熱部を形成するものである。
【００１４】
この本実施形態に係る伝熱部形成方法で用いる各プレス装置１０、２０、３０は、伝熱部の一方の面形状を成型する型面を下方に向けて所定範囲上下動自在に配設される上型１１、２１、３１と、伝熱部の他方の面形状を成型する型面を上方に向けて上型１１、２１、３１下方に上型１１、２１、３１に対向させて配設される下型１２、２２、３２と、この上型１１、２１、３１及び下型１２の近傍に配設され、上型１１、２１、３１と下型１２、２２、３２との間のプレス可能位置に被加工材１００のプレス対象箇所が到達したかどうかを判定するマーク検出手段４０とを備える構成である。
【００１５】
これらプレス装置１０、２０、３０の上型１１、２１、３１及び下型１２、２２、３２は、被加工材１００の幅方向中間部分に所定の凹凸形状パターンを形成する他、幅方向両端部に幅方向中央部分に対して段違いとなる段差部分１１０を被加工材長手方向へ連続させて形成すると共に、この段差部分１１０の幅方向外側部分に所定幅の平坦部分１２０を形成し、さらに、この平坦部分１２０に所定高さの凸部１３０を被加工材長手方向へ所定間隔で複数形成する型形状となっている（図５参照）。こうして、被加工材１００の幅方向両端部に段差部分１１０、平坦部分１２０、及び凸部１３０をそれぞれ形成し、段差部分１１０で被加工材１００に長手方向の曲げに対する所定の強度を与えると共に、凸部１３０で平坦部分１２０に被加工材幅方向の曲げに対する所定の強度を与えることから、被加工材１００が変形しにくく、被加工材１００にプレス成型後の形状を保たせて後工程での加工を容易化できる。加えて、平坦部分１２０がプレス後の被加工材１００における所定の加工代となることから、プレス後に被加工材１００を伝熱部として最終的に溶接加工する場合に、平坦部分１２０を溶接代として用いて溶接作業を容易に行えると共に、被加工材１００を幅方向両側から把持可能となり、被加工材１００の搬送も容易に行える。
【００１６】
一方、プレス装置１０、２０、３０より前段側で且つ被加工材１００のコイル１０１からの引出直後となる位置には、被加工材１００の表面状態を撮像する所定の撮像装置５０が配設され、この撮像装置５０で得られた画像を所定の画像解析手段（図示を省略）で解析して被加工材１００表面の欠陥を判別し、被加工材１００に欠陥がある場合には被加工材１００のプレス装置側への送りを停止して、前記欠陥部分をこの欠陥部分前後の被加工材１００の残り部分に対して除去すると共に、前記欠陥部分より送り方向後方側の残り部分に対し撮像装置５０で撮像しつつプレス装置側への送りを再開する仕組みとなっている。
【００１７】
そして、撮像装置５０による撮像位置とプレス装置１０との間には、被加工材１００を少なくとも一つの伝熱部として形成可能な所定長さ分だけプールする部分（プール部６０）が設けられる。このプール部６０で十分な長さの被加工材１００が確保されることで、被加工材１００の欠陥部分を検出・除去されても、欠陥部分より送り方向前方側の被加工材１００に対するプレス成型を伝熱部一つ分だけは最後まで確実に行うことができ、被加工材１００に対する加工のロス分を少なくできる。
【００１８】
さらに、このプール部６０とプレス装置１０との間に、２対のローラからなる平滑手段８０が配設され、この平滑手段８０の中間に被加工材１００へのプレス加工位置を規定する所定のマーク１４０を被加工材１００表面に対し被加工材長手方向へ所定間隔で複数マーキングするマーク付与手段７０が配設される。各プレス装置１０、２０、３０は、所定の一方向に送られる被加工材１００のマーク１４０を各マーク検出手段４０で検知すると、マーク１４０で規定される被加工材１００の所定位置に対してプレスを行う仕組みである。
【００１９】
次に、本実施形態に係る伝熱部形成方法による被加工材の成型動作について説明する。あらかじめ、被加工材１００はコイル１０１からの引出直後時点において撮像装置５０で欠陥を監視されており（図２参照）、欠陥がない場合には、被加工材１００はプール部６０を経て、平滑手段８０で被加工材１００を均平に平滑化した後にマーク付与手段７０で長手方向所定間隔でプレス位置指示用のマーク１４０を表面に付けられた上で、プレス装置側に送られる。マーク１４０は、被加工材の送り方向に一致する長手方向の両端部分所定位置にそれぞれ付けられると共に、両端部分に挟まれた中間部分の複数箇所に所定間隔でそれぞれ付けられる（図３参照）。
【００２０】
マーク付与後のプレス動作は、まず、被加工材送り方向について三つのプレス装置のうち最も後方側となるプレス装置１０で行う。このプレス装置１０の上型１１と下型１２とをあらかじめ互いに離れた初期状態とした後、被加工材１００を所定の被加工材送り部（図示を省略）で送り、被加工材１００の送り方向の最前方となる一端部をプレス装置１０の上型１１と下型１２との間に挿入していく。この被加工材送り部で被加工材１００をプレス装置１０の上下型間に送込む間、プレス装置１０のマーク検出手段４０を通じてマーク検出が行われる。
【００２１】
被加工材１００の一端部がプレス装置１０の型間に移動し、マーク検出手段４０が被加工材１００の最も一端寄りのマーク１４０を検出すると、被加工材１００の送りが一時停止されると共に、プレス装置１０が上型１１と下型１２を互いに近付け、被加工材１００をプレスする（図４（Ａ）参照）。被加工材１００の一端部はプレス装置１０の上型１１と下型１２で押圧され、均等に圧力を加えられて型に応じた所定の凹凸形状に確実に成型される。
【００２２】
被加工材１００一端部の成型後、プレス装置１０は上型１１と下型１２とを互いに離隔させる一方、被加工材送り部が被加工材１００の送りを再開し、被加工材１００の一端部をプレス装置１０から次のプレス装置２０側に進める。
続いて、被加工材送り方向について中間に位置するプレス装置２０にプレス動作を行わせる。このプレス装置２０の上型２１と下型２２とをあらかじめ互いに離れた初期状態とした後、被加工材送り部で被加工材１００を送り、被加工材１００の既に凹凸形状を加工した一端部をプレス装置２０の上下型間に通して通過させ、被加工材１００の一端部に隣接する部分を上型２１と下型２２との間へ移動させる。
【００２３】
このプレス装置２０においても、マーク検出手段４０を通じてマーク検出を行っており、被加工材１００の一端部隣接部分がプレス装置２０の型間に移動し、マーク検出手段４０が被加工材１００の一端側から二番目のマーク１４０を検出すると、被加工材１００の送りが一時停止されると共に、プレス装置２０が上型２１と下型２２を互いに近付け、被加工材１００をプレスする（図４（Ｂ）参照）。前記プレス装置１０同様、被加工材１００の一端部隣接部分はプレス装置２０の上型２１と下型２２で押圧され、均等に圧力を加えられて型に応じて所定の凹凸形状に確実に成型される。
【００２４】
この成型後、プレス装置２０が上型２１と下型２２とを互いに離隔させる一方、被加工材送り部が被加工材１００の送りを再開し、次のマーク１４０がマーク検出手段４０で検出されるまで被加工材１００を送り方向へ移動させる。そして、マーク検出手段４０がマーク１４０を検出したら、プレス装置２０が前記同様に被加工材１００の新たな所定部分をプレスする。
【００２５】
この後、前記同様に被加工材１００の送り、マーク検出、プレス成型の一連の工程が被加工材１００の最も両端寄りのマーク１４０を除いたマーク１４０の数だけ複数回繰返され、マーク１４０によりプレスを指示される各プレス装置２０が、プレス毎に所定長さずつ送られる被加工材１００に対し被加工材長手方向へ所定間隔でプレスを複数回行うこととなり、被加工材１００にはプレス装置２０により成型された凹凸形状パターンが被加工材長手方向へ複数並んだ状態となる。
【００２６】
最後に、プレス装置２０による複数回のプレスが全て終了した後、被加工材送り方向の最前方側となるプレス装置３０にプレス動作を行わせる。このプレス装置３０の上型３１と下型３２とをあらかじめ互いに離れた初期状態とした後、被加工材送り部で被加工材１００を送り、被加工材１００の既に凹凸形状を加工した各部をプレス装置３０の上下型間に通して通過させ、被加工材１００の他端部を上型３１と下型３２との間へ移動させる。長手方向他端部をプレス装置の上型３１と下型３２との間に挿入していく。
【００２７】
このプレス装置３０においても、マーク検出手段４０を通じてマーク検出を行っており、被加工材１００の他端部がプレス装置３０の型間に移動し、マーク検出手段４０が被加工材１００の最も他端側のマーク１４０を検出すると、被加工材１００の送りが一時停止されると共に、プレス装置３０が上型３１と下型３２を互いに近付け、被加工材１００をプレスする（図４（Ｃ）参照）。前記同様、被加工材１００の他端部はプレス装置３０の上型３１と下型３２で押圧され、均等に圧力を加えられて型に応じた所定の凹凸形状に確実に成型される。このプレス装置３０のプレス成型中に被加工材１００は、所定の長さでカッター部９０で切断される。
【００２８】
プレス装置３０によるプレス成型が終了すると、プレス装置３０が上型３１と下型３２とを互いに離隔させる一方、被加工材送り部が被加工材１００の送りを再開し、被加工材１００を送り方向へ移動させてプレス装置３０から排出し、この加工済の被加工材１００を伝熱部として次工程へ移送する。
このように本実施形態に係る伝熱部形成方法においては、長尺の被加工材１００に対しプレス装置２０でプレス位置をずらしながらプレスを複数回行い、被加工材１００に所定の凹凸形状パターンを複数並んだ状態として形成することから、長尺の被加工材１００に対しても凹凸形状パターンを全体にわたって適切にプレス成型できることとなり、金型より大きい長尺の伝熱部を確実に成型でき、伝熱部一つあたりの大きさを大きくして熱交換能力を高めた熱交換器を製作可能となる。
【００２９】
また、プレス成型前にあらかじめ撮像装置５０で被加工材１００を撮像して被加工材１００表面の欠陥の有無をチェックし、欠陥がある場合には欠陥部分を除去した上で被加工材１００をプレス装置１０、２０、３０に送ることから、確実に欠陥のない被加工材１００を各プレス装置に送って加工でき、プレス後の伝熱部に欠陥を残すこともなく、不良品化を防止すると共に、安全性を確保できる。
【００３０】
さらに、被加工材１００にマーク付与手段７０でプレス位置指示用のマーク１４０を付け、各プレス装置１０、２０、３０のマーク検出手段４０がマーク１４０を検出すると、プレス装置１０、２０、３０がマーク１４０に合わせて被加工材１００のプレスを行うことから、プレス装置１０、２０、３０が被加工材１００のプレスを行うべき位置を正しく取得して該当する位置に対しプレスを行うことができ、厳密にプレス位置合わせが行え、被加工材１００における加工後の形状精度を向上させられる。
【００３１】
（本発明の第２の実施形態）
以下、本発明の第２の実施形態に係る伝熱部形成方法を図６及び図７に基づいて説明する。図６は本実施形態に係る伝熱部形成方法におけるプレス成型前段のマーキング付与手段構成図、図７は図６に記載のマーク付与手段によるマーキング動作説明図である。
【００３２】
前記各図において本実施形態に係る伝熱部形成方法は、前記第１の実施形態と同様にコイル１０１から長尺の金属薄板の被加工物１００がプール部６０及び平滑手段８０を介してプレス装置１０、２０、３０へ供給される構成とし、この構成に加え、前記平滑手段８０の後段においてマーク付与手段の複数の塗布ノズル７１、７２、７３で被加工材１００上に複数のマークを付与する構成である。
【００３３】
前記マーク付与手段７１は、被加工材１００の略中央の仮想の中心線Ｃ０を演算して、この中心線Ｃ０上に後段のプレス装置１０、２０、３０がプレス加工を実行する所定位置に対応する間隔でマークＰ１、〜、Ｐｎを付与する構成である。また、前記塗布ノズル７２、７３は、前記演算された中心線Ｃ０に直交する直交線Ｃ０１、〜、Ｃ０ｎを演算して、この直交線Ｃ０１、〜、Ｃ０ｎの両端所定箇所にマークＰ１１・Ｐ１２、〜、Ｐｎ１・Ｐｎ２を付与する構成である。
【００３４】
次に、前記構成に基づく本実施形態の伝熱部形成方法による伝熱部の成型動作について説明する。まず、前記実施形態の場合と同様にコイル１０１から被加工物１００がプール部６０及び平滑手段８０を介して引き出される。このように引き出された被加工材１００に対して塗布ノズル７１が略中央にマークＰ１、Ｐ２を付与し、このマークＰ１、Ｐ２を結ぶ仮想の線分に中心線Ｃ０を演算する。このマークＰ１、Ｐ２の間隔は、第一番目にプレス加工を施す領域に対応する位置間隔である。
【００３５】
この演算された中心線Ｃ０に直交してマークＰ１を通る直交線Ｃ０１を演算し、この直交線Ｃ０１の両端近傍にＰ１１、Ｐ１２マークを塗布ノズル７２、７３で付与する。この最先端部の直交線Ｃ０１がカッター部９０により切断する切断箇所Ｃ１Ｃ２となる。この中心線Ｃ０に直交しマークＰ２を通る直交線Ｃ０２を演算し、この直交線Ｃ０２の両端近傍にマークＰ２１、Ｐ２２を塗布ノズル７２、７３で付与する。
【００３６】
前記中心線Ｃ０を前段側（コイル１０１側）へ延長させ、この延長された中心線Ｃ０上の第二番目にプレス加工を施す領域に対応する位置にマークＰ３を塗布ノズル７１が付与する。この延長されたＣ０に直交しマークＰ３を通る直交線Ｃ０３を演算し、この直交線Ｃ０３の両端近傍にマークＰ３１、Ｐ３２を塗布ノズル７２、７３が付与する。
【００３７】
このように中心線Ｃ０を順次延長して最終番目（ｎ−１）までマークを付与し、最終マークＰｎを通る直交線分の直交線Ｃ０ｎがカッター部９０より切断する切断箇所ＣｎＣｎ＋１となる。
以上のように隣接する３点のマークＰ１・Ｐ２・Ｐ３（又はＰ２・Ｐ３・Ｐ４、〜、Ｐｎ−２・Ｐｎ−１・Ｐｎ）の平面部分のみで、伝熱部を形成するのに必要な長さ（マークＰ１からマークＰｎの間隔）の全体が連続する直線を中心線Ｃ０として形成できることとなり、この中心線Ｃ０に基づいて複数のプレス加工位置を示すマークＰ１、〜、Ｐｎ、Ｐ１１、〜、Ｐｎ１、Ｐ１２、〜、Ｐｎ２をバナナシェープ状の被加工材１００上に確実且つ正確に付与できることとなる。
【００３８】
このマークＰ１、〜、Ｐｎ、Ｐ１１、〜、Ｐｎ１、Ｐ１２、〜、Ｐｎ２が付与され、直交線Ｃ０１及び直交線Ｃ０ｎで切断された被加工材１００を後段のプレス装置１０、２０、３０で前記第１の実施形態と同様にプレス加工が実行される。
（本発明の第３の実施形態）
以下、本発明の第３の実施形態に係る伝熱部形成方法を図８ないし図１１に基づいて説明する。図８は本実施形態に係る伝熱部形成方法におけるマーキング付与動作を実行する部分のブロック構成図、図９及び図１０は図８に記載の伝熱部形成方法によるマーキング動作説明図、図１１は図８に記載の伝熱部形成方法によりマークが付与された被加工材の全体平面図を示す。
【００３９】
前記各図において本実施形態に係る伝熱部形成方法は、前記第２の実施形態と同様にコイル１０１から長尺の金属薄板の被加工物１００がプール部６０、平滑手段８０、マーク付与手段７０及びカッター部９０を介してプレス装置１０、２０、３０へ供給される構成とし、この構成に加え、前記平滑手段８０の後段において被加工材１００の幅方向全領域で且つ長手方向の所定長さを撮像する端縁撮像手段５１と、前記撮像される被加工材１００の端縁距離を演算する端縁距離演算部５２と、この演算された端縁距離に基づいて前記プレス装置１０、２０、３０がプレス加工を施すプレス位置を判断するプレス位置判断部５３と、この判断されたプレス位置データに基づいてマーク付与手段７０を移動制御してマーク位置を制御するマーク位置移動制御部５４とを備える構成である。
【００４０】
前記端縁距離演算部５２は、端縁撮像手段５１により撮像された撮像データに基づいて前記被加工材１００の表面に仮想の中心点Ｐ０１、Ｐ０２、Ｐ０３及びこの仮想の中心点Ｐ０１、Ｐ０２、Ｐ０３の両側の所定距離に仮想の側端点Ｐ０１１・Ｐ０１２、Ｐ０２１・Ｐ０２２、Ｐ０３１・Ｐ０３２を特定し、この仮想の側端点Ｐ０１１・Ｐ０１２、Ｐ０２１・Ｐ０２２、Ｐ０３１・Ｐ０３２から被加工材１００の側端縁までの端縁距離α１・β１、α２・β２、α３・β３を演算する構成である。
【００４１】
前記プレス位置判断部５３は、前記演算された端縁距離α１・β１、α２・β２、α３・β３に基づいて前記被加工材１００の湾曲状態（バナナシェープ状態）を類推し、この類推された湾曲状態の被加工材１００に対してプレス装置１０、２０、３０がプレス加工を施すプレス位置を判断してプレス位置データを出力する構成である。前記マーク位置移動制御部５４は、出力されたプレス位置データに基づいてマーク付与手段７０の被加工材１００に対するマーク付与位置を移動制御する構成である。
【００４２】
次に、前記構成に基づく本実施形態の伝熱部形成方法による伝熱部の成型動作について説明する。まず、前記実施形態の場合と同様にコイル１０１から被加工物１００がプール部６０及び平滑手段８０を介して引き出される。このように引き出された被加工材１００の表面を端縁撮像手段５１が撮像し、この撮像データに基づいて前記端縁距離演算部５２は、図９に示すように被加工材１００のほぼ中央に仮想の中心点Ｐ０１を設定し、この仮想の中心点Ｐ０１から長手方向に延出する仮想の中心線Ｃ０１を演算する。また、この仮想の中心線Ｃ０１上にプレス位置の間隔に相当する間隔で仮想の中心点Ｐ０２、Ｐ０３を設定する。このように設定された仮想の中心点Ｐ０１、Ｐ０２、Ｐ０３から両側に所定間隔離反させて側端点Ｐ０１１・Ｐ０１２、Ｐ０２１・Ｐ０２２、Ｐ０３１・Ｐ０３２を特定する。さらに、端縁距離演算部５２は、各々特定した側端点Ｐ０１１・Ｐ０１２、Ｐ０２１・Ｐ０２２、Ｐ０３１・Ｐ０３２から被加工材１００の側端縁までの端縁距離α１・β１、α２・β２、α３・β３を演算してプレス位置判断部５３へ出力する。
【００４３】
このプレス位置判断部５３は、図９に示すように端縁距離α1・β1、α2・β2、α3・β3に関する変化の推移（α1＞α2＞α3；減少傾向）、（β1＜β2＜β3；増加傾向）に基づいて被加工材１００の湾曲状態を類推し、この類推された湾曲状態の被加工材１００に対してプレス装置１０、２０、３０がプレス加工を施すプレス位置を判断してプレス位置データをマーク位置移動制御部５４へ出力する。このマーク位置移動制御部５４は、プレス位置データに基づいてマーク付与手段７０を補正距離γだけ増加傾向側にスライド移動させる（図１０を参照）。
【００４４】
このスライド移動させたマーク付与手段７０は、図１０に示すように仮想の中心線Ｃ０１から前記補正移動距離γだけ偏移した位置に新たな中心線Ｃ１を設定し、この中心線Ｃ１に基づいて中心点Ｐ１、Ｐ２、Ｐ３及び側端点Ｐ１１・Ｐ１２、Ｐ２１・Ｐ２２、Ｐ３１・Ｐ３２、・・・が被加工材１００上に搬送方向へ順次マーク付与手段７０により塗布されることとなる。
【００４５】
このように被加工材１００が湾曲形態であっても図１１に示すように被加工材１００の先端部分における複数の端縁距離をα１・β１、α２・β２、α３・β３で被加工材１００の最適位置にプレス加工の位置を選択できることとなる。
このプレス加工の位置が特定されると、このプレス位置を示す側端点Ｐ１１・Ｐ１２、Ｐ２１・Ｐ２２、Ｐ３１・Ｐ３２、・・・に基づいてカッター部９０及びプレス装置１０、２０、３０が前記各実施形態と同様に切断及びプレス成型を実行することとなる。
【００４６】
【発明の効果】
以上のように本発明によれば、長尺の被加工材における長手方向にマーキングされた複数個のマークを結ぶ仮想の中心線を演算し、この仮想の中心線上の仮想の中心点及び／又はこの仮想の中心点から所定距離の仮想の側端点を特定し、この特定された仮想の中心点又は仮想の側端点から被加工材の側端縁までの端縁距離を算出し、この端縁距離の変化推移に基づいて増加傾向側へ補正距離だけスライド移動させて新たなマークを複数付与し、この新たなマークで規定される被加工材の所定位置に対し所定のプレス装置でプレス位置をずらしながらプレスを複数回行い、被加工材に所定の凹凸形状パターンを複数並んだ状態として形成することにより、湾曲形態を有する長尺の被加工材に対しても先端部分の端縁距離の変化推移で被加工材の湾曲状態を類推できることとなり、この類推された湾曲状態を有する被加工材の最適位置にプレス加工の位置を選択できる。また、プレス装置がマークに合わせて被加工材のプレスを行い、被加工材のマークを付けられた複数箇所に凹凸形状パターンがそれぞれ形成されることにより、プレス装置が被加工材のプレスを行うべき位置を正しく取得して該当する位置をプレスすることができ、厳密にプレス位置合わせが行え、被加工材における加工後の形状精度を向上させられる。さらに、凹凸形状パターンを全体にわたって適切にプレス成型できることとなり、金型より大きい長尺の伝熱部を確実に成型でき、伝熱部一つあたりの大きさを大きくして熱交換能力を高めた熱交換器を製作できるようになるという効果を奏する。
【００４７】
また、本発明によれば、被加工材の長手方向両端部に対し複数並設したプレス装置のいずれかでそれぞれプレスを行い、被加工材の両端部に長手方向中間部分とは少なくとも異なる凹凸形状パターンを他の凹凸形状パターンと並んだ状態として形成することにより、長尺の被加工材両端部に伝熱部として最適となる凹凸形状パターンを適切にプレス成型できることとなり、長手方向中間部分と条件が異なる両端部についても熱交換能力が最適化された伝熱部を形成できると共に、複数並設したプレス装置で被加工材の各成型工程を連続的に行え、成型作業能率を大幅に向上させられるという効果を有する。
【００４８】
また、本発明によれば、プレス装置が被加工材の幅方向端部に長手方向へ連続させて段差部分を形成し、被加工材に長手方向の曲げに対する所定の強度を与えることにより、被加工材が長尺であっても曲がりにくくなることとなり、被加工材の加工後の形状を維持させて後工程での加工を容易にすると共に、伝熱部としての強度を高めることができるという効果を有する。
【００４９】
また、本発明によれば、プレス装置が被加工材の幅方向端部に所定の平坦部分と複数の凹部又は凸部を形成し、平坦部分を被加工材における所定の加工代とすることにより、プレス後に被加工材を伝熱部として最終的に溶接加工する場合に、平坦部分を溶接代として用いて溶接作業を容易に行えると共に、被加工材を幅方向両側から把持可能となり、被加工材の搬送も容易に行えるという効果を有する。さらに、平坦部分に複数の凹部又は凸部で被加工材幅方向の曲げに対する所定の強度を与えることにより、平坦部分が被加工材幅方向に曲りにくくなり、平坦部分を把持して被加工材を支持する場合における被加工材の幅方向のたわみを防ぐことができるという効果を有する。
【００５０】
また、本発明によれば、プレス成型前にあらかじめ撮像装置で被加工材を撮像して被加工材表面の欠陥の有無をチェックし、欠陥がある場合には欠陥部分を除去して被加工材の欠陥のない部分をプレス装置に送ることにより、プレス装置で欠陥のある被加工材を加工した後に欠陥判明による不良品化で被加工材が無駄になるのを防ぐと共に、確実に欠陥部分を除いた上で被加工材をプレス装置に送ることで、誤ってプレス成型後の伝熱部に欠陥が残ったままとなるのを防止でき、安全性を確保できるという効果を有する。
【図面の簡単な説明】
【図１】本発明の第１の実施形態に係る伝熱部形成方法を適用するプレス装置の概略構成図である。
【図２】本発明の第１の実施形態に係る伝熱部形成方法による被加工材供給状態説明図である。
【図３】本発明の第１の実施形態に係る伝熱部形成方法による被加工材マーク状態説明図である。
【図４】本発明の第１の実施形態に係る伝熱部形成方法による被加工材成型工程説明図である。
【図５】本発明の第１の実施形態に係る伝熱部形成方法による被加工材成型後状態説明図である。
【図６】本発明の第２の実施形態に係る伝熱部形成方法におけるプレス成型前段のマーキング付与手段構成図である。
【図７】図６に記載のマーク付与手段によるマーキング動作説明図である。
【図８】本発明の第３の実施形態に係る伝熱部形成方法におけるマーキング付与動作を実行する部分のブロック構成図である。
【図９】図８に記載の伝熱部形成方法マーキング動作説明図である。
【図１０】図８に記載の伝熱部形成方法マーキング動作説明図である。
【図１１】図８に記載の伝熱部形成方法によりマークが付与された被加工材の全体平面図
【符号の説明】
１０、２０、３０プレス装置
１１、２１、３１上型
１２、２２、３２下型
４０マーク検出手段
５０撮像装置
５１端縁撮像手段
５２端縁距離演算部
５３プレス位置判断部
５４マーク位置移動制御部
６０プール部
７０マーク付与手段
７１、７２、７３塗布ノズル
８０平滑手段
９０カッター部
１００被加工材
１０１コイル
１１０段差部分
１２０平坦部分
１３０凸部
１４０マーク[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a heat transfer portion forming method for forming a heat transfer portion of a heat exchanger by press forming a work material, and in particular, press forming a work material a plurality of times so that a plurality of uneven patterns are arranged. The present invention relates to a heat transfer portion forming method.
[0002]
[Prior art]
The heat transfer part in the heat exchanger is generally made of a thin metal plate, and is formed into a predetermined shape by press working for use. Conventionally, a set of molds has been used to mold the heat transfer section using a press device, and workpieces are placed between the molds that make up the set, and the workpieces are moved in a relational motion, allowing the workpieces to move. The uneven | corrugated shaped pattern as a heat-transfer part was formed in the metal thin plate which is material.
[0003]
[Problems to be solved by the invention]
Since the conventional heat transfer part press molding has been performed as described above, the uneven pattern of the entire heat transfer part is molded with a set of molds, forming an uneven pattern larger than the size of the mold. I couldn't. For this reason, the size of the heat transfer part is limited by the size of the mold, and there is a problem that a heat transfer part having a large area cannot be manufactured due to limitations in the dimension of the mold.
[0004]
In addition, the thin metal sheet wound in the shape of a coil, which is the material of the heat transfer part, does not have parallel linearity at both ends due to stress distribution and non-uniformity of elongation during rolling, and gently It is in a so-called banana shape state that bends. When trying to form a heat transfer part of a long object with this banana-shaped metal thin plate, there is a problem that a plurality of pressing positions cannot be accurately determined from both ends, and accurate pressing is not possible. It was.
[0005]
The present invention has been made in order to solve the above-described problems. A plurality of predetermined concavo-convex patterns can be formed side by side by pressing a workpiece a plurality of times with a press device, and even for a long workpiece. It is an object of the present invention to provide a method for forming a heat transfer part that can easily form a heat transfer surface larger than a mold by forming an uneven shape without any leakage.
[0006]
[Means for Solving the Problems]
The heat transfer part forming method according to the present invention is a heat transfer part for forming a heat transfer part for a heat exchanger by press-molding a workpiece made of a thin metal plate into a predetermined uneven shape with an upper die and a lower die of a press device. In the forming method, for a long workpiece that is transferred in a single feed direction parallel to the longitudinal direction, a press device having a mold shorter than the workpiece is provided at a predetermined interval in the longitudinal direction on the workpiece. Pressing a plurality of predetermined locations, and forming the heat transfer part as a shape in which a plurality of predetermined uneven patterns are arranged in the longitudinal direction And at least before pressing the workpiece with the pressing device, a predetermined mark for defining a press position on the workpiece with respect to the workpiece surface is provided with a predetermined mark applying device. A virtual center line that connects a plurality of marks that are given at predetermined intervals in the direction and connects the plurality of marks marked at predetermined intervals in the longitudinal direction of the workpiece is calculated, and an interval that corresponds to the interval between the press positions on the virtual center line. To specify a virtual center point and / or a virtual side end point at a predetermined distance on both sides of the virtual center point, and the virtual center point or virtual side end point sequentially specified in the conveying direction of the workpiece. Each edge distance to the side edge of the workpiece is calculated, and based on the transition of each edge distance change, the mark applying device is slid to the increasing tendency side by the correction distance, and a plurality of distances are applied to the workpiece surface. The direction of the individual marks A plurality of grant, upon detecting a mark the granted at predetermined mark detection means, performs the press to a predetermined position of the workpiece defined by the mark Is. Thus, in the present invention, a long work material A virtual center line connecting a plurality of marks marked in the longitudinal direction is calculated, and a virtual center point on the virtual center line and / or a virtual side end point at a predetermined distance from the virtual center point is specified. Calculate the edge distance from the specified virtual center point or the virtual side end point to the side edge of the workpiece, and slide the correction distance toward the increasing tendency based on the change in the edge distance. A plurality of new marks, and a predetermined position on the workpiece defined by the new marks. In contrast, by performing the press a plurality of times while shifting the press position with a predetermined pressing device, by forming a plurality of predetermined uneven shape patterns on the workpiece, Has a curved form Even for long workpieces The curved state of the workpiece can be inferred from the change of the edge distance of the tip portion, and the press working position can be selected as the optimum position of the workpiece having the inferred curved state. Further, the pressing device presses the workpiece in accordance with the mark, and the uneven device is formed at a plurality of locations marked with the workpiece, whereby the pressing device presses the workpiece. The power position can be correctly acquired and the corresponding position can be pressed, the press position can be strictly adjusted, and the shape accuracy after processing of the workpiece can be improved. further, The uneven pattern can be properly press-formed throughout, and heat transfer parts that are longer than the mold can be reliably formed, and the heat exchange capacity is increased by increasing the size of each heat transfer part. Can be made.
[0007]
In addition, the heat transfer portion forming method according to the present invention includes, as necessary, a plurality of other press devices having a mold shorter than the workpiece before and after the press device in the feed direction of the workpiece, Either one of the other pressing devices presses the predetermined range on one end side in the longitudinal direction and the predetermined range on the other end side of the workpiece before and after pressing to a plurality of locations on the workpiece by the pressing device, respectively. The part is formed as a shape in which a plurality of at least two types of uneven patterns are arranged in the longitudinal direction. As described above, in the present invention, the pressing is performed by any one of a plurality of press devices arranged in parallel with respect to both ends in the longitudinal direction of the workpiece, and the uneven shape is at least different from the longitudinal intermediate portion at both ends of the workpiece. By forming the pattern side by side with other concavo-convex pattern, the concavo-convex pattern that is optimal as a heat transfer part can be appropriately press-molded at both ends of the long workpiece, and the longitudinal intermediate portion and conditions Heat transfer parts with optimized heat exchanging capacity can be formed at both ends that differ, and each molding process of workpieces can be performed continuously with multiple press devices, greatly improving the molding work efficiency. It is done.
[0008]
Further, in the heat transfer portion forming method according to the present invention, if necessary, the pressing device forms step portions that are stepped with respect to the center portion in the width direction at both ends in the width direction of the work material. It is formed continuously in the direction. As described above, in the present invention, the pressing device forms a stepped portion continuously in the longitudinal direction at the end portion in the width direction of the workpiece, and gives the workpiece a predetermined strength against bending in the longitudinal direction. Even if the processed material is long, it becomes difficult to bend, and the shape of the processed material after the processing can be maintained to facilitate the processing in the subsequent process, and the strength as the heat transfer section can be increased.
[0009]
Further, in the heat transfer portion forming method according to the present invention, the press device forms a flat portion having a predetermined width at both ends in the width direction of the workpiece, and a predetermined recess or A plurality of convex portions are formed at predetermined intervals in the longitudinal direction of the workpiece. Thus, in the present invention, the press device forms a predetermined flat portion and a plurality of concave portions or convex portions at the width direction end portion of the workpiece, and the flat portion is used as a predetermined machining allowance in the workpiece. When the work material is finally welded as a heat transfer part after pressing, the flat part can be used as a welding allowance for easy welding work, and the work material can be gripped from both sides in the width direction. The material can be transported easily. Further, by giving the flat portion a predetermined strength against bending in the workpiece width direction by a plurality of recesses or projections, the flat portion becomes difficult to bend in the workpiece width direction, and the workpiece is gripped by the flat portion. Can be prevented from bending in the width direction of the workpiece.
[0010]
In addition, the heat transfer portion forming method according to the present invention detects a surface state or an internal structure of the work material with a predetermined detection device, at least before the work material is press-molded with the press device, if necessary. The detected data is analyzed by a predetermined data analysis means to determine the surface or internal defect of the workpiece, and when the workpiece is defective, the feed of the workpiece to the press device is stopped. The defective part is removed from each part on the front and rear side in the feeding direction of the defective part, and the defective part in the feeding direction rear side is newly detected and sent to the pressing device while being detected by the detection device. It is. Thus, in the present invention, before press molding, the workpiece is imaged in advance by an imaging device to check for the presence of defects on the workpiece surface, and if there is a defect, the defective portion is removed and the workpiece is removed. By sending the defect-free part to the press device, after the defective work material is processed by the press device, it is possible to prevent the work material from being wasted due to defective products by identifying the defect, and to ensure that the defective part is By sending the workpiece to the press device after removing it, it is possible to prevent a defect from remaining in the heat transfer section after the press molding by mistake and to ensure safety.
[0012]
DETAILED DESCRIPTION OF THE INVENTION
(First embodiment of the present invention)
Hereinafter, a heat transfer portion forming method according to a first embodiment of the present invention will be described with reference to FIGS. FIG. 1 is a schematic configuration diagram of a press apparatus to which a heat transfer portion forming method according to the present embodiment is applied, FIG. 2 is an explanatory diagram of a workpiece supply state by the heat transfer portion forming method according to the present embodiment, and FIG. Work material mark state explanatory view by the heat transfer part forming method according to the embodiment, FIG. 4 is a work material forming process explanatory view by the heat transfer part forming method according to the present embodiment, FIG. 5 is a heat transfer part according to the present embodiment It is state explanatory drawing after the workpiece material shaping | molding by the formation method.
[0013]
In each of the drawings, the heat transfer portion forming method according to the present embodiment is based on the end of three pressing devices arranged in parallel in the feed direction of the workpiece 100 with respect to the workpiece 100 made of a long thin metal plate. The two pressing devices 10 and 30 respectively perform predetermined pressing on both ends of the workpiece 100 in the longitudinal direction, and the intermediate pressing device 20 determines the longitudinal direction of the workpiece 100 to be fed by a predetermined length. The press is performed a plurality of times at intervals, and a plurality of predetermined uneven patterns are arranged on the workpiece 100 in the longitudinal direction of the workpiece to form a heat transfer portion for the heat exchanger.
[0014]
Each of the press devices 10, 20, and 30 used in the heat transfer portion forming method according to this embodiment is disposed so as to be movable up and down within a predetermined range with a mold surface for molding one surface shape of the heat transfer portion facing downward. The upper molds 11, 21, and 31 and the mold surface for molding the other surface shape of the heat transfer section are directed upward and disposed below the upper molds 11, 21, 31 so as to face the upper molds 11, 21, 31. The lower molds 12, 22, 32, and the upper molds 11, 21, 31 and the lower mold 12 are disposed in the vicinity of the upper molds 11, 21, 31 and the lower molds 12, 22, 32. It is a structure provided with the mark detection means 40 which determines whether the press target location of the workpiece 100 arrived at the possible position.
[0015]
The upper molds 11, 21, 31 and the lower molds 12, 22, 32 of the press devices 10, 20, 30 form a predetermined concavo-convex pattern at the intermediate portion in the width direction of the workpiece 100, and both end portions in the width direction And forming a stepped portion 110 having a step difference with respect to the central portion in the width direction continuously in the longitudinal direction of the workpiece, and forming a flat portion 120 having a predetermined width on the outer side in the widthwise direction of the stepped portion 110, The flat portion 120 has a mold shape in which a plurality of convex portions 130 having a predetermined height are formed at predetermined intervals in the longitudinal direction of the workpiece (see FIG. 5). In this way, the stepped portion 110, the flat portion 120, and the convex portion 130 are formed at both ends in the width direction of the workpiece 100, respectively, and the stepped portion 110 gives the workpiece 100 a predetermined strength against bending in the longitudinal direction, Since the projection 130 gives the flat portion 120 a predetermined strength against bending in the workpiece width direction, the workpiece 100 is unlikely to be deformed, and the workpiece 100 is kept in the shape after press molding in a subsequent process. Can be easily processed. In addition, since the flat portion 120 becomes a predetermined machining allowance in the workpiece 100 after pressing, when the workpiece 100 is finally welded as a heat transfer portion after pressing, the flat portion 120 is replaced with a welding allowance. As a result, the workpiece 100 can be gripped from both sides in the width direction, and the workpiece 100 can be easily conveyed.
[0016]
On the other hand, a predetermined imaging device 50 that images the surface state of the workpiece 100 is disposed at a position upstream of the press devices 10, 20, 30 and immediately after the workpiece 100 is pulled out from the coil 101. The image obtained by the imaging device 50 is analyzed by a predetermined image analysis means (not shown) to determine a defect on the surface of the workpiece 100. If the workpiece 100 has a defect, the workpiece 100 is stopped from feeding to the pressing device, and the defective portion is removed from the remaining portion of the workpiece 100 before and after the defective portion, and the remaining portion on the rear side in the feed direction from the defective portion is imaged. The apparatus 50 is configured to resume feeding to the press apparatus while taking an image.
[0017]
And between the imaging position by the imaging device 50 and the press apparatus 10, the part (pool part 60) which pools the to-be-processed material 100 by the predetermined length which can be formed as at least 1 heat-transfer part is provided. By securing a sufficiently long workpiece 100 in the pool portion 60, even if a defective portion of the workpiece 100 is detected and removed, a press on the workpiece 100 in the feed direction front side from the defective portion is performed. The molding can be reliably performed only for one heat transfer portion to the end, and the processing loss for the workpiece 100 can be reduced.
[0018]
Further, smoothing means 80 composed of two pairs of rollers is disposed between the pool section 60 and the pressing apparatus 10, and a predetermined position for defining a press processing position on the workpiece 100 is provided between the smoothing means 80. Mark providing means 70 is provided for marking a plurality of marks 140 at a predetermined interval in the longitudinal direction of the workpiece 100 with respect to the surface of the workpiece 100. When each of the pressing devices 10, 20, 30 detects the mark 140 of the workpiece 100 that is sent in a predetermined direction by each mark detection means 40, the press device 10, 20, 30 corresponds to a predetermined position of the workpiece 100 defined by the mark 140. This is a mechanism for pressing.
[0019]
Next, the molding operation of the workpiece by the heat transfer portion forming method according to the present embodiment will be described. The workpiece 100 is previously monitored for defects by the imaging device 50 immediately after being pulled out from the coil 101 (see FIG. 2). If there is no defect, the workpiece 100 passes through the pool portion 60 and is smoothed. After the workpiece 100 is smoothed evenly by the means 80, marks 140 for indicating the press position are attached to the surface at predetermined intervals in the longitudinal direction by the mark applying means 70, and then sent to the press apparatus side. The marks 140 are respectively attached at predetermined positions at both end portions in the longitudinal direction that coincide with the feed direction of the workpiece, and are respectively attached at predetermined intervals at a plurality of intermediate portions sandwiched between the both end portions (see FIG. 3).
[0020]
The press operation after the application of the mark is first performed by the press device 10 which is the rearmost side among the three press devices in the workpiece feed direction. After the upper mold 11 and the lower mold 12 of the press device 10 are set in an initial state separated from each other in advance, the workpiece 100 is fed by a predetermined workpiece feed section (not shown), and the workpiece 100 is fed. One end part which becomes the forefront of the direction is inserted between the upper die 11 and the lower die 12 of the press device 10. While the workpiece 100 is fed between the upper and lower molds of the press apparatus 10 by this workpiece feed section, mark detection is performed through the mark detection means 40 of the press apparatus 10.
[0021]
When one end of the workpiece 100 moves between the dies of the press apparatus 10 and the mark detection means 40 detects the mark 140 closest to the one end of the workpiece 100, the feed of the workpiece 100 is temporarily stopped. The pressing device 10 brings the upper die 11 and the lower die 12 close to each other and presses the workpiece 100 (see FIG. 4A). One end of the workpiece 100 is pressed by the upper mold 11 and the lower mold 12 of the pressing device 10 and is uniformly molded into a predetermined uneven shape corresponding to the mold by applying pressure evenly.
[0022]
After molding one end of the workpiece 100, the press device 10 separates the upper mold 11 and the lower mold 12 from each other, while the workpiece feeding section resumes feeding the workpiece 100, and one end of the workpiece 100 is removed. The part is advanced from the press device 10 to the next press device 20 side.
Subsequently, the pressing device 20 located in the middle in the workpiece feed direction is caused to perform a pressing operation. After the upper die 21 and the lower die 22 of the press device 20 are set in an initial state separated from each other in advance, the workpiece 100 is fed by the workpiece feeding portion, and one end portion where the uneven shape of the workpiece 100 has already been processed. Is passed between the upper and lower molds of the press device 20, and a portion adjacent to one end of the workpiece 100 is moved between the upper mold 21 and the lower mold 22.
[0023]
Also in this press apparatus 20, mark detection is performed through the mark detection means 40, a portion adjacent to one end of the workpiece 100 moves between the molds of the press apparatus 20, and the mark detection means 40 is one end of the workpiece 100. When the second mark 140 from the side is detected, the feeding of the workpiece 100 is temporarily stopped, and the press device 20 brings the upper die 21 and the lower die 22 close to each other and presses the workpiece 100 (FIG. 4 ( B)). Similar to the pressing device 10, a portion adjacent to one end of the workpiece 100 is pressed by the upper die 21 and the lower die 22 of the pressing device 20, and is uniformly molded into a predetermined uneven shape according to the die by applying pressure evenly. Is done.
[0024]
After this molding, the press device 20 separates the upper die 21 and the lower die 22 from each other, while the workpiece feed portion resumes feeding the workpiece 100, and the next mark 140 is detected by the mark detection means 40. The workpiece 100 is moved in the feed direction until And if the mark detection means 40 detects the mark 140, the press apparatus 20 will press the new predetermined part of the workpiece 100 similarly to the above.
[0025]
Thereafter, a series of steps of feeding the workpiece 100, detecting the mark, and press-molding are repeated a plurality of times as many as the number of marks 140 excluding the mark 140 closest to the both ends of the workpiece 100, as described above. Each press device 20 that is instructed to press presses the workpiece 100 that is fed by a predetermined length for each press several times in the longitudinal direction of the workpiece at predetermined intervals. A plurality of concavo-convex patterns formed by the apparatus 20 are arranged in the longitudinal direction of the workpiece.
[0026]
Finally, after all of the multiple presses by the press device 20 are completed, the press device 30 which is the foremost side in the workpiece feed direction is caused to perform a pressing operation. After the upper mold 31 and the lower mold 32 of the press device 30 are set in an initial state separated from each other in advance, the workpiece 100 is fed by the workpiece feed section, and each portion of the workpiece 100 that has already processed the uneven shape is processed. The other end of the workpiece 100 is moved between the upper die 31 and the lower die 32 by passing between the upper and lower dies of the press device 30. The other end in the longitudinal direction is inserted between the upper die 31 and the lower die 32 of the press device.
[0027]
Also in this press apparatus 30, mark detection is performed through the mark detection means 40, the other end portion of the workpiece 100 moves between the molds of the press apparatus 30, and the mark detection means 40 is the most other part of the workpiece 100. When the end mark 140 is detected, the feeding of the workpiece 100 is temporarily stopped, and the press device 30 brings the upper die 31 and the lower die 32 close to each other and presses the workpiece 100 (FIG. 4C). reference). Similarly to the above, the other end portion of the workpiece 100 is pressed by the upper mold 31 and the lower mold 32 of the press device 30, and is uniformly molded into a predetermined uneven shape corresponding to the mold by applying pressure evenly. During the press molding of the press device 30, the workpiece 100 is cut by the cutter unit 90 with a predetermined length.
[0028]
When the press molding by the press device 30 is completed, the press device 30 separates the upper die 31 and the lower die 32 from each other, while the workpiece feed unit resumes feeding the workpiece 100 and feeds the workpiece 100. The processed workpiece 100 is transferred to the next process as a heat transfer section.
As described above, in the heat transfer portion forming method according to the present embodiment, the long workpiece 100 is pressed a plurality of times while shifting the press position with the press device 20, and a predetermined uneven pattern is formed on the workpiece 100. Are formed in a state of being arranged in a plurality, so that the uneven pattern can be appropriately press-formed over the entire length of the workpiece 100, and a long heat transfer portion larger than the mold can be reliably molded. It becomes possible to manufacture a heat exchanger with an increased heat exchange capacity by increasing the size per one heat transfer section.
[0029]
Further, before press molding, the workpiece 100 is imaged in advance by the imaging device 50 to check the presence or absence of defects on the surface of the workpiece 100. If there is a defect, the defective portion is removed and the workpiece 100 is removed. Since it is sent to the press devices 10, 20, and 30, the workpiece 100 without defects can be reliably sent to each press device and processed, and no defects are left in the heat transfer section after pressing, thus preventing defective products. In addition, safety can be ensured.
[0030]
Further, a mark 140 for indicating the press position is attached to the workpiece 100 by the mark applying means 70, and when the mark detecting means 40 of each press apparatus 10, 20, 30 detects the mark 140, the press apparatuses 10, 20, 30 are Since the workpiece 100 is pressed in accordance with the mark 140, the pressing devices 10, 20, and 30 can correctly acquire the position where the workpiece 100 should be pressed and can press the corresponding position. Thus, the press positioning can be performed strictly, and the shape accuracy after processing in the workpiece 100 can be improved.
[0031]
(Second embodiment of the present invention)
Hereinafter, a heat transfer portion forming method according to a second embodiment of the present invention will be described with reference to FIGS. FIG. 6 is a configuration diagram of marking applying means before press molding in the heat transfer portion forming method according to the present embodiment, and FIG. 7 is an explanatory diagram of marking operation by the mark applying means shown in FIG.
[0032]
In each of the drawings, the heat transfer portion forming method according to the present embodiment is similar to the first embodiment, in which a long metal thin workpiece 100 is pressed from the coil 101 through the pool portion 60 and the smoothing means 80. In addition to this configuration, a plurality of marks are applied on the workpiece 100 by a plurality of application nozzles 71, 72, and 73 of the mark applying unit in the subsequent stage of the smoothing unit 80. It is the structure to do.
[0033]
The mark applying means 71 calculates a virtual center line C0 at the substantially center of the workpiece 100, and corresponds to a predetermined position on the center line C0 at which the subsequent press apparatuses 10, 20, and 30 perform press processing. The marks P1,..., Pn are provided at intervals. The application nozzles 72 and 73 calculate orthogonal lines C01 to C0n orthogonal to the calculated center line C0, and marks P11 and P12 are placed at predetermined positions on both ends of the orthogonal lines C01 to C0n. To Pn1 and Pn2.
[0034]
Next, the molding operation of the heat transfer part by the heat transfer part forming method of the present embodiment based on the above configuration will be described. First, the workpiece 100 is pulled out from the coil 101 through the pool portion 60 and the smoothing means 80 as in the case of the above embodiment. The application nozzle 71 assigns marks P1 and P2 to the substantially center of the workpiece 100 drawn in this way, and calculates a center line C0 to a virtual line segment connecting the marks P1 and P2. The interval between the marks P1 and P2 is the position interval corresponding to the first area to be pressed.
[0035]
An orthogonal line C01 orthogonal to the calculated center line C0 and passing through the mark P1 is calculated, and P11 and P12 marks are applied by application nozzles 72 and 73 near both ends of the orthogonal line C01. The orthogonal line C01 at the foremost part becomes a cutting point C1C2 cut by the cutter part 90. An orthogonal line C02 orthogonal to the center line C0 and passing through the mark P2 is calculated, and marks P21 and P22 are applied by application nozzles 72 and 73 near both ends of the orthogonal line C02.
[0036]
The center line C0 is extended to the previous stage side (coil 101 side), and the coating nozzle 71 gives a mark P3 at a position corresponding to the second area to be pressed on the extended center line C0. An orthogonal line C03 orthogonal to the extended C0 and passing through the mark P3 is calculated, and marks P31 and P32 are provided by application nozzles 72 and 73 near both ends of the orthogonal line C03.
[0037]
In this way, the center line C0 is sequentially extended to give marks to the last (n−1), and the orthogonal line C0n of the orthogonal line segment passing through the final mark Pn becomes a cutting point CnCn + 1 where the cutter unit 90 cuts.
As described above, it is necessary to form the heat transfer portion only by the plane portions of the three adjacent marks P1, P2, P3 (or P2, P3, P4, Pn-2, Pn-1, Pn). A straight line having a continuous entire length (interval between the mark P1 and the mark Pn) can be formed as the center line C0, and a plurality of marks P1,..., Pn, P11 indicating a plurality of pressing positions based on the center line C0. ~, Pn1, P12, ~, Pn2 can be reliably and accurately applied on the banana-shaped workpiece 100.
[0038]
The workpieces 100 to which the marks P1,..., Pn, P11,..., Pn1, P12,..., Pn2 are applied and cut along the orthogonal line C01 and the orthogonal line C0n are pressed by the subsequent pressing devices 10, 20, and 30. Press work is executed in the same manner as in the first embodiment.
(Third embodiment of the present invention)
Hereinafter, a heat transfer portion forming method according to a third embodiment of the present invention will be described with reference to FIGS. FIG. 8 is a block configuration diagram of a portion that performs a marking applying operation in the heat transfer portion forming method according to the present embodiment. FIGS. 9 and 10 are explanatory diagrams of marking operations by the heat transfer portion forming method shown in FIG. FIG. 9 shows an overall plan view of a workpiece to which marks are given by the heat transfer portion forming method shown in FIG.
[0039]
In each of the drawings, the heat transfer portion forming method according to the present embodiment is similar to the second embodiment in that the work piece 100 made of a long thin metal plate is formed from the coil 101 into the pool portion 60, the smoothing means 80, and the mark applying means. 70 and the cutter unit 90 to be supplied to the press devices 10, 20, 30. In addition to this configuration, in the subsequent stage of the smoothing means 80, the entire length in the width direction of the workpiece 100 and a predetermined length in the longitudinal direction An edge imaging means 51 for imaging the thickness, an edge distance calculation unit 52 for calculating the edge distance of the workpiece 100 to be imaged, and the press devices 10, 20 based on the calculated edge distance. , 30 is a mark position for controlling the mark position by controlling the movement of the mark applying means 70 based on the determined press position data, and the press position determining section 53 for determining the press position to be pressed. A configuration and a movement control unit 54.
[0040]
The edge distance calculation unit 52 has virtual center points P01, P02, and P03 and virtual center points P01, P02, and the like on the surface of the workpiece 100 based on the imaging data captured by the edge imaging unit 51. Virtual side end points P011 and P012, P021 and P022, and P031 and P032 are specified at predetermined distances on both sides of P03, and the side ends of the workpiece 100 from the virtual side end points P011 and P012, P021 and P022, and P031 and P032 In this configuration, edge distances α1 · β1, α2 · β2, and α3 · β3 to the edge are calculated.
[0041]
The press position determination unit 53 analogizes the curved state (banana shape state) of the workpiece 100 based on the calculated edge distances α1, β1, α2, β2, α3, β3, and this analogy is estimated. In this configuration, the press devices 10, 20, and 30 determine the press position where the press work is performed on the workpiece 100 in a curved state, and output the press position data. The mark position movement control unit 54 is configured to control the movement of the mark application position of the mark application means 70 with respect to the workpiece 100 based on the output press position data.
[0042]
Next, the molding operation of the heat transfer part by the heat transfer part forming method of the present embodiment based on the above configuration will be described. First, the workpiece 100 is pulled out from the coil 101 through the pool portion 60 and the smoothing means 80 as in the case of the above embodiment. The edge imaging means 51 images the surface of the workpiece 100 pulled out in this way, and based on this imaging data, the edge distance calculation unit 52 is substantially at the center of the workpiece 100 as shown in FIG. Is set to a virtual center point P01, and a virtual center line C01 extending in the longitudinal direction from the virtual center point P01 is calculated. Further, virtual center points P02 and P03 are set on the virtual center line C01 at intervals corresponding to the press position intervals. The side end points P011 and P012, P021 and P022, and P031 and P032 are specified by being separated by a predetermined distance from both sides of the virtual center points P01, P02, and P03 set in this way. Further, the edge distance calculation unit 52 includes edge distances α1 · β1, α2 · β2, α3 · β2, α3 · β3 is calculated and output to the press position determination unit 53.
[0043]
The press position determination unit 53 As shown in FIG. Change of edge distance α1, β1, α2, β2, α3, β3 (α1>α2>α3; decreasing trend) ) , ( β1 <β2 <β3 ;Increasing tendency ) Based on the bending state of the workpiece 100, and press position data is determined by determining the press position where the press devices 10, 20, and 30 press the workpiece 100 in the curved state thus estimated. Is output to the mark position movement control unit 54. The mark position movement control unit 54 moves the mark applying means 70 by the correction distance γ based on the press position data. On the increasing trend side Slide (See Figure 10) .
[0044]
As shown in FIG. 10, the slid mark-adding means 70 sets a new center line C1 at a position shifted from the virtual center line C01 by the correction movement distance γ, and based on the center line C1. The center points P1, P2, P3 and the side end points P11, P12, P21, P22, P31, P32,... Are sequentially applied onto the workpiece 100 by the mark applying means 70 in the conveying direction.
[0045]
In this way, even if the workpiece 100 is in a curved form, the workpiece 100 has a plurality of edge distances α1 · β1, α2 · β2, and α3 · β3 as shown in FIG. Therefore, the press working position can be selected as the optimal position.
When the position of the press work is specified, the cutter unit 90 and the press devices 10, 20, and 30 are respectively connected to the side end points P11 / P12, P21 / P22, P31 / P32,. Cutting and press molding are executed in the same manner as in the embodiment.
[0046]
【The invention's effect】
As described above, according to the present invention, a long workpiece is processed. A virtual center line connecting a plurality of marks marked in the longitudinal direction is calculated, and a virtual center point on the virtual center line and / or a virtual side end point at a predetermined distance from the virtual center point is specified. Calculate the edge distance from the specified virtual center point or virtual side end point to the side edge of the work piece, and slide the correction distance to the increasing tendency side based on the change of the edge distance. A plurality of new marks, and a predetermined position on the workpiece defined by the new marks. In contrast, by performing the press a plurality of times while shifting the press position with a predetermined press device, by forming a plurality of predetermined uneven shape patterns on the workpiece, Has a curved form Even for long workpieces The curved state of the workpiece can be inferred from the change of the edge distance of the tip portion, and the press working position can be selected as the optimum position of the workpiece having the inferred curved state. Further, the pressing device presses the workpiece in accordance with the mark, and the uneven device is formed at a plurality of locations marked with the workpiece, whereby the pressing device presses the workpiece. The power position can be correctly acquired and the corresponding position can be pressed, the press position can be strictly adjusted, and the shape accuracy after processing of the workpiece can be improved. further, The uneven pattern can be properly press-formed throughout, and heat transfer parts that are longer than the mold can be reliably formed, and the heat exchange capacity is increased by increasing the size of each heat transfer part. The effect is that it becomes possible to make a vessel.
[0047]
Further, according to the present invention, the pressing is performed by any one of a plurality of press devices arranged in parallel with respect to both ends in the longitudinal direction of the work material, and the uneven shape at least different from the longitudinal intermediate portion is provided at both ends of the work material By forming the pattern side by side with other concavo-convex pattern, the concavo-convex pattern that is optimal as a heat transfer part can be appropriately press-molded at both ends of the long workpiece, and the longitudinal intermediate portion and conditions Heat transfer parts with optimized heat exchanging capacity can be formed at both ends that differ, and each molding process of workpieces can be performed continuously with multiple press devices, greatly improving the molding work efficiency. Has the effect of being
[0048]
Further, according to the present invention, the pressing device forms a stepped portion in the longitudinal direction at the widthwise end of the workpiece, and gives the workpiece a predetermined strength against bending in the longitudinal direction. It becomes difficult to bend even if the work material is long, and it is possible to maintain the shape of the work material after work to facilitate work in the subsequent process and to increase the strength as the heat transfer part. Has an effect.
[0049]
Further, according to the present invention, the press device forms a predetermined flat portion and a plurality of concave portions or convex portions at the end portion in the width direction of the workpiece, and the flat portion serves as a predetermined machining allowance in the workpiece. When the work material is finally welded as a heat transfer part after pressing, the flat part can be used as a welding allowance for easy welding work, and the work material can be gripped from both sides in the width direction. The material can be easily transported. Furthermore, by giving the flat portion a predetermined strength against bending in the workpiece width direction by a plurality of recesses or projections, the flat portion becomes difficult to bend in the workpiece width direction, and the workpiece is gripped by the flat portion. This has the effect of preventing the deflection in the width direction of the workpiece when supporting the workpiece.
[0050]
Further, according to the present invention, before press molding, the workpiece is imaged in advance by an imaging device to check the presence or absence of defects on the workpiece surface. If there is a defect, the defective portion is removed and the workpiece is removed. By sending the defect-free part to the press device, after the defective work material is processed by the press device, it is possible to prevent the work material from being wasted due to defective products by identifying the defect, and to ensure that the defective portion is By sending the workpiece to the press device after removing it, it is possible to prevent a defect from remaining in the heat transfer section after the press molding by mistake and to secure safety.
[Brief description of the drawings]
FIG. 1 is a schematic configuration diagram of a press apparatus to which a heat transfer portion forming method according to a first embodiment of the present invention is applied.
FIG. 2 is an explanatory diagram of a workpiece supply state by a heat transfer portion forming method according to the first embodiment of the present invention.
FIG. 3 is an explanatory diagram of a workpiece mark state by the heat transfer portion forming method according to the first embodiment of the present invention.
FIG. 4 is an explanatory diagram of a workpiece forming step by the heat transfer portion forming method according to the first embodiment of the present invention.
FIG. 5 is an explanatory diagram of a state after molding a workpiece by the heat transfer portion forming method according to the first embodiment of the present invention.
FIG. 6 is a configuration diagram of marking applying means in the pre-press molding stage in the heat transfer portion forming method according to the second embodiment of the present invention.
7 is an explanatory diagram of a marking operation by the mark applying means shown in FIG. 6. FIG.
FIG. 8 is a block configuration diagram of a portion that performs a marking applying operation in a heat transfer section forming method according to a third embodiment of the present invention.
9 is an explanatory diagram of marking operation of the heat transfer portion forming method shown in FIG. 8. FIG.
10 is an explanatory diagram of a marking operation of the heat transfer portion forming method shown in FIG. 8. FIG.
11 is an overall plan view of a workpiece to which marks are given by the heat transfer portion forming method shown in FIG.
[Explanation of symbols]
10, 20, 30 Press device
11, 21, 31 Upper mold
12, 22, 32 Lower mold
40 Mark detection means
50 Imaging device
51 Edge imaging means
52 Edge distance calculator
53 Press position judgment part
54 Mark position movement controller
60 pool
70 Mark giving means
71, 72, 73 Application nozzle
80 Smoothing means
90 Cutter section
100 Work material
101 coil
110 Stepped part
120 flat part
130 Convex
140 mark

Claims

In a heat transfer part forming method of forming a heat transfer part for a heat exchanger by press-molding a workpiece made of a thin metal plate into a predetermined uneven shape with an upper die and a lower die of a press device,
For a long workpiece that is transferred in a single feed direction parallel to the longitudinal direction, a plurality of press devices having a mold shorter than the workpiece are set at predetermined intervals in the longitudinal direction on the workpiece. Each of the predetermined locations is pressed, and the heat transfer portion is formed as a shape in which a plurality of predetermined uneven shape patterns are arranged in the longitudinal direction ,
Prior to press-molding at least the workpiece with the pressing device, a predetermined mark for defining a press position on the workpiece with respect to the workpiece surface is provided in the longitudinal direction of the workpiece with a predetermined mark applying device. Give multiple at predetermined intervals,
Calculate a virtual center line connecting a plurality of marks marked at predetermined intervals in the workpiece longitudinal direction,
Specify virtual side end points at predetermined distances on both sides of the virtual center point and / or the virtual center point at an interval corresponding to the interval of the press position on the virtual center line,
Calculate each edge distance from the virtual center point or virtual side end point specified sequentially in the conveying direction of the workpiece to the side edge of the workpiece,
Based on the transition of each edge distance change, the mark applying device slides the correction distance toward the increasing tendency side to apply a plurality of marks on the workpiece surface in the transport direction, and the applied marks A heat transfer portion forming method, wherein when a predetermined mark detecting means detects the above, a predetermined position of the workpiece defined by the mark is pressed .

In the heat-transfer part formation method of the said Claim 1,
Before and after the pressing direction of the work material feeding direction of the pressing device, a plurality of other pressing devices having a mold shorter than the work material are provided side by side,
Any one of the other pressing devices presses the predetermined range on the one end side in the longitudinal direction and the predetermined range on the other end side of the workpiece before and after the press molding to the plurality of workpieces by the press device, A method for forming a heat transfer portion, wherein the heat transfer portion is formed as a shape in which a plurality of at least two types of uneven patterns are arranged in the longitudinal direction.

In the heat-transfer part formation method of the said Claim 1 or 2,
The method for forming a heat transfer section, wherein the pressing device forms, at both ends in the width direction of the workpiece, stepped portions that are stepped with respect to the central portion in the width direction in the longitudinal direction of the workpiece. .

In the heat-transfer part formation method in any one of the said Claim 1 thru | or 3,
The press device forms a flat portion having a predetermined width at both ends in the width direction of the workpiece, and forms a plurality of predetermined recesses or protrusions at predetermined intervals in the longitudinal direction of the workpiece on the flat portion. A method for forming a heat transfer section.

In the heat-transfer part formation method in any one of the said Claim 1 thru | or 4,
At least before pressing the workpiece with the pressing device, the surface state or internal structure of the workpiece is detected by a predetermined detection device, and the obtained detection data is analyzed by predetermined data analysis means. Determining defects on the surface or inside of the workpiece, and if there is a defect in the workpiece, stop feeding the workpiece to the press device, and remove the defective portion on the front and rear sides in the feed direction of the defect portion. A method of forming a heat transfer portion, wherein the heat transfer portion is removed with respect to the portion and newly fed toward the press device while detecting the rear portion in the feed direction of the defective portion with the detection device.