KR101137252B1 - Roll forming system and method thereof, and formed article prepared by using the same - Google Patents

Abstract

The present invention optimizes the thickness and material of the local stiffness demanding part by supplying materials having different thicknesses and materials to the roll forming process at the same time to be roll-formed by butt welding with each other through a welding unit before being put into the roll former unit. A roll forming apparatus and a roll forming method for producing a forming beam, and a molded article manufactured using the same, are provided.

Roll Forming, Forming Beam, Local Stiffness, Butt Weld

Description

Roll forming apparatus and roll forming method, and forming beam manufactured using the same {ROLL FORMING SYSTEM AND METHOD THEREOF, AND FORMED ARTICLE PREPARED BY USING THE SAME}

The present invention relates to a roll forming apparatus and a roll forming method, and a bumper beam manufactured using the roll forming unit. More specifically, the roll forming unit is formed by simultaneously feeding and mutually welding materials having different thicknesses and materials in a roll forming process. The present invention relates to a roll forming apparatus and a roll forming method capable of producing a molded beam having optimized thickness and material of a local rigidity request portion, and a molded article manufactured using the same.

In general, the roll forming method is to be formed by bending the coil in a variety of shapes by passing the roll former unit formed in a row in a multi-stage roll former constituting a pair of the upper roll and the lower roll by uncoiling, in particular, such as a vehicle bumper beam It is to produce a straight beam type bent into various shapes.

1 is a conceptual diagram illustrating a roll forming apparatus and a step-by-step process according to the prior art for achieving the above-mentioned roll forming method. First, the roll forming apparatus and the process according to the prior art first uncoiler to release the coil 200 to be supplied. 201 is formed in front of the process line to form an uncoil step (S110), and the straightener 203 for unfolding the strip-shaped steel sheet released from the uncoiler 201 to the steel plate panel 250 of the plate is rearward. Is provided in to form a straightening step (S120).

And the rear of the straightener 203 is provided with a brake press 205 for forming a hole for various uses for assembling the beams to be formed in the steel plate panel 250 supplied from the straightener 203 is piercing step Proceed to (S130).

In addition, the roll former unit 207 composed of at least ten stages of roll formers R1 to R7 (some not shown) is disposed at the rear of the brake press 205 to provide the uncoiler 201 and the straightener 203. ), And the roll forming step (S140) of forming a roll of the steel sheet panel 250 supplied through the brake press 205 in the shape of a forming beam 260 to be obtained by sequentially bending molding.

In addition, a round bender 209 for forming a curvature of a roll forming molded article having a predetermined curvature is provided at the rear of the roll former unit 207 to pass the forming beam 260 along a radius of curvature to be formed. A bending step S150 of manufacturing the curvature shaping beam 260 is achieved.

In addition, a cutting step (S160) is formed at the rear of the round bender 209 to cut the shaping beam 260 according to the specification of a molded article for forming a product by forming a cutting press 211 for cutting the shaping beam 260 to a predetermined standard. ).

For example, the roll forming apparatus and the forming beam produced through the process are illustrated in FIG. 2. The bumper beam 300, which is bent in a predetermined shape along the length direction, is formed in the roll forming apparatus.

However, in the case of the roll forming forming beam 300 as described above, a single coil is formed using a single roll forming process, so that the thickness and the material may be partially changed even when locally rigidity is required. In particular, in the case of the bumper beam 300 as an application example in FIG. 2, a separate reinforcement is welded to a portion where local stiffness is required, or a coil material having a thickness greater than the first required must be used. There was a problem.

Therefore, the present invention has been invented to overcome the above problems, and the problem to be solved by the present invention is to supply a material having a different thickness and material to the roll forming process at the same time before being put into the roll former unit To provide a roll forming apparatus and a roll forming method for producing a forming beam optimized by the thickness and material of the local rigidity requirements by performing a butt-weld welding with each other through a welding unit, and a molded article manufactured using the same .

Roll forming apparatus of the present invention for realizing the above technical problem is a multi-stage uncoiler for releasing the central coil and both coils having different thicknesses or materials, respectively, in the width direction center and both sides of the front of the process line; At the rear of the multi-stage uncoiler, a straightener for unfolding the central coil and both coils released from the uncoiler to a central flat plate and both flat plates; A welding unit for welding the two flat plates against each other with respect to the central flat plate supplied from the straightener at the rear of the straightener, and welding the flat plates in a strip shape; A brake press for molding holes for various uses for assembling the beams to be formed in the flat plate supplied from the welding unit; A roll former unit which sequentially forms a flat plate supplied through the straightener, the welding unit, and the brake press at the rear of the brake press, and rolls each into a forming beam having a predetermined shape; At the rear of the roll former unit, a round bender comprising a plurality of curvature forming rolls for forming a constant curvature in the forming beam; And a cutting press at the rear of the round bender, for cutting the shaping beam to a certain standard.

Here, the welding unit is installed in the width direction at the upper side between the straightener and the brake press on the process line through both strut frames, rail grooves are formed on both sides of the center along the lower surface in the longitudinal direction, respectively, An upper frame each forming a through slot connected to each of the rail grooves; A guide plate having both ends fixedly installed at a center between the two side support frames to support the central flat plate and the two flat plates supplied from the straighteners from the lower side and to guide them in the process direction; Both side support means installed on each side of the support frame on both sides of the guide plate corresponding to both sides of the guide plate by pressing the support plate in the rolling contact state so that the two sides of the plate against the center plate against the center plate ; Two side laser optical heads which are slidably installed in each rail groove of the upper frame and irradiate a laser beam oscillated from a laser oscillator to abutted joint portion of the central plate and both plates; In each of the rail grooves, the screw rod coupled to each of the rail blocks is characterized by consisting of both movement means for moving the respective laser optical head in the width direction by the motor drive.

The guide plate is characterized in that to form a weld guide groove corresponding to the joint portion welded to each other and the center plate and the two plates on the cross section.

Each support means includes a support rod inserted on each support frame; A plurality of support rollers rotatably installed at inner ends of the supporting rods through roller brackets and in rolling contact with the respective outer ends of the two flat plates; And a coil spring elastically acting on each roller bracket with respect to each strut frame in a state of being fitted on the support rod.

Here, the support roller is preferably made of a urethane material.

In addition, each of the laser optical head is connected to the laser oscillator and the optical cable, the optical cable is preferably inserted through the through slot on the upper frame is connected.

Each of the moving means is a screw rod in each rail groove of the upper frame, each inner end is rotatably installed in the central partition wall and meshed with each rail block; Rotational shafts are integrally connected to the outer ends of the respective screw rods in a state in which they are respectively installed on the upper outer side of each support frame, characterized in that the driving motor for providing rotational force to the screw rods.

Here, the drive motor is preferably made of a step motor capable of controlling the rotational speed and the rotation direction.

And roll forming method of the present invention, in the front of the process line, using the multi-stage uncoiler uncoil step of simultaneously unwinding the central coil and both coils of different thickness or material to be supplied for molding; (S1) of the multi-stage uncoiler In the rear, the straightening step of straightening the central coil and both coils released from the uncoil step by using a straightener to a central flat plate and both flat plates; (S2) at the rear of the straightener, the straightener using the welding unit A welding step of welding the two flat plates in a state where the two flat plates are opposed to each other with respect to the central flat plate supplied from the sheet; (S3) at the rear of the welding unit, supplied from the welding step using a brake press. Piercing step of forming a hole of various uses for the assembly of the beams to be formed on the plate; (S4 In the rear of the brake press, using a multi-stage roll former, a roll forming step of forming a shape of a forming beam to be obtained by sequentially bending and forming each of the plates supplied from the piercing step; (S5) The roll former At the rear of the unit, a bending step of shaping a forming beam supplied from the roll forming step using a round bender to a predetermined curvature to be formed; (S6) At the rear of the round bender, from the bending step using a cutting press. It characterized in that it comprises a cutting step (S7) for cutting the shaping beam supplied to a predetermined standard.

Here, the laser welding in the welding step (S3) is preferably made of TIG welding.

In addition, there is provided a molded article produced using the above-mentioned roll forming apparatus and roll forming method.

In other words, the molded article is formed into a flat plate thicker than the front surface of the rear surface, characterized in that made of a pipe between the closed section in which the welding line is formed along the upper and lower surfaces in the longitudinal direction.

As described above, according to the roll forming apparatus and the roll forming method according to the present invention, before supplying a material having a different thickness and material to the roll forming unit at the same time through the welding unit, Butt-welding allows roll forming to produce shaped beams optimized for the thickness and material of the local rigidity requirements.

In addition, the method of manufacturing a roll forming beam formed by a single roll forming process using a single single coil material has been remarkably improved, and in part, even when local rigidity is required in a single roll forming process. The thickness and material can be manufactured, and this can solve the problem of welding a separate reinforcement part to the forming beam which requires the local local rigidity or using a coil material having a thickness greater than the initial required. Will be.

Hereinafter, with reference to the accompanying drawings, preferred embodiments of the present invention will be described in detail as follows.

3 is a roll forming apparatus and a step-by-step process diagram according to an embodiment of the present invention, Figure 4 is a perspective view of a welding unit applied to the roll forming apparatus according to an embodiment of the present invention.

In the roll forming apparatus according to the present embodiment, first, as shown in FIG. 3, first, the uncoilers 1a and 1b are formed in three stages in the width direction center and both sides of the front of the process line. Each of the two uncoilers 1b is configured in the room, but in FIG. 3, one of the two uncoilers is not shown), and the central coil 10a and the two side coils 10b supplied thereto are provided (but one side is unreasoned). Will be released.

Here, the central coil 10a and both coils 10b have different thicknesses or materials, and the thickness and the material are selected and supplied in consideration of the characteristics of the molded article.

That is, in this embodiment, as shown in Fig. 7, an example in which the vehicle bumper beam 60 is a molded product, in the case of the vehicle bumper beam 60, the front face F1 requires rigidity as compared to the rear face F2. The same material that is about 0.2t thicker than the thickness (1.2t) of both coils 10b to be the material of the back surface F2 by the thickness (1.4t) of the central coil 10a to be the material of the front surface F1. Board was used.

A straightener 2 is formed at the rear of the three-stage uncoilers 1a and 1b so that the central coils 10a and both coils 10b, which are released from each of the uncoilers 1a and 1b, are moved to the center plate 20a and It is spread out on both sides of the flat plate 20b.

And the welding unit (3) to the rear of the straightener (2) to butt weld the two flat plates (20b) to each other with respect to the central flat plate (20a) supplied from the straightener (2) with a strip of flat plate 30 ) Is configured.

Here, the welding unit (3), as shown in Figures 4, 5 and 6, in the width direction in the upper direction through the two side support frame 101 in the rear of the straightener (2) on the process line. An upper frame 103 is installed, and the upper frame 103 has a central partition 105 along a longitudinal lower surface thereof, and rail grooves 107 are formed on both sides of the partition 105, respectively. The through slots 109 connected to the rail grooves 107 are respectively formed on the upper surface thereof.

A guide plate 111 is fixedly installed at both centers between the two side support frames 101, and the guide plate 111 is provided with a central flat plate 20a and two flat plates 20b supplied from the straightener 2. ) Is supported at the bottom to guide in the process direction, the weld guide guide groove (G) is formed on the cross-section corresponding to the joint to be welded to the center plate (20a) and both sides of the plate (20b).

In addition, the support plate 113 is installed on each side of the both sides of the support frame 101 corresponding to both sides of the guide plate 111, respectively, and the center plate using the support rollers 115 with spring force. Both sides of the flat plate 20b are pressed against and supported by the rolling contact state with respect to the 20a.

Here, each of the support means 113 has a support rod 117 is inserted into the respective support frame 101, the inner end of the support rod 117 to be rotatable through the roller bracket 119 Two support rollers 115 are installed to make a rolling contact with each outer end of the two flat plates 20b.

In addition, while the coil spring 121 is fitted on the support rod 117, one end of the coil spring 121 is supported by each support frame 101, and the other end is supported by each roller bracket 119. It is made to provide an elastic force to the roller bracket 119 with respect to the support frame 101.

Here, the support roller 115 is made of a urethane material, it is preferable to prevent the damage of the outer end of the both sides of the flat plate 20b.

In addition, the laser optical head 125 is slidably installed in each rail groove 107 of the upper frame 103 through the rail block 123, and the laser optical head 125 is connected through the optical cable 127. It is connected to an external laser oscillator 129 to irradiate a laser beam oscillated from the laser oscillator 129 to the butt joint of the central plate 20a and the both sides 20b to perform laser welding.

At this time, the optical cable 127 connecting the laser optical head 125 and the external laser oscillator 129 is inserted and connected through the through slot 109 on the upper frame 103.

In addition, in the rail grooves 107, the screw rod 133 coupled to each of the rail blocks 123 is driven by a motor to move the laser optical head 125 in the width direction to move the movement means (131) Each of the moving means 131 is provided in each rail groove 107 of the upper frame 103 so that each inner end of the screw rod 133 is rotatably installed at the central partition 105. It is engaged with each rail block 123, the driving shaft 135 is installed on the upper outer side of each holding frame 101, the rotating shaft 137 is integrally connected to the outer end of each screw rod 133 Is connected to and is configured to provide rotational force to the screw rod 133.

Here, the drive motor 135 is preferably made of a step motor capable of controlling the rotation speed and rotation direction.

On the other hand, the rear side of the welding unit 3 is provided with a brake press 4 to form a hole for various uses for the assembly of the beams to be formed in the welded plate 30 supplied from the welding unit 3 It is composed.

In the rear of the brake press 4, the flat beam 30, which is supplied through the straightener 2, the welding unit 3, and the brake press 4, is sequentially formed by bending and forming a shaping beam 40, respectively. The roll former unit 5 which roll-forms by this is comprised.

The roll former unit 5 is configured by arranging at least ten roll formers R1, R2, R3..R6, and R7 (some not shown) in a row.

In the rear of the roll former unit 5, a round bender 6 composed of a plurality of curvature forming rolls for forming a predetermined curvature in the forming beam 40 is formed.

In addition, a cutting press 7 is formed at the rear of the round bender 6 to cut the curvature-formed forming beam 50 to a predetermined standard.

Therefore, the roll forming method for forming the bumper beam 60 (see FIG. 7) into a molded article using the roll forming apparatus having the above-described configuration, as shown in FIG. 3, first, in front of the process line Uncoiling step of simultaneously releasing the central coil (10a; 1.4t) of the different thickness or material to be supplied for molding using the three-stage uncoilers (1a, 1b) and the respective coils (10b; 1.2t) of both sides at the same time Proceed to (S1).

After the uncoil step S1, the central coil 10a and each of both coils released from the uncoil step S1 using the straightener 2 at the rear of the three-stage uncoilers 1a and 1b. A straightening step S2 is performed to straighten the 10b to the central flat plate 20a and both flat plates 20b.

Subsequently, at the rear of the straightener 2, the TIGs are brought into contact with each other both the flat plates 20b with respect to the central flat plate 20a supplied from the straightening step S2 using the welding unit 3. A welding step (S3) of welding one strip of flat plate 30 through laser welding is performed.

And at the rear of the welding unit 3, a piercing step of forming a hole for various uses for assembling the beams to be formed in the flat plate 30 supplied from the welding step S3 using the brake press 4 ( Proceed to S4).

Subsequently, at the rear of the brake press 4, the plate 40 supplied from the piercing step S4 is sequentially used by using a plurality of roll formers R1, R2, R3, R6, R7 (not shown). The roll forming step (S5) of forming a beam into a shape of a forming beam to be obtained by bending molding is performed.

In addition, at the rear of the roll former unit 5, the bending beam supplied from the roll forming step S5 is formed using a round bender 6 to a predetermined curvature to perform a bending step S6. In the rear of the round bender 6, by cutting the forming beam supplied from the bending step (S6) using a cutting press (7) to a predetermined standard to proceed to the cutting step (S7), as shown in FIG. The molded article to be applied to the bumper beam 60 is completed.

Thus, the molded article manufactured by the above-mentioned roll forming apparatus and the roll forming method takes the bumper beam 60 as an example, as shown in FIG. 7, and the front surface F1 has thickness compared with the back surface F2. It is molded into a thick flat plate, and is molded and manufactured in the pipe section of the closed section in which the welding line WL is formed along the longitudinal upper surface F3 and the lower surface F4.

That is, the roll forming apparatus and the roll forming method according to the present invention simultaneously supply materials having different thicknesses and materials to the required portions according to the rigidity requirements in the roll forming forming process, and then, before being introduced into the roll former unit 5, welding is performed. By butt-welding with each other through the unit 3 to form a roll forming to form a molded article having the optimal rigidity by selectively applying the thickness and material of the local rigidity requirements.

1 is a roll forming apparatus and a step-by-step conceptual view according to the prior art.

3 is a perspective view of a molded article manufactured from a bumper beam for a vehicle using a roll forming apparatus according to the prior art.

3 is a roll forming apparatus and a step-by-step process diagram according to an embodiment of the present invention.

4 is a perspective view of a welding unit applied to a roll forming apparatus according to an embodiment of the present invention.

5 is a front sectional view of a welding unit applied to a roll forming apparatus according to an embodiment of the present invention.

6 is a side cross-sectional view of a welding unit applied to a roll forming apparatus according to an embodiment of the present invention.

7 is a perspective view of a molded article manufactured from a bumper beam for a vehicle using a roll forming apparatus according to an embodiment of the present invention.

Claims (14)

A multi-stage uncoiler releasing a central coil and two coils each having a different thickness or material supplied from the center and both sides in the width direction of the front of the process line; At the rear of the multi-stage uncoiler, a straightener for unfolding the central coil and both coils released from the uncoiler to a central flat plate and both flat plates; A welding unit for welding the two flat plates against each other with respect to the central flat plate supplied from the straightener at the rear of the straightener, and welding the flat plates in a strip shape; A brake press for molding holes for various uses for assembling the beams to be formed in the flat plate supplied from the welding unit; A roll former unit which sequentially forms a flat plate supplied through the straightener, the welding unit, and the brake press at the rear of the brake press, and rolls each into a forming beam having a predetermined shape; A round bender behind the roll former unit, the round bender comprising a plurality of curvature forming rolls for forming a predetermined curvature in the forming beam; And a cutting press for cutting the shaping beam to a predetermined standard from the rear of the round bender. The welding unit is Between the straightener and the brake press on the process line is installed in the width direction on the upper side through the two holding frame, the rail grooves are formed on both sides of the center along the longitudinal bottom surface, respectively, and the upper surface is connected to the respective rail grooves An upper frame for forming each of the through slots; A guide plate having both ends fixedly installed at a center between the two side support frames to support the central flat plate and the two flat plates supplied from the straighteners from the lower side and to guide them in the process direction; Both side support means installed on each side of the support frame on both sides of the guide plate corresponding to both sides of the guide plate by pressing the support plate in the rolling contact state so that the two sides of the plate against the center plate against the center plate ; Two side laser optical heads which are slidably installed in each rail groove of the upper frame and irradiate a laser beam oscillated from a laser oscillator to abutted joint portion of the central plate and both plates; Two side moving means for moving the respective laser optical head in the width direction by the motor driven by the screw rod coupled to each rail block in each rail groove; Roll forming apparatus, characterized in that consisting of. delete In claim 1, The guide plate is A roll forming apparatus, characterized in that a welded guide groove is formed in correspondence with a joint portion in which the central flat plate and both flat plates are butted together. In claim 1, Each support means A support rod inserted on each strut frame; A plurality of support rollers rotatably installed at inner ends of the support rods through roller brackets and in rolling contact with the respective outer ends of the two flat plates; And a coil spring elastically acting on each roller bracket with respect to each strut frame in a state of being fitted on the support rod. In claim 4, The support roller A roll forming apparatus, wherein the material is made of urethane material. In claim 1, Each laser optical head The laser forming apparatus is connected to the laser oscillator, wherein the optical cable is inserted through the through slot on the upper frame is connected to the roll forming apparatus. In claim 1, Each of the means of transportation A screw rod in each rail groove of the upper frame, the inner end of which is rotatably installed in a central partition wall and engaged with each rail block; Roll forming apparatus characterized in that the rotating shaft is integrally connected to the outer end of each of the screw rod in the state installed on the upper outer side of each support frame to provide a rotational force to the screw rod. delete In the roll forming method, In the front of the process line, by using a multi-stage uncoiler uncoil step of simultaneously releasing the central coil and both coils of different thickness or material to be supplied for molding; (S1) In the rear of the multi-stage uncoiler, a straightening step of using a straightener to straighten the central coil and both coils released from the uncoil step into a central flat plate and both flat plates; (S2) At the rear of the straightener, a welding step of welding a butt-like flat plate by welding the butt with both sides of the plates against each other with respect to the central plate supplied from the straightener using a welding unit; (S3) At the rear of the welding unit, a piercing step of forming a hole for various uses for assembling the beams to be formed on the plate supplied from the welding step by using a brake press; (S4) In the rear of the brake press, using a multi-stage roll former, the roll forming step of rolling the plate supplied from the piercing step into a shape of a forming beam to be obtained by sequentially bending and forming each; (S5) At the rear of the roll former unit, a bending step of molding a forming beam supplied from the roll forming step using a round bender to a predetermined curvature to be formed; (S6) At the rear of the round bender, a cutting step of cutting a shaping beam supplied from the bending step to a predetermined standard using a cutting press; (S7) Roll forming method comprising a. delete The closed section in which the front surface is formed into a flat plate thicker than the rear surface by using the roll forming apparatus of any one of claims 1 and 3 to 7, wherein a welding line is formed along the upper and lower surfaces in the longitudinal direction. Molded parts made of pipe. delete The molded article of claim 9, wherein the front surface is formed into a flat plate thicker than the rear surface by the roll forming method, and a welded line is formed along the upper and lower surfaces in the longitudinal direction. delete

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