RU2425725C2 - Device for folding and procedure for folding parts with rollers - Google Patents

Abstract

FIELD: metallurgy.

SUBSTANCE: device consists of base for reception of part with industrial robot carrying in arm folding tool with at least one folding roller. At least part of folding roller has a shape of a cone or truncated cone with specified aperture angle. The end of the part is preliminary folded by means of the cone roller.

EFFECT: raised quality of parts.

22 cl, 7 dwg

Description

The invention relates to a flanging device with a multi-axis industrial robot, in particular with an industrial robot carrying a tool with a flanging head and at least one flanging roller mounted on the flanging head.

Such a flanging device is known, for example, from DE U-29910871. The flanging tool shown by the robot shown therein contains a flanging roller with which the flanging edge of the part is folded and pressed. Preliminary and final flanging, if necessary, can be carried out in several work operations.

However, when using such a flanging device during the pre-flanging, the edges form folds in the material. These folds to obtain a defect-free surface must be eliminated at the stage of final flanging, which, however, usually succeeds only in a limited volume and, in addition, requires costs.

Therefore, the objective of the invention is to provide a device for flanging, which allows the flanging of parts as simple as possible and without folding.

In addition, another objective of the present invention is to provide a method of flanging parts with rollers, with which you can reliably prevent the formation of folds.

According to the invention, this problem is solved using the subject of independent claims. Preferred improvements of the invention are the subject of the dependent claims.

The flanging device according to the invention comprises a flanging bed for receiving the part and a multiaxial manipulator, in particular an industrial robot carrying a flanging tool with at least one flanging roller. At least parts of the flanging roller have the shape of a cone or a truncated cone with a vertex, an axis of symmetry passing through the top of the cone, and with an opening angle α, and for the opening angle α, there is: 180 °> α≥140 °.

The idea of the invention is that folding during pre-flanging should be prevented in advance. As it was shown experimentally, and with the help of modeling, folding is explained by local elongations of the material, in particular, near the edge of the edge, with preliminary flanging.

Therefore, in particular, in the region of the edge edge, the local elongation of the material should be kept relatively small. The elongation caused by “wrapping” the material of the edge around the flanging roller can be reduced, in particular, in the region of the edge of the edge, due to the fact that instead of the usual cylindrical flanging roller, a conical is chosen, and the term “conical” is used hereinafter as a shortening and is understood as a flanging roller, which has either the shape of a full cone or the shape of a truncated cone, or has at least some regions the shape of a full cone or the shape of a truncated cone.

Due to its straight guide, such a conical flanging roller does not run around the entire side surface of the cone with a robot, but, strictly speaking, only one circle. Other areas of the lateral surface exert a noticeably lower downforce on the edge. Thus, the pressing force along the portion of the side surface between the base and the top of the cone has a gradient that prevents local extensions of the edge edge.

As it turned out, the optimum value is the gradient of the clamping force when the angle of the opening angle α of the cone is at least 140 °, preferably at least 160 °.

Along with the opening angle of the cone, other parameters, such as, for example, the diameter of the flanging roller, are important to prevent local elongations. The base of the conical flanging roller has a diameter d of preferably at least 60 mm.

In one embodiment, a conical flanging roller is provided as a preliminary flanging roller, and another cylindrical roller as a final flanging roller. However, the flanging roller can be made in such a way that it has a conical region or a region in the form of a truncated cone and a cylindrical region, so that it can be used both as a preliminary roller and a final flanging roller.

It is preferable that the flanging roller is rigidly located on the output shaft of the drive, with which the flanging roller is driven at a predetermined speed during flanging. The direction of rotation of the flanging roller is in the direction of the moving industrial robot, and the speed of rotation of the flanging roller is greater than the speed of the industrial robot.

Friction between the flanging edge and the surface of the flanging rollers processing the flanging edge should be as possible. The “scrolling” of driven flanging rollers on the flanging edge should be avoided anyway. Moreover, as a suitable embodiment of the flanging rollers, it turned out to be made of carbide, preferably steel core with an ebonite shell located on it. In this case, the ebonite shell can be applied by vulcanization.

The device according to the invention has the advantage that the edge material, due to the optimized conical geometry of the flanging roller, experiences less local elongation than with traditional flanging rollers. As a result, wrinkles on the parts are formed less frequently, and therefore it is also possible to abandon the costly efforts to reduce wrinkles during the final flanging or to reduce the speed of translational motion.

According to the present invention, the method for flanging metal parts with rollers includes the following steps: first, the part to be flanged is set with its edge on the flanging bed. The edge is pre-flanged by a pre-flange roller guided by a multi-axis manipulator, for example, an industrial robot, the pre-flange roller being in the shape of a cone or a truncated cone with a symmetry axis, a cone apex and a cone opening angle α, where the cone opening angle α is at least 140 ° . The edge is then finally flanged, preferably with a cylindrical final flanging roller.

Owing to the optimized conical geometry of the flanging roller, especially near the edge of the edge, the local elongations that can lead to folding are smaller compared to traditional methods. At the same time, there are two possibilities for guiding the flanging roller:

the axis of symmetry of the conical flanging roller during the flanging process is located almost perpendicular to the plane of the flanging bed. Moreover, “almost perpendicular” means that the axis of symmetry permeates the plane of the flanging bed at an angle of more than 45 °.

In this case, the axis of symmetry of the pre-flange roller is preferably rotated by an angle β counterclockwise relative to the perpendicular to the direction of translational movement.

However, the axis of symmetry of the conical flanging roller during the flanging process can also be located almost parallel to the plane of the flanging bed. In this case, “almost parallel” means that the axis of symmetry permeates the plane of the flanging bed at an angle of less than 45 °.

In this second case, the axis of symmetry of the pre-flange roller is preferably rotated angle β clockwise relative to the perpendicular to the direction of translation.

Before starting the pre-flanging, the edge angle γ between the edge and the flanging bed and thus the part plane must be a maximum of 90 °.

The translational speed v ₁ at which the flanging roller is guided during the preliminary flanging is preferably 1000-1600 mm / sec. Both during preliminary and final flanging of the edge, several stages of preliminary or final flanging can be provided.

The flanging device is particularly suitable for flanging car parts with rollers, such as car doors, engine hoods and the boot lid.

Embodiments of the invention are explained in more detail below based on the attached drawings.

Figure 1 is a schematic side view of a flanging device with an industrial robot and a flanging tool with a driven flanging roller;

2 is a schematic view of a flanging roller according to a first embodiment;

3 is a schematic view of a flanging roller according to a second embodiment;

4 is a schematic view of a flanging roller according to a third embodiment;

5 is a schematic side view of a flanging roller during a flanging process.

6 and 7 show two possibilities for flanging rollers. Wherein:

figa is a schematic side view of a first opportunity;

figb is a schematic view of a first possibility in another perspective;

figa is a schematic side view of a second possibility;

figb is a schematic view of a second possibility in another perspective.

The same elements in all the drawings have the same reference position.

1 schematically shows a flanging device 1, which along the main axis consists of a six-axis industrial robot 2 and a flanging (i.e., hemming) tool 5.

The flanging tool 5 is moved by an industrial robot 2 relative to the part 10 with one or more flanging edges 11 fixedly mounted on the housing and fixed there on the flanging frame 12.

The housing can be made in the form of a rotary table (not shown) on which a flanging bed 12 is mounted, and the rotary table rotates against the direction of rotation of the robot and for this is included in the control system of the industrial robot 2 or is controlled with it.

The industrial robot depicted in FIG. 1, has six axes of rotation. However, the number of axles may be less or more. Industrial robot 2 contains a robot control device 13, with the help of which its movements are controlled and regulated and, if necessary, also the progress of the flanging process. For this, the control process 13 of the robot 2 and the flanging tool 5, which is derived from the edge of the flanging edges, is programmed, and the data of computer-aided design (CAD data) and computer-aided manufacturing (CAM data) of part 10 are recorded in RAM.

Industrial robot 2 contains a backstage and a stirrup 3, on the front end of which a manipulator is mounted or in another way a robot arm 4 with one or more axes of movement. On the exit side, the robot arm 4 has a flange to which a flanging tool 5 is flanged.

The flanging tool 5 shown in FIG. 1, comprises a flanging roller 6. A flanging roller 6 is rigidly fixed to the output shaft 7. The output shaft 7 is connected to a gear 8 flanged to the drive motor 9. The gear 8 and the drive motor 9 are located inside the flanging tool 5.

To perform the flanging by rollers on the part 10, the industrial robot 2 is driven by the control device 13 and at the same time goes around the flanging edge 11 with a speed v ₁ . At the same time, the flanging roller 6 is pressed against the flanging edge, so that the flanging roller 6 bends down the flanging edge. When this flanging roller 6 is driven in rotation, which is carried out by the drive motor 9, gear 8 and, finally, the output shaft 7. The flanging roller 6 rotates in the direction of movement of the robot 2 along the outer contour of the flanging edge 11.

In this case, the rotation speed v ₂ or, accordingly, the number of revolutions of the flanging roller 6 is greater than the moving speed _{2 of} the moving robot 2, i.e. v ₂ > v ₁ . The speed v _{1 of an} industrial robot 2 is usually 1000-1600 mm / s.

Thus, the part 10 in the area of the flanging edge 11 is slightly crimped by the flanging roller 6 in the opposite direction to the movement of the robot. Due to this, the distribution (expansion) of the part 10 in the area of the flanging edge 11 is reduced.

Industrial robot 2 contains a control device 13, with the help of which the movements and the entire course of the process of flanging by rollers are measured and regulated. The control device 13 is made in the form of an automated (i.e., controlled computer) control system with one or more processors, several interfaces for input / output of data, and with several storage devices for operating parameters, process parameters, and other relevant data.

In the control device 13, the motion path and the corresponding motion path of the industrial robot 2 and the flanging tool 8 are programmed and recorded in the RAM.

The flanging device 1 comprises, in the area of its flanging head 15, a measuring device 20, with which the flanging parameters recorded during the flanging are measured. The measuring device 20 is connected to the robot control device 13 by the line 19. The control device 13, in turn, is connected to the industrial robot 13 by the line 21.

Using the measuring device 20 during the flanging by the rollers, in particular, the number of revolutions and the pressing force of the flanging roller 6 are measured and the set / actual value is adjusted by the correction device. The adjustment also takes into account, in particular, the exact setting of the clamping force of the rotating flanging roller 6.

Since the speed of movement of the robot 2 when circling and processing the part 10 can vary, the number of revolutions of the powered flanging roller 6 must be adapted to it. This correction is also carried out depending on the speed of movement of the robot 2 using the control device 13, which sets the number of revolutions of the flanging roller 6 depending on the speed of movement of the robot 2 using the programmed data recorded in the main memory.

In order to effectively prevent the part 10 from being distributed in the region of the flanging edge 11 leading to folding on the flanging edge 11, the flanging roller 6 has a special geometry.

Figure 2, 3 and 4 schematically shows alternative embodiments of the flanging roller 6.

The flanging roller 6 according to FIG. 2 has a cone shape with a side surface 14 and a base 16. The geometry of the cone is characterized by its opening angle α and the diameter d of its base 16. The opening angle α of at least 140 ° is particularly favorable for preventing folding. Diameter d is at least 60 mm.

Flanging roller 6, as shown in figure 2, may be in the form of a full cone. However, it can also, as shown in FIG. 3, have the shape of a truncated cone. A roller 6 in the form of a cone or a truncated cone is used to pre-flange the part 10. For the final flanging, for example, a cylindrical final flanging roller (not shown) can be used.

However, the technological operations of preliminary and final flanging can be performed using one single flanging roller 6. For this, the flanging roller 6 according to FIG. 4 has a conical section 25 for preliminary flanging and a cylindrical section 23 for final flanging. Both preliminary and final flanging can be carried out in several passes.

Figure 5 schematically shows a side view of a conical flanging roller 6 and flanging edges 11 in the process of flanging.

The flanging roller 6 is brought in such a way that it in the first section 18 is pressed against the flanging edge 11 with a relatively large clamping force and fits snugly against it. In the second section 22, located closer to the top of the cone, the radius of the flanging roller 6 is noticeably smaller due to its conical geometry, and the side surface 14 of the cone in this second section 22 is less tight against the flanging edge 11. Thus, the flanging roller 6 does not run in the entire side surface 14, but, strictly speaking, only one circumference thereof.

Local elongations leading to folding on the flanging edge 11 occur as a result of the “winding” of the edge material around the flanging roller 6. The conical geometry of the flanging roller 6 due to its smaller radius in the second section 22, located closer to the top of the cone, is especially insignificant local elongation near the edge 24 of the edge.

The edge 11 forms a contact angle γ with the plane of the part 10. Before pre-flanging, this angle γ should be a maximum of 90 °.

6 and 7 show two different possibilities for guiding the flanging roller 6.

On figa, the axis of symmetry 27 of the conical flanging roller 6 runs almost parallel to the plane of the flanging frame 12 and thereby essentially also the surface of the part 10. The top 26 of the cone is facing the part 10. In this case, "almost parallel" means that the axis of symmetry 27 permeates the plane of the flanging bed 12 at an angle of less than 45 °.

With this orientation of the flanging roller 6, the angle β, as shown in FIG. 6b, according to the mathematical definition, must be negative, i.e. formed by rotating from perpendicular 28 clockwise in the direction v _{1 of the} translational motion.

In the case of an alternative possibility according to FIG. 7a, the axis of symmetry 27 is almost perpendicular to the plane of the flange bed 12. Moreover, “almost perpendicular” means that the axis of symmetry 27 penetrates the plane of the flange bed 12 at an angle of more than 45 °.

With this alternative orientation of the flanging roller 6, the angle β, as shown in FIG. 7b, according to the mathematical definition, must be positive, i.e. formed by rotation from perpendicular 28 counterclockwise in the direction of v ₁ translational motion.

List of Reference Items

1. Flanging device

2. Industrial robot

3. Arrow

4. Robot arm

5. Flanging tool

6. Flanging roller

7. Output shaft

8. Transmission

9. Drive motor

10. Detail

11. Flanging edge

12. Flanging bed

13. Robot control device

14. Side surface

15. Flanging head

16. The basis

17. The first section

18. Line

19. Measuring device

20. Line

21. The second section

22. The cylindrical section

23. Edge of the edge

24. Conical section

25. The top of the cone

26. The axis of symmetry

26. Direction perpendicular to v ₁

α - opening angle

β - angle of movement

γ - contact angle

v ₁ - translational speed

Claims (22)

1. Device (1) for flanging with rollers with a flanging bed (12) intended for receiving part (10), with a multi-axis manipulator, in particular an industrial robot (2) carrying a flanging tool (5) with at least one flanging device roller (6), characterized in that at least parts of the flanging roller (6) have the shape of a cone or a truncated cone with a vertex (26), an axis of symmetry (27) passing through the vertex (26) of the cone, and an opening angle α, the opening angle α is 180 °> α≥140 °. 2. The device (1) according to claim 1, characterized in that the cone opening angle α is 180 °> α≥160 °. 3. The device (1) according to claim 1 or claim 2, characterized in that the base (16) of the conical flanging roller (6) has a diameter of d≥60 mm. 4. The device (1) according to claim 1, characterized in that the flanging roller (6) is provided as a preliminary flanging roller. 5. The device (1) according to claim 1, characterized in that it contains an additional cylindrical flanging roller provided for the final flanging. 6. The device (1) according to claim 1, characterized in that the flanging roller (6) is provided for both preliminary and final flanging. 7. The device (1) according to claim 1, characterized in that the flanging roller (6) is rigidly located on the output shaft (7) of the drive (8), with which the flanging roller (6) is rotated with a certain number during flanging revolutions. 8. The device (1) according to claim 1, characterized in that the flanging roller (6) essentially consists of a carbide core with an ebonite shell. 9. A method of flanging parts with rollers, comprising the following steps:
- installation of the part to be flanged (10) with the edge (11) on the flanging bed (12);
- pre-flanging of the edge (11) using the cone-shaped pre-flanging roller (6) guided by the multiaxial manipulator, moreover, for the cone opening angle α, 180 °> α≥140 °;
final flanging of the edge (11). 10. The method according to claim 9, characterized in that the final flanging is performed using the roller of the final flanging in the form of a cylinder. 11. The method according to claim 9 or 10, characterized in that the local elongation of the edge material on its edge (24) caused by the flanging roller (6) is minimal and has an edge gradient from the edge (24) to its beginning. 12. The method according to claim 9, characterized in that the axis of symmetry of the conical flanging roller (6) in the flanging process is located almost perpendicular to the plane of the flanging bed (12). 13. The method according to p. 12, characterized in that the axis of symmetry of the flanging roller (6) is rotated counterclockwise at an angle β of movement relative to the perpendicular (28) to the direction v _{1 of the} translational motion. 14. The method according to claim 9, characterized in that the axis of symmetry (27) of the conical flanging roller (6) during flanging is located almost parallel to the plane of the flanging bed (12). 15. The method according to 14, characterized in that the axis of symmetry of the flanging roller (6) is rotated clockwise by the angle β of movement relative to the perpendicular (28) to the direction v _{1 of the} translational motion. 16. The method according to claim 9, characterized in that for the edge angle γ between the edge (11) and the flanging bed (12) before starting the preliminary flanging, it is valid: γ≤90. 17. The method according to claim 9, characterized in that the flanging roller (6) during the preliminary flanging is guided with a speed v _{1 of} translational motion, and this takes place: 1000 mm / s≤v ₁ ≤1600 mm / s. 18. The method according to claim 9, characterized in that there are two or more stages of pre-flanging. 19. The method according to claim 9, characterized in that two or more stages of the final flanging are carried out. 20. The method of flanging the rollers of car parts, characterized in that use the device for flanging according to claim 1. 21. The method according to claim 20, characterized in that the flanging is carried out by the rollers of the car doors, engine hoods and trunk lids. 22. Detail of a car with a flanging edge machined using a flanging device according to claim 1.

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