KR20100137101A - Apparatus for forming double curved aluminum panel of atypical building structure's skin panel - Google Patents

Abstract

PURPOSE: An apparatus for forming three-dimensional curves on aluminum panels for producing skin panels of the atypical structure is provided to prevent pressed mark since an aluminum board is covered with carbon fiber fabric. CONSTITUTION: An apparatus for forming three-dimensional curves on aluminum panels for producing skin panels of the atypical structure comprises a lower variable mold(10), an upper variable pressing device(20), a heating unit(30), a transfer unit(40), and a cooling unit. The lower variable mold supports an aluminum board(A) on the lower part. The upper variable pressing device is formed of disc-shaped pressing rollers(21), an arm(22), and a fixed shaft(23). The pressure roller vertically moves along the outer shape of the lower variable mold. The upper variable pressing device forms aluminum boards into a desired shape. The heating unit heats the aluminum board and the pressure roller. The transfer unit transfers the lower variable mold and the aluminum board.

Description

3D curved surface forming apparatus of aluminum plate for manufacturing outer panel of atypical building {APPARATUS FOR FORMING DOUBLE CURVED ALUMINUM PANEL OF ATYPICAL BUILDING STRUCTURE'S SKIN PANEL}

The present invention relates to an apparatus and method for forming a three-dimensional curved surface of an aluminum sheet for manufacturing a skin panel of an atypical building, and more particularly, a lower variable mold, an upper variable pressure device, a heating means, a conveying means, and a cooling means. By using a three-dimensional curved surface forming apparatus and method of the aluminum plate made of a low-cost and at a low cost to provide a device for producing a small amount of a variety of skin panels of the atypical building at a quick and low cost.

In general, an atypical building refers to a building having a shape that is inclined, narrowed, distorted, or free from the existing rectangular shape. In recent years, the number of such atypical buildings has been increasing greatly in the world, which is due to the cultural and technical symbolism of atypical buildings, the development of information technology (IT), the introduction of building information modeling (BIM) technology, and construction technology. It is largely attributable. As shown in <Table 1>, the proportion of such non-standard buildings is steadily increasing worldwide. The ratio of non-standard buildings, which was about 10% in the early 1990s, was about 25% in the late 2000s. As can be seen, the proportion of these atypical buildings will increase more and more in the future.

<Table 1> Global Ratio of Atypical Buildings

However, until now, atypical buildings have been difficult to be built due to the difficulty in design and high construction cost in production and construction. The design and construction of atypical buildings have various difficulties due to their atypical structure. Among them, the most problematic part of the technical and economic aspects is the skin part of the atypical building. In order to construct the skin of an atypical building, it is necessary to divide one large skin into several smaller panels (this is called panelization). It is difficult to mass produce as it is almost impossible, and the complexity of the panel form makes the manufacturing cost much more than expected.

In other words, since the outer panel of a typical structured building is made in a certain form, it can be mass-produced in the same shape, so the construction cost is not a big problem, but the outer panel of an atypical building is made of various forms having different radii and curvatures. Production is impossible, and accordingly the production and construction costs are greatly increased, there was a problem that the product quality is poor.

To solve this fundamental problem of atypical building skin, Frank Gary's Disney Concert Hall, a typical example of a conventional atypical building, uses a one-way curved surface that is relatively easy to produce and is difficult to produce. By avoiding the use of curved surfaces, it was designed and constructed in a manner that essentially eliminates the manufacturing and cost problems caused by the curved surface, and this method has been the most commonly used method for the construction of atypical buildings.

However, in the case of the Dongdaemun Design Plaza to be built in Dongdaemun, Korea, unlike the conventional concert hall Disney concert hall, a double curved panel (double-curved panel) It occupies more than 40%, making it one of the most difficult constructions of the atypical structure ever seen in terms of production technology and economic cost of the skin. In this case, if the composite plate occupies more than 40%, a considerable number of two-sided curved panels still exist even if the shell model is divided to reduce the curved panels, and they have complicated geometric shapes with different edge lengths and radii. Because of this, there is a problem that the production time and manufacturing costs are significantly increased.

If a mold is used millions of times, such as a car, it is reasonable to make an expensive mold and mass produce it. However, in the case of an unstructured building, the same type of outer panel is rarely used repeatedly. It is not economical to make expensive templates like technology. In addition, the one-way curved panel can be manufactured in a relatively precise manner, mainly by using a method such as roller rolling. However, two-way curved surfaces, such as the curved surface of an atypical building, can be molded by hand using a hydraulic press, but these methods are mainly used for making sculptures, and are limited in various forms. Although it can be made without, but the production time is too expensive and expensive, there is a fatal problem that it is difficult to apply to the atypical building, the construction period and construction cost is an important factor.

At present, special processing methods are attempted to solve the problems of fabrication of outer panels of atypical buildings, including (i) Hydro Forming, (ii) Dieless Forming, and (iii) Explosive Forming. Explosive Forming) and (iv) Multiple Post Hydroforming. The following is a brief description of the special processing method.

(i) Hydro Forming Method

Manufacturing method: A method that receives geometric information directly from a computer model and presses it with a metal plate on a mold made of steel or polyamide material. The mold plays a fixed role when entering a machine. Two types of mother molds and insert molds are needed to make the shape, and the same mother mold can be used if the panel dimensions are the same.

Features: It takes about 5 minutes for one molding and mold replacement takes about 3 ~ 4 hours, and in order to reduce the manufacturing cost, the number of panels of the same type must be increased, and the production cost is based on 1600mm X 1200mm. 150 million won, insert mold is 35 million won, mold replacement cost is 800,000 won per time.

(ii) Dieless Forming Method

Manufacturing method: The material is fixed on the plate, and the moving tool and the table, which are rounded at the end, are processed by moving the table interactively through CNC control, and fixed plate in the z-axis direction. And moving tool descends at very slow speed.

Features: No tooling required, 3D data is sent to CNC (Computer Numerical Control) for processing.

(iii) Explosive Forming Method

Production method: A type of hydroforming, which generates a water pressure in the water by exploding the explosives in water, which has a disadvantage in that only one mold is required and it is impossible to apply when there is a hole in the steel plate.

(iv) Multiple Post Hydroforming

Manufacturing method: It is a method that receives the geometric information directly from the data and controls it with a computer and pushes the metal plate by hydraulic pressure on a variable frame composed of several posts.

However, the special processing method as described above also has the following problems to be applied to the recent atypical buildings in which the double curved panel occupies a substantial portion of the entire envelope.

First, if the curved surface occupies more than 40% of the total skin of the building, and the panels constituting the skin have different edge lengths and radii, it is a skin panel that cannot be mass produced. It still poses the problem of long production time,

Second, since one expensive mold is needed at a time, there is a problem that a small amount of atypical buildings having different radius values and curvatures and that it is not applicable to various outer skin panels at cost.

Third, it is difficult to produce small quantities and various types of secondary curved surfaces such as skin panels of atypical buildings quickly and at low cost.

The present invention was created in order to solve the fundamental problem of the conventional molding method in forming the outer panel of the atypical building as described above, the lower variable type for supporting the entire aluminum plate formed from the bottom during the entire process of forming the aluminum plate Molds; It consists of a plurality of disk-type pressure roller that can be rotated, an arm connected to the pressure roller and a fixed shaft for fixing the arm, the plurality of disk-type pressure roller is formed in the shape of the lower variable mold Therefore, each pressing roller can be freely moved in the height direction, the upper variable pressure device for pressing the aluminum plate formed by the weight of the disc-shaped pressure roller to obtain a desired shape by bringing the lower variable mold and the aluminum plate in close contact with each other. Wow; Heating means for heating the aluminum plate and the variable pressure roller provided for molding; Transfer means for moving the lower variable mold and the aluminum sheet provided for molding for a molding operation; By providing a three-dimensional curved surface forming apparatus of an aluminum sheet for the outer panel of the atypical building, characterized in that the cooling means for cooling the finished aluminum sheet, the double-curved panel is a large portion of the entire outer shell In the recent atypical building occupied, it is possible to produce it quickly and at low cost by lowering the production cost of a small quantity and various shape of the outer panel.

In another aspect, the present invention is a method for forming a three-dimensional curved surface of an aluminum sheet for the production of a small amount of polymorphic outer skin panel of an atypical building,

A first step of processing a bottom deformable mold which supports the entirety of the formed aluminum sheet underneath during the entire molding process of the aluminum sheet;

A second step of placing an aluminum plate to be molded on the machined lower deformable mold and fixing the aluminum plate and the lower deformable mold for molding operation;

A third step of primary heating to pre-heat the aluminum sheet by means of heating when the shaped aluminum sheet fixed on the lower variable mold is moved by the conveying means;

A fourth step of secondary heating to simultaneously heat the aluminum plate and the variable pressure roller of the upper variable pressure device when the first heated aluminum plate is moved to the upper variable pressure device to be molded;

A fifth step of bringing the lower variable mold into close contact with the aluminum plate by the weight of the plurality of variable pressure rollers of the upper variable pressure device to form a heated aluminum plate;

A sixth step of cooling the completed aluminum sheet by using cooling means;

The present invention provides a method of forming a three-dimensional curved surface of an aluminum sheet for manufacturing an outer panel of an atypical building, comprising a seventh step of separating the cooled aluminum sheet from the lower variable mold. Compared to the molding method, it is possible to produce a high quality outer panel quickly and at low cost.

According to the present invention, prior to the patent application for the present invention, prior to the patent application of the present invention, the prior art research was commissioned to WIPS for a three-dimensional curved surface forming apparatus and method for manufacturing an outer panel of an atypical building. Although Japanese Patent Laid-Open No. 1994-211531, Japanese Patent Laid-Open No. 2004-074191, Japanese Patent Laid-Open No. 2003-236629 and Japanese Patent Registration No. 3787900 have been proposed as cited techniques applied in the same field with similar purposes as the present invention. However, there have been reports of reviewing that there is no relevant prior art material in comparison with the present invention.

The present invention is a small amount of a variety of non-standard buildings in recent years in which the double curved panel occupies a significant portion of the entire outer shell, which has a considerable difficulty even in the conventional special processing method due to high manufacturing cost and long manufacturing time. In the production of the outer skin panel, the production cost is significantly lowered, which is an excellent advantage that it can be produced quickly at low cost, which allows the architectural designer to increase the proportion freely and without restriction of creation. It is possible to design the atypical building, and the building contractor is effective to construct the atypical building at low cost without worrying about the construction cost.

Hereinafter, with reference to the preferred embodiment of the present invention and the accompanying drawings, it will be described in more detail.

First, a brief description of the overall configuration of the present invention, the present invention is largely the lower variable mold (10); An upper variable pressurizing device 20 including a plurality of disc-shaped press rollers 21, an arm 22, and a fixed shaft 22; Heating means (30, 30a, 30b); A transfer means 40; And cooling means.

First, in order to form a double-curved skin panel (double-curved panel) of an atypical building (small amount and various shapes), the lower variable mold 10 is formed into a double-curved surface. Fabricated according to the shape of the outer skin panel, the aluminum plate (A) to be molded on the lower variable mold (10) is placed. Next, while the aluminum plate A placed on the lower variable mold 10 is moved by the transfer means 40, the lower variable mold which is continuously moved is made into a semi-molten state which is easily heated and molded for the first time. While pressing (10) and the aluminum plate (A) using the upper variable pressure device (20), they are molded into the shape of a double curved skin panel required by the designer. Thereafter, the molded aluminum sheet A in a high temperature state is sufficiently cooled, and then removed from the three-dimensional curved forming apparatus of the aluminum sheet according to the present invention, thereby requiring a small amount and various shapes of atypical building skin panels. Can be produced simply and at low cost.

1 is a view showing an overall combined perspective view of the three-dimensional curved surface forming apparatus of the aluminum plate according to the present invention, Figure 2 is an exploded perspective view of the three-dimensional curved forming apparatus of the aluminum plate according to the present invention. 1 and 2, the three-dimensional curved molding apparatus of the aluminum sheet according to the present invention is basically a lower variable mold 10, an upper variable pressure device 20, heating Means 30, conveying means 40, cooling means, and an aluminum sheet A to be molded.

Looking at the basic components according to the present invention in more detail, first, the lower variable mold 10 supports the entire aluminum plate (A) to be molded from the bottom during the entire molding process of the aluminum plate (A) to be described below The conveying means are moved together during the whole process. In order for the lower deformable mold 10 to support the aluminum sheet A, the aluminum sheet A is fixed after drilling using a fixing pin made of a material (steel) having a higher melting point than aluminum. The lower variable mold 10 is a small amount of atypical building and is manufactured in conformity to the shape of a double curved skin panel (double-curved panel) having various shapes. According to a preferred embodiment of the present invention, the lower variable mold 10 processes the ALC lightweight panel into the shape of the outer panel to be molded using a CNC (Computer Numerical Control) router, but to achieve the object of the present invention It does not limit the use of other materials and other methods that may be possible. In addition, according to a preferred embodiment of the present invention, the lower variable mold 10 and the aluminum plate (A) is 50mm to 150mm, preferably about 100mm longer each side than the size of the outer panel of the atypical building. Ready For example, if the size of each skin panel of an atypical building is a panel consisting of 1200 mm by 1600 mm in width, the lower variable mold 10 and the aluminum plate A have a width of 1400 mm X in which each side is 100 mm longer. It is prepared to be 1800mm long.

Next, the upper variable pressure device 20 of the present invention will be described. The upper variable pressure device 20 includes a plurality of disk-type pressure rollers 21 rotatable, and an arm 22 connected to the pressure roller. ) And a fixed shaft 23 for fixing the arm. The plurality of disk-type pressure rollers 21 can be freely moved individually in the height direction of each of the pressure rollers 21 according to the outer shape (height) of the lower variable mold 10, the disk-type pressure roller 21 By pressing the aluminum plate (A) to be formed by the weight of the) to closely contact the lower variable mold 10 and the aluminum plate (A) it is possible to obtain a variety of double curved shape of the atypical building desired by the designer. The disk press roller 21 of the variable pressure device 20 may be made of stainless or steel, but other materials in a temperature range higher than the melting point of aluminum, which is a material to be molded. It does not exclude the use of. According to a preferred embodiment of the present invention, the variable pressure roller 21 may be formed in a disc shape having a diameter of 300 mm, a thickness of 16 mm, and a weight of about 9 kg, and according to another preferred embodiment of the present invention, the upper variable pressure It is also possible to cover the carbon fiber fabric 50 on the aluminum plate A to be molded so that no press marks generated by the device are generated on the aluminum plate A.

Next, the heating means 30 according to the present invention will be described. The present invention uses a semi-solid metal forming technique, which is a technique for forming a metal material in a musky zone where a liquid phase and a solid phase coexist, and are a reaction solid (semi-melt, firing). It is a technology that forms metal by finding unique viscosity property in) state and takes only the advantages of existing casting and forging process. Therefore, in order to form an aluminum plate into a three-dimensional curved surface for manufacturing an outer panel of an atypical building having a small amount and various shapes as in the object of the present invention, the material used is formed in a reaction solid state (plasticity) in which the molding is easy. It is especially important to find the temperature range indicated.

According to a preferred embodiment of the present invention, the aluminum sheet A to be molded is mainly AL3003 series, but other materials may be used which can achieve the same object of the present invention. In order to find the temperature range indicating the exact reaction solidity (firing) state of the AL3003-based aluminum sheet (A) used in accordance with a preferred embodiment of the present invention, the thickness of the aluminum sheet (A) is 4 mm and formed at each temperature. As a result of the experiment on the characteristics, the characteristics as shown in Table 2 below were obtained.

<Table 2> Molding Characteristics by Temperature of AL3003 Series Aluminum Sheet (4mm Thickness)

As can be seen from the above diagram, in the case of AL3003 series aluminum sheet, reaction state is insufficient at below 650 ℃ and molding is inaccurate. Molding quality was rather deteriorated. However, in the temperature range of 650 ° C. to 665 ° C., the AL3003 series aluminum sheet is in a plastic state (semi-molten state, reaction solid state) that is easy to form, and is a small amount and various forms of atypical building skin panels, which is the object of the present invention. Aluminum sheet could be molded into three-dimensional curved surface for fabrication.

Therefore, according to a preferred embodiment of the present invention, if the aluminum plate (A) of the AL3003 series that is moved by the transfer means 40 to be molded on the lower variable mold 10 is transferred, from 650 ℃ to In the temperature range of 665 ° C., the aluminum sheet A reaches the semi-melt (reaction, firing) state in order to facilitate the molding by first heating the aluminum sheet A of the series. Next, when the aluminum plate A in this temperature range is continuously moved by the conveying means 40 to reach the position of the upper variable pressurizing device 20, the aluminum plate A and the upper variable pressing device 20. By heating together to a temperature range of 650 ℃ to 665 ℃, to prevent the decrease in formability due to the temperature loss of the aluminum plate by the temperature difference of both materials.

The heating means 30 according to a preferred embodiment of the present invention is the primary heating or / and 2 to the aluminum plate (A) and the upper variable pressure device 20 using a high frequency induction heating coil as shown in FIG. Alternatively, as shown in FIG. 4, the aluminum plate A and the upper variable pressurizing device 20 may be firstly heated and / or secondly heated using an electric furnace or a gas furnace, but the same method of the present invention. It does not preclude the use of other heating means that can achieve the purpose.

Next, the conveying means 40, which is another component of the present invention, is placed on the lower variable mold 10 in which the aluminum plate A to be formed is heated, and is heated by the heating means 30, and then the upper variable pressure. The device 20 is molded into a curved surface panel of an atypical building desired by the designer, and then cooled by cooling means, which will be described later, and then aluminum is used throughout the molding process until the molded aluminum sheet is separated from the lower variable mold. The member and the lower variable mold are moved. Although in accordance with a preferred embodiment of the present invention the use of a conveying belt is preferred, other means of achieving the same object can be used.

The cooling means, which is another component of the present invention, is a means for cooling the aluminum plate A formed into a desired shape by being in close contact with the lower variable mold by the upper variable pressure device in the temperature range of the semi-molten state. The cooling means may be a water cooling method for cooling the molded aluminum sheet by passing through the water spray nozzle tunnel, or air cooling or forced cooling may be used if necessary.

5 to 10 show in sequence the steps of a method for forming a three-dimensional curved surface of an aluminum sheet for the production of an outer panel of a (small polymorphic) atypical building according to a preferred embodiment of the present invention.

As shown in FIG. 5, the lower variable mold 10 supporting the entire aluminum plate A from the lower side during the entire molding process of the aluminum plate A and being moved together during the whole operation by the transfer means 40 is For example, ALC lightweight panels are machined into the shape of a double-curved panel to be molded using a CNC (Computer Numerical Control) router.

Next, as shown in Figure 6, the aluminum plate (A) to be molded on the machined lower variable mold 10 is placed to be perforated and fixed by a fixing pin and then moved by the conveying means 40 to form a molding operation It is started. At this time, by covering the carbon fiber fabric 50 on the aluminum plate (A) to be molded, it is possible to prevent the pressurization trace generated by the upper variable pressure device in the future to occur on the aluminum plate (A).

Next, as shown in FIG. 7, when the lower variable mold 10 and the aluminum plate A are moved by the transfer means 40 to reach the position of the primary heating means 30a, the aluminum plate is half. The molten (reaction, firing) state is reached (temperature range of 650 ° C. to 665 ° C. in the case of AL3003 series aluminum plate), and continuously moved as shown in FIG. When the position is reached, the upper variable pressure device 20 is heated by the second heating means to heat the aluminum plate A and the upper variable pressure device 20 so that a temperature loss due to the temperature difference of the material does not occur. The aluminum sheet A is brought into close contact with the lower variable mold 10 so as to be molded into a double curved panel shape of an atypical building required by the designer.

Next, as shown in FIG. 9, the molded aluminum plate A is cooled at a high temperature by using a cooling means, and as shown in FIG. 10, the cooled aluminum plate is removed from the lower variable mold. By doing so, the double-curved skin panels of atypical buildings of various shapes can be manufactured.

The present invention having the configurations and effects described above can be modified in various ways, and the above description is not intended to limit the scope of the present invention. In addition, various modifications and variations are possible without departing from the spirit and scope of the invention, and modifications apparent to those skilled in the art to which the invention pertains are included in the following claims.

1 is an overall combined perspective view of a three-dimensional curved surface forming apparatus of an aluminum sheet according to the present invention

Figure 2 is an exploded perspective view of the three-dimensional curved surface forming apparatus of the aluminum plate according to the present invention

Figure 3 is a front view of the three-dimensional curved surface forming apparatus of the aluminum plate according to an embodiment of the present invention

Figure 4 is a side view of the three-dimensional curved surface forming apparatus of the aluminum plate according to another preferred embodiment of the present invention

5 to 10 is a view showing each step of the method of forming a three-dimensional curved surface of the aluminum plate for manufacturing the outer panel of the atypical building according to the present invention

<Description of the symbols for the main parts of the drawings>

10: lower variable mold 20: upper variable pressure device

21: disk-type pressure roller 22: arm

23: fixed shaft 30, 30a, 30b: heating means

40: conveying means 50: carbon fiber fabric

A: Aluminum Plate

Claims (10)

In the three-dimensional curved surface forming apparatus of aluminum sheet for the production of small amount of polymorphic skin panels of atypical buildings, A lower deformable mold (10) for supporting the entire aluminum sheet to be molded at the bottom during the entire molding process of the aluminum sheet; It consists of a plurality of disk-type pressure roller 21 which can be rotated, an arm (22) connected to the pressure roller and a fixed shaft (23) for fixing the arm, the plurality of disk-type pressure The roller 21 is an aluminum plate (A) formed by the weight of the disc-shaped pressure roller 21, each pressing roller 21 can be freely moved in the height direction according to the outer shape of the lower variable-type mold (10) An upper variable pressing device 20 for pressing the lower variable mold 10 and the aluminum sheet A to obtain a desired shape; Heating means (30) for heating the aluminum plate (A) and the variable pressure roller (21) provided for molding; A transfer means 40 for moving the lower variable mold 10 and the aluminum plate A provided for molding for a molding operation; Three-dimensional curved surface forming apparatus of the aluminum plate for the production of the outer panel of the atypical building, characterized in that the cooling means for cooling the aluminum plate (A) is completed molding According to claim 1, wherein the disk-shaped pressure roller 21 of the variable pressure device 20 is made of aluminum (3) of the aluminum plate for the outer panel fabrication of atypical building, characterized in that made of stainless (steel) or steel (steel) material. Dimensional Surface Forming Equipment [3] The apparatus for forming a three-dimensional curved surface of an aluminum plate according to claim 2, wherein the disk-shaped pressure roller 21 of the variable pressure device 20 has a diameter of 300 mm and a thickness of 16 mm. The method of claim 1, wherein the lower die-type mold 10 is for manufacturing the outer panel of the atypical building, characterized in that the ALC lightweight panel is processed into the shape of the plate to be molded using a CNC (Computer Numerical Control) router. 3D surface forming device of aluminum sheet According to claim 1, wherein the heating means 30 is a three-dimensional curved surface of the aluminum plate for manufacturing the outer panel of the atypical building, characterized in that selected from high-frequency induction heating coil or gas furnace heating method or electric furnace heating method. Molding equipment The method of claim 5, wherein the heating means 30 is the first heating means 30a for heating only the aluminum plate conveyed by the conveying means, and the first heating means in series with the variable pressure roller around the The three-dimensional curved surface forming apparatus of the aluminum plate for manufacturing the outer panel of the atypical building, characterized in that it comprises a secondary heating means (30b) for heating the aluminum plate and the variable pressure roller at the same time to be wrapped The method of claim 6, wherein the primary heating temperature (30a) and / and the secondary heating temperature (30b) of the aluminum plate for manufacturing the outer panel of the atypical building, characterized in that consisting of 650 ℃ to 665 ℃. Dimensional Surface Forming Equipment The carbon fiber fabric 50 is further provided on the aluminum plate A to be molded, which is mounted on the lower variable mold so that the pressure traces generated by the variable pressure roller 21 do not occur. Three-dimensional curved surface forming apparatus of aluminum sheet for the production of the outer panel of the atypical building The method of claim 1, wherein the cooling means for cooling the aluminum plate (A) is completed is formed of aluminum plate for manufacturing the outer panel of the atypical building, characterized in that selected from the water-cooled or air-cooled method using a nozzle. Dimensional Surface Forming Equipment The apparatus for forming a three-dimensional curved surface of an aluminum sheet according to any one of the preceding claims, wherein the aluminum sheet A provided to be formed is AL 3003.

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