KR100431641B1 - Roll forming apparatus for jointing superposed sheet materials, coupled rolls used therein, and jointing method using the same - Google Patents

Abstract

A roll forming apparatus is provided which forms a linear recess and enlarges the size of the cross section near the bottom of the recess than the size of the cross section near the inlet. The roll forming apparatus 100 includes at least two pairs of forming roller pairs arranged along the advancing direction of the superposed plate material, and the pair of rollers disposed upstream have a first width W1 and a first height H1. The first roller 110 formed with the annular first convex portion 111 having () and the second roller formed with the annular first concave portion 121 having the second width W2 and the first depth D1. And a third roller 130 including an annular second convex portion 131 having a third width W3 and a second height H2, wherein the pair of rollers disposed downstream are formed. And a fourth roller 140 having an annular second recess 141 having a fourth width W4 and a second depth D2, wherein the fourth roller is formed from the bottom of the second recess. And an annular ridge having a raised trapezoidal cross section, wherein the second height is lower than the first height, and the fourth width 140 is wider than the second width W2. .

Description

ROLL FORMING APPARATUS FOR JOINTING SUPERPOSED SHEET MATERIALS, COUPLED ROLLS USED THEREIN, AND JOINTING METHOD USING THE SAME}

The present invention relates to joining overlapping sheets to each other, and more particularly, to a roll forming apparatus and a method for forming a joining structure by deforming the sheet itself on the joining portion.

Joining the overlapping sheets in the process of processing the plate material to produce the article is a very frequent operation. Welding or riveting is mainly used as such a joining method. However, welding or riveting is not possible due to physical properties, welding cannot be tolerated, or leakage or stress concentration in the rivet hole is a problem. Other methods may be adopted.

Among them, it is strongly adopted to form a joining structure in which the ends of the butted plates are deformed to maintain a bonding state to each other. Commonly used as a method of forming the bonded structure by such a deformation is to fold each other end of the butted plate using an anvil and a hammer or a substitute thereof. However, this method can be used only at the end of the plate, and cannot be used when joining the intermediate portions of the overlapping plate to each other.

Representative of the method of deforming the middle of the plate material to join each other is clinching, and various devices for performing such clinching have been developed. Each of these tools has unique characteristics, which in some cases serve as advantages or disadvantages.

Here we will look at some of the features of such clinching devices by way of example and look at how those properties work against the intended use of the inventors of the present invention.

U.S. Patent 5,490,310 to Schleicher Louis C discloses an apparatus and method for forming a clinch joint.

Fig. 15 shows the structure of the clinching device disclosed by this patent publication. As shown in the figure, the clinching device 500 includes a punch assembly 510 including a punch 520 which presses a local part of a plate and deforms it into a nest shape. And a die assembly 530 that supports the plate that is pressed by.

The assembly 530 includes a die button 540 supporting a periphery of a local portion of the plate pressurized by the punch 520, that is, an outer portion of the nest, and an anvil 550 supporting the lower portion of the nest.

The die button 540 is divided into several sectors, and each sector is deformed in a radially outward direction like a cantilever in nest formation.

The punch assembly 510 includes a spring that serves to remove the punch 520 from the nest after forming the nest, and the die assembly 530 includes a spring for pushing the nest out of the die button 540. .

The end shape of the punch 520 has a circular or approximately elliptical shape.

In this clinching device 500, since the fatigue load accumulates in the die button 540, which is deformed every nest formation, periodic replacement is required.

In order for the overlapping plate to be strongly joined, the diameter of the bottom of the nest is required to be larger than the diameter of the inlet of the nest, and such expansion is hardly expected in clinching using the clinching device 500.

To form a continuous nest along the seam using a punch 520 with a circular end shape, a very large number of clinching is required, and a punch having an approximately elliptical end portion in which a longitudinal peripheral line is formed almost straight. Nesting clinched using 520 is a weak coupling force in the straight portion.

US Pat. No. 5,884,386 to Blacket Stuart Edmund et al. Discloses a panel clinching methods and apparatus.

Fig. 16 shows the structure of the clinching device disclosed by this patent publication. As shown in the figure, the clinching device 600 includes a punch 620 including a sleeve 670 for pushing the rivet 660 while deforming into a nest shape by applying pressure to a local part of the sheet, and And a die assembly 630 that bears the plate pressed by such a sleeve 670.

The assembly 630 includes a plurality of collets 680 supporting the outer portion of the nest and anvil 650 supporting the lower portion of the nest.

The collet 680 can expand and contract, and forms an inner space that is expanded in diameter from the inlet of the nest to the bottom.

In the clinching device 600, since the fatigue load accumulates in the collet 680 deformed at each nest formation, periodic exchange is required. In addition, despite the shape of the interior space of the collet 680, considering that the wall of the collet 680 should be easily expanded, the diameter of the bottom of the nest is larger by the collet than the diameter of the inlet of the nest, In contrast, it is not expected to pinch near the entrance of the nest.

In addition, a method of inserting a rivet having a circular cross section into a nest cannot form a continuous joint line, and is expensive due to a consumable subsidiary material called a rivet.

U.S. Patent No. 5,992,206 to Kuehne Timm discloses a clinching die having metallic restoring member.

Fig. 17 shows the configuration of the clinching die 700 disclosed by this patent publication. As shown in the figure, the clinching die 700 has a cylindrical space and includes a shaping element 780 supporting the outer portion of the nest and an anvil 750 supporting the lower portion of the nest.

Molding member 780 is composed of two members each forming a semi-cylindrical space, the two members are separated from each other each time the nest is formed. The distant members are restored by the elastic restoring member 790. In such a clinching die 700, it is hardly expected that the diameter of the bottom of the nest will be larger than the diameter of the entrance of the nest.

Since this clinching die is also configured to use a punch having a circular end shape, a very large number of clinching is required to form a continuous nest along the joining line.

The present invention aims to provide a roll forming apparatus capable of joining overlapping plates by forming a linear coupling portion rather than a point coupling portion.

This invention seeks to provide a roll forming apparatus which can ensure that the size of the cross section near the bottom of the recess is enlarged than the size of the cross section near the inlet.

1 is a perspective view showing the main components of the roll forming apparatus according to an embodiment of the present invention,

FIG. 2 is a plan view showing an overlapping plate member having a coupling groove formed by the roll forming apparatus shown in FIG. 1;

3 is a cross-sectional view of the overlapping plate showing a coupling groove formed in the overlapping plate immediately after passing between the first pair of rollers of the roll forming apparatus shown in FIG.

4 is a cross-sectional view of the overlapping plate showing a coupling groove formed in the overlapping plate immediately after passing between the rollers of the second pair of roll forming apparatus shown in FIG.

5 is a perspective view of the convex roller of the first pair of rollers of the roll forming apparatus shown in FIG.

Figure 6 is a front view of the convex roller shown in Figure 5,

7 is a perspective view of a concave roller of the first pair of rollers of the roll forming apparatus shown in FIG.

8 is a front view of the concave roller shown in FIG. 5,

9A is a view showing a state in which the convex rollers and the concave rollers shown in FIGS.

9B is an enlarged view of the convex portion of the convex roller and the concave portion of the concave roller in FIG. 9A;

10 is a perspective view of the convex roller of the second pair of rollers of the roll forming apparatus shown in FIG.

11 is a front view of the convex roller shown in FIG. 10,

12 is a perspective view of the concave rollers of the second pair of rollers of the roll forming apparatus shown in FIG.

FIG. 13 is a front view of the concave roller shown in FIG. 12,

14A is a view showing a state in which the convex rollers and the concave rollers shown in FIGS. 10 to 13 are mounted to the support frame in combination.

14B is an enlarged view of the convex portion of the convex roller and the concave portion of the concave roller in FIG. 14A;

15 is a cross-sectional view for explaining the configuration of a roll forming apparatus according to a conventional example,

16 is a cross-sectional view for explaining the configuration of a roll forming apparatus according to another conventional example,

17 is a cross-sectional view for explaining the configuration of a roll forming apparatus according to another conventional example.

The roll forming apparatus provided according to the present invention includes at least two pairs of forming roller pairs arranged along the traveling direction of the overlapping plate material.

Such pairs of forming rollers are a pair of rollers having an outline that can form a groove having a uniform width in the direction of travel of the overlapping plate and having a substantially U-shaped cross-section, and along the travel direction of the overlapping plate. A space disposed downstream of the pair of rollers that can push up the bottom of the U-shaped groove formed by the pair of rollers and a space allowing the side wall to open out as the bottom of the U-shaped groove is pushed away. And a pair of rollers having an inclusive contour.

According to yet another aspect of the present invention, there is provided a roller pair for use in a roll forming apparatus for forming a linear coupling groove for joining two or more overlapping sheets as described above. This roller pair has a convex roller having an annular convex portion having a rectangular cross section rounded corners on the middle circumference of the flat roller, and a width larger than the width of the convex portion of the convex roller on the middle circumference of the flat roller. An annular recess having a rectangular cross section and one concave roller formed with an annular ridge having a trapezoidal cross section raised from the bottom of the annular recess. The ridge has a height lower than the depth of the recess, and an annular space having a triangular cross section is formed between the side wall of the recess and the side wall of the ridge.

According to another aspect of the present invention, there is provided a method of forming and joining a joining portion to two or more sheets of overlapping sheets using a roll forming apparatus as described above. This method allows the overlapping sheet to pass between a convex roller having a rectangular annular convex portion and a first roller pair of concave rollers having a rectangular concave portion to form a coupling groove having a uniform width and a U-shaped cross section. And an overlap plate having a U-shaped coupling groove formed therein with an annular recess having a width larger than the width of the U-shaped coupling groove and having a rectangular cross section and an annular ridge having a trapezoidal cross section raised from the bottom of the annular recess. Passing between the second pair of rollers including the concave rollers to elevate the bottom of the U-shaped coupling groove and to push the side wall outward.

These and other features and advantages of this invention will become more apparent upon reading the detailed description of the preferred embodiments below.

As shown in FIG. 1, the roll forming apparatus 100 according to an embodiment of the present invention includes two pairs of forming rollers 110, 120, 130, and 140 arranged along a traveling direction of the overlapping plate. The overlapping plate material in which two or more sheets to be overlapped is linear to enter the gap between the first pair of rollers 110 and 120 and exit between the second pair of rollers 130 and 140 to firmly bond the overlapping plate 200 to each other. To form a joint.

The linear coupling portion 210 is formed of a groove 210 having a predetermined width along the joint line as shown in FIG. 2, but the overlapping plates 201 and 202 are not separated from each other, as shown in FIG. 4. The width at the bottom 212 of the groove 210 should be wider than the width at the inlet 211 of the. Since the groove 210 having such a cross-sectional shape is difficult to be molded at one time, the width at the inlet 211 of the groove 210 and the bottom 212 of the groove 210 as shown in FIG. After forming a substantially constant width, it should be molded stepwise in such a way that the width of the bottom 212 of the groove 210 is expanded to have a shape as shown in FIG. 4.

In order to implement such a step forming, the first pair of rolls 110 and 120 of the roll forming apparatus 100 according to the present invention may have a first width W1 and a first height (as shown in FIGS. 5 and 6). A first roller 110 having an annular first convex portion 111 having H1) and an annular first concave having a second width W2 and a first depth D1 as shown in FIGS. 7 and 8. The second roller 120 having the portion 121 formed therein is combined. As shown in FIGS. 9A and 9B, the first roller 110 and the second roller 120 are combined in such a manner that the center line of the first width W1 and the center line of the second width W2 coincide with each other. Two side wall spaces LS1 and LS2 and one bottom space BS1 exist between the first convex portion 111 and the first concave portion 121. That is, the relationship between the first width W1, the second width W2, and the first height H1 and the first depth D1 is expressed by Equations 1 and 2 below.

W2 = W1 + LS1 + LS2

D1 = H1 + BS1-PD

Here, PD refers to the thickness of the overlap panel.

In addition, the second pair of rolls are formed with a third roller 130 having an annular second convex portion 131 having a third width W3 and a second height H2 as shown in FIGS. 10 and 11. As shown in FIG. 12 and FIG. 13, a fourth roller 140 having an annular second recess 141 having a fourth width W4 and a second depth D2 is combined. As shown in FIGS. 14A and 14B, the third roller 130 and the fourth roller 140 are combined to have the center line of the third width W3 and the center line of the fourth width 140 coincident with each other. Between the second convex portion 131 and the second concave portion 141, there are two side wall spaces LS3 and LS4 larger than the side wall spaces LS1 and LS2, and the ridge 142 and the second. Between the convex portions 131, there is one floor space BS2 smaller than or equal to the previous floor space BS1. That is, the third width W3 is formed to be the same as the first width W1, but the fourth width 140 is wider than the second width W2. In other words, the third roller 130 is formed by cutting off the height H1 of the first convex portion 111 of the first roller 110 to lower the height H2. However, the fourth roller 140 cuts off the side wall of the first recess 121 of the second roller 120 to widen the second width W2 to the fourth width W4 and form a trapezoidal cross section at the bottom thereof. It is formed by raising the ridge part 142 which has, and making the 1st depth D1 shallower to 2nd depth D2. Looking at the relationship between the depth and the width of the first roller 110 to the fourth roller 140, as shown in the following equation.

W3 = W1

W4 = W2 + ΔW = W1 + LS1 + LS2 + ΔW = W3 + LS1 + LS2 + ΔW

Here, ΔW refers to the difference between the second recess 141 and the first recess 121.

H2 = H1-ΔH

Here, ΔH refers to the difference between the first convex portion 111 and the second convex portion 131.

D2 = D1-H3

Here, H3 refers to the height of the ridge 142.

H3 = ΔH

After the overlapping plate 200 passes between the first pair of rollers 110 and 120 and is deformed as shown in FIG. 3, and enters between the second pair of rollers 130 and 140, FIG. The bottom 212 of the illustrated groove 210 is deformed while being pushed up by the ridge 142 of the fourth roller 140 to have a shape as shown in FIG. 4. That is, as shown in FIG. 14B, when the bottom 212 of the groove 210 is pressurized by the ridge 142, the pressure is transmitted to the side wall of the groove 210, and the side wall is buckled by such pressure and the bottom A portion of the sidewall near 212 is incorporated into the bottom 212, and the sidewall is pushed into the spaces 143, 144 defined by ΔW.

In this embodiment, the first and second pairs of rollers 130 and 140 are supported by a frame 150 having a substantially C-shaped cross section. That is, one end of each roller 110, 120, 130, 140 is supported by a radial bearing (not shown) installed on the web 151 of the C-shaped frame 150, and the other end is provided with both flanges 152. It is supported by a radial bearing (not shown) installed in the support blocks 154, 155, 156, 157 protruding from the inner surface of the 153.

The radial bearings provided on the web 151 and the flanges 152 and 153 are preferably provided with a position adjusting mechanism so that the distance between each pair of rollers 110 and 120, 130 and 140 can be adjusted.

Preferably, a conveyor roller (not shown) capable of guiding the transfer of the overlapping plate material is provided on the upstream side of the first pair of rollers 110 and 120 and the downstream side of the second pair of rollers 130 and 140.

The conveying force for conveying the overlapping sheet material may be supplied by applying a rotational force by a motor (not shown) to at least one of the first and second pairs of rollers 130 and 140, or by providing a separate driving roller.

In this embodiment, it is assumed that the plate-shaped overlapping plate member is deformed in two steps by using the first and second pairs of rollers, but it may be preferable to deform it in multiple stages depending on the physical properties of the overlapping plate member. That is, the process of transforming the flat plate-like overlap plate into the overlap plate having a groove as shown in FIG. 3 may be performed in two or more steps. For this purpose, one or more pairs of additional roller pairs (not shown) must be provided upstream of the first pair of rollers 110, 120, the contours of which are paired with the first pair of rollers 110 from the contours of the flat roller pair. , 120, should have the contour of the geometric shape corresponding to the middle of the contour. In addition, the process of deforming the overlapping plate having a groove as shown in FIG. 3 to the overlapping plate having a groove as shown in FIG. 4 may also be performed in two or more steps. To this end, one or more pairs of additional roller pairs (not shown) must be provided between the first pair of rollers 110 and 120 and the second pair of rollers 130 and 140, the contours of which are The contour of the pair of rollers 110, 120 to the contour of the second pair of rollers 130, 140 should have a contour of geometric shape. If additional roller pairs are provided both upstream of the first pair of rollers 110, 120 and between the first pair of rollers 110, 120 and the second pair of rollers 130, 140, The contour of the pair of rollers 110, 120 may have a somewhat deformed contour from the contours shown in the figures and described above for smooth deformation of the overlap plate.

Regardless of how the number of roller pairs and the contour of each roller pair are adjusted, in order to achieve the object of the present invention, a roller pair having the same contour as the second pair of rollers 130 and 140 shown in the drawings and described above is Should be provided. That is, a key technical idea for achieving the object of the present invention is the contour of the second pair of rollers (130, 140). Therefore, here, the contour of the second pair of rollers will be defined more clearly. The second pair of rollers 130, 140 is a combination of one convex roller (formerly named third roller 130) and one concave roller (formerly named fourth roller 140). As shown in Fig. 11, the convex roller is a roller having an annular convex portion having a height of H2, a width of W3, and a cross-sectional shape of a rounded corner on a circumferential middle of the flat roller. As shown in Fig. 13, the concave roller is formed of an annular concave having a depth of D1 and a width W4 which is ΔW1 larger than the width of the convex portion and a rectangular cross-sectional shape on the circumferential middle of the flat roller, and the height from the bottom of the concave portion And an annular ridge 142 having a trapezoidal cross section whose width of the upper side is W5 smaller by ΔW2 than the width of the concave portion. A space having a triangular cross section remains between the side wall of the rectangular recess and the side wall of the trapezoidal ridge. The convex roller and the concave roller are combined such that the center of the convex portion and the center of the concave portion are arranged in a straight line to form the second pair of rollers 130 and 140. It is preferable that the above-mentioned convex portions, concave portions and ridges have a width, height and depth according to the following equation.

D1 <H2 + H3

W4 = W3 + ΔW1

W5 = W4-ΔW2

ΔW1 <ΔW2, that is, W5 <W3

Although the configuration of the roll forming apparatus according to the present invention is described above based on the preferred embodiment, such embodiments are merely exemplary and are not intended to limit the present invention. It will be apparent to those skilled in the art that the present invention may be modified, changed, or adjusted from the above-described embodiments without departing from the technical spirit of the present invention.

When the roll forming apparatus according to the present invention is used, the bonding force can be very strongly bonded by using a linear groove formed by simply passing between rollers in bonding the overlapping members to each other.

Claims (11)

In the roll forming apparatus for forming a linear coupling groove for joining two or more sheets overlapping, At least two pairs of forming roller pairs arranged along the direction of travel of the overlap plate, The forming roller pairs, A pair of rollers having a contour to form a linear linear width and cross-sectional grooves having a substantially U-shape in the direction of the superimposed plate, and The sidewalls are formed as the ridge and the U-shaped groove are pushed up to be disposed downstream of the pair of rollers along the traveling direction of the overlapping plate to push up the bottom of the U-shaped groove formed by the pair of rollers. A roll forming apparatus comprising a pair of rollers having a contour that includes a space that permits to spread outward. The method according to claim 1, The pair of rollers disposed upstream have a first roller having an annular first convex portion having a first width and a first height and a second roller having an annular first concave portion having a second width and a first depth. Include, The first roller and the second roller are combined so that the centerline of the first width and the centerline of the second width coincide. And the second width is wider than the first width. The method according to claim 2, The pair of rollers arranged downstream have a third roller having an annular second convex portion having a third width and a second height and a fourth roller having an annular second concave portion having a fourth width and a second depth. Include, The fourth roller includes an annular ridge having a trapezoidal cross-section raised from the bottom of the second recess, The second height is formed lower than the first height, And wherein the fourth width is wider than the second width. The method according to claim 3, Roll forming apparatus characterized in that the width of the upper surface of the raised portion is formed narrower than the first width. The method according to claim 3, And the height of the ridge has the same height as the difference between the first height and the second height. The method according to any one of claims 1 to 5, One end of each roller is supported by a radial bearing installed on the web of the C frame, and the other end is supported by a radial bearing installed on a support block protruding from the inner surface of both flanges. . The method according to any one of claims 1 to 5, Rolling apparatus, characterized in that the radial bearings installed on the web and the flange of the C-type frame has a positioning mechanism for adjusting the distance between each pair of rollers. The method according to any one of claims 1 to 5, And a conveyor roller for guiding the transfer of the overlapping plate material on the upstream side of the first pair of rollers and the downstream side of the second pair of rollers. The method according to any one of claims 1 to 5, Roll forming apparatus, characterized in that at least one of the first and second pair of rollers is connected to a motor for supplying a conveying force for conveying the overlapping plate material. In the roller pair used in the roll forming apparatus for forming a linear coupling groove for joining two or more sheets of overlapping sheet, One convex roller having an annular convex portion having a rectangular cross section rounded corners on the middle circumference of the flat roller, and A concave roller having an annular recess having a width larger than the width of the convex portion of the convex roller and having a rectangular cross section and an annular ridge having a trapezoidal cross section raised from the bottom of the annular recess on a middle circumference of the flat roller. and, The ridge has a height lower than the depth of the recess, And an annular space having a triangular cross section formed between the side wall of the recess and the side wall of the ridge. In the method of forming a joining portion in two or more sheets of overlapping and joining, Passing the overlapping plate between the convex roller having a rectangular annular convex and the concave roller having a rectangular concave portion to form a coupling groove having a uniform width and a U-shaped cross section; The overlap plate formed with the U-shaped coupling groove has a width larger than the width of the U-shaped coupling groove, and a concave roller having an annular recess having a rectangular cross section and an annular ridge having a trapezoidal cross section raised from the bottom of the annular recess. Passing through the second pair of rollers, the bottom of the U-shaped coupling groove and pushing the side wall outward.