RU2587701C2 - Roll-forming line for manufacture of elements of c-shaped profile for assembly of carcass structure from rolled steel - Google Patents

Abstract

FIELD: technological processes.

SUBSTANCE: invention relates to metal forming and can be used in making sections, in particular, C-shaped, in accordance with the software. Working positions of roll-forming line are closed with a movable screen and are divided into zones. At that, the loading zone comprises a guide chute, while a zone for reading and determining the reference point of the length of tape feed comprises a mechanism for reading and determining the reference point of the length of tape feed, a zone of tape perforation with a unit of tools for perforation, a shaping and tape drive zone with a row of profiling rolls, a zone for edges bending with an edge bending mechanism, a zone for punching of holes for fasteners with a hole punching mechanism, a zone for cutting flanges with a flange cutting mechanism, a zone of profile pressing and cutting in length with a combined pressing and cutting mechanism, and a zone of finished profile unloading.

EFFECT: expanded functionality.

11 cl, 21 dwg

Description

The invention relates to the field of metal forming and can be used in the manufacture of profiles, in particular C-shaped.

Known roll forming machine according to the patent of the Russian Federation No. 2254193, class. B21D 5/06, 2005, comprising a cage for pre-shaping and drive milling cages with cantilever-mounted shafts, the free ends of which are closed by an earring, and roller pairs mounted on the shafts with closed pairs of vertical and horizontal profiling mounted on the shafts installation surfaces of the rollers. Each working shaft has a base collar and they are all located in the same plane with each other, on each lower shaft there are two bushings of calculated size, between which a lower roller is installed, each earring is pivotally mounted on the bed with the possibility of movement and fixing in the horizontal plane and turning on 180 ° and is equipped with two sliders holding the shafts and allowing them to be moved and fixed in a vertical plane, each roller pair in each stand has a base plane abutting against the sleeve.

This machine has a very narrow focus - bending profiles of a certain configuration, which significantly reduces the technological capabilities of the machine, reduces the stability of the profiling process and affects the quality of the resulting profiles.

Known roll forming machine according to the patent of the Russian Federation No. 2401710, class. B21D 5/08, 2010, with several forming devices for sequentially forming a hat-shaped beam from a flat metal strip with a length-varying profile having a central flange, two walls and two side flanges. The forming devices have a pair of pressure rollers for each side flange and at least one support roller for the central flange, while the pairs of pressure rollers in the forming devices are made during the forming operation with the ability to move horizontally and vertically.

Support rollers are arranged to move in the vertical direction. The roll forming machine has two support rollers for the central flange located next to each other and made with the possibility of individual movement towards each other and vice versa and rotation around the axes perpendicular to their axes. Each pair of pinch rollers is configured to individually rotate around two axes perpendicular to each other, with one axis parallel to the axes of the pinch rollers.

This bending machine can be used to form a pre-processed workpiece in the form of short flat strips, as well as to form hat-shaped beams directly from a roll of a metal strip, that is, the technical capabilities of the machine are limited only by profiling a single product from a metal strip.

A device for profiling and bending a strip of metal according to the patent of the Russian Federation No. 86121, cl. B21D 5/06, 5/08, 2009, adopted by the applicant for the prototype. It contains a rolling mill with an electric drive and with a device for flanging edges, containing shafts installed in pairs in the bearings of the rolling mill, made on the left and right with flanging rollers of various shapes, a radius bending device with radius forming rollers, each on a separate shaft, with the possibility of independent regulation of them position in the plane and interaction with a profiled metal strip to obtain a cylindrical surface. It contains a frame and an electric cabinet with a control station, a roll unwinder, a rolling mill, a rib flanging device installed on the rolling mill in the continuation of the edge flanging device, on one of the shafts of which are installed on it along its two longitudinal sides together with a radius bending device; an encoder for determining the length of a strip of metal, a circular saw, switched on by an encoder signal, a supporting device, a device for flanging ribs, contains rolling bearings installed in the bearings the shafts are smooth, shafts made on the left and right with rib-forming rollers of different shapes, shafts made centrally with rollers of longitudinal profiles of the front side of the metal strip and installed in the bearings of the rolling mill on the left and right with smooth shafts, rib-forming rollers of different shapes, while all shafts are installed in pairs, the axes of all the shafts are parallel to each other and perpendicular to the axes of the rib-forming rollers, the radius bending device contains a guide roller table, a horizontal stand with an electric drive with pairs and toothed rollers of transverse profiles, a vertical stand with electric drive, supporting rollers, a rotary table, radius forming rollers of the radius bending device are toothed, one is concave, the other is convex, and installed in a vertical stand.

This device for profiling and bending metal strips combines the execution of operations, both profiling edges and stiffeners, and bending strips along a given radius.

However, this limits the functionality of the device, through which profiles are made of a strip of metal like wavy slate sheets, used when performing roofing in industrial and individual construction, for example, in the construction of hangars or similar arched (cylindrical) structures.

The technical task of the invention is the creation of an automated device with wide functional capabilities, which allows to make ready-made structural elements from a multifunctional profile for assembling various volumetric spatial structures from them, which have wide possibilities of use in the construction of buildings and structures.

The problem is solved in that in the proposed solution, the automated device is equipped with additional working positions with tooling and tools, additional working positions are built step by step into the rolling mill and form a roll-bending line with it for the manufacture of individual profiled C-shaped section elements according to the program set by the computer, and workers and additional working positions of the roll-bending line are closed by a movable screen and divided into zones, namely: the tape loading zone, the read zone I and determining the reference point for the length of the tape broach, the zone of perforation of the tape, the zone of profiling and broaching of the tape, the zone of bending of the edges, the zone of punching holes for fasteners, the zone of cutting flanges, the zone of crimping and trimming the profile along the length, the discharge zone of the finished profile, and the length determinant metal strip is made in the form of a mechanism for reading and determining the reference point of the length of the tape and placed in the reading zone and determining the reference point of the length of the tape.

In addition, the computer software is able to locate and issue to the printer for printing the assembly drawing of a given prefabricated structure, automatically set and produce individual elements for a given prefabricated structure according to predefined algorithms on a roll-bending line, and the automated device itself is equipped with a printer marker for marking of each element of the prefabricated structure, indicating the number, its length, weight, coordinates of the location of this element on the drawing traction.

In addition, the tape loading area is equipped with a guide tray, and the reading and determining point of reference for the tape length is equipped with a mechanism for reading and determining the reference point for the tape length, which is made in the form of two rollers, the lower and the upper, the lower roller is made of reading, its end is covered friction material, and the upper roller is clamped and installed with the possibility of contact with the end of the lower roller.

In addition, the punching zone of the tape is located after the reading zone and determining the reference point for the length of the pulling tape, equipped with an actuator block for punching with a set of tools for punching service holes, and / or punching edges, and / or window cutting for cross-connection, and / or cutting for punches, and / or cutting at an angle, and the block of actuators for punching is made in the form of a horizontal base on which the drive hydraulic cylinders with a set of interchangeable cutting with tool.

In addition, in the zone of profiling and broaching the tape, which is made in the form of a series of profiling rolls, lower and upper, the lower of which are forming, the first pair of profiling rolls is installed with the ability to capture and transmit a signal to activate the reading mechanism and determine the reference point of the length of the tape draw and the remaining pairs of profiling rolls are installed with the possibility of pulling the tape.

In addition, the zone of the bending of the edges is located after the zone of profiling and pulling the tape and is intended for bending of the edges and obtaining, mainly, consistent cross-section of the manufactured profile through the mechanism of bending of the edges.

In addition, the hole punching area for fasteners is intended for punching holes in the sides of the obtained C-shaped profile for self-tapping screws and / or for tubular rivets to connect the individual elements of the C-shaped profile into a prefabricated frame structure and is equipped with a hole punching mechanism.

In addition, the flange cutting zone is equipped with a flange cutting mechanism, which is made in the form of a spatial structure on which two hydraulic cylinders are placed and mounted at an angle to each other and to the base of the C-shaped profile as actuators, the working bodies of which are equipped with a cutting tool.

In addition, the crimping and trimming zone along the length is intended for local crimping of the obtained C-shaped profile and is equipped with a combined crimping mechanism and a cutting device in the form of a rigid spatial structure with a hydraulic cylinder as an actuator and a cutting tool in the form of a flat knife.

In addition, the mechanism for bending the edges is made in the form of a horizontal base, from the bottom of which guides with rollers are placed on the sides, by means of which rolling with bending of the edges is carried out.

In addition, the mechanism for punching holes for fasteners is made in the form of a base, on which hydraulic cylinders with interchangeable punching tools are placed as an actuator, or in the form of a truncated cone for receiving recesses for the head of self-tapping screws, or in the form of a cylinder for receiving holes for tubular rivets.

The technical result from the use of the present invention is that an automated universal device has been created that allows not only to obtain a C-shaped profile, but also to expand its multifunctionality, performing individual elements from it, used to make various prefabricated structures from them. Thanks to the embedded computer program on this device, it is possible to perform, in addition to profiling, various operations, namely, cutting down service holes, cutting edges, cutting windows for cross-connection, cutting down punches, cutting at an angle, punching holes for fasteners, cutting flanges crimp. This variety of operations makes it possible to produce individual ready-made elements from the obtained C-shaped profile for the manufacture of various prefabricated load-bearing three-dimensional spatial structures, which are used later in the frame construction of buildings and structures as, for example, load-bearing walls, partitions, in the form of floor trusses and coatings .

In FIG. 1 shows a general view of an automated device with a tape unwinder from the discharge side of a finished C-shaped profile;

in FIG. 2 shows views of the machine - front, side and ¾ top-back;

in FIG. 3 - machine in front view with the designation of the technological zones of the processing tape;

in FIG. 4 is a view of the machine from the side of the tape loading zone;

in FIG. 5 - a mechanism for reading and determining the reference point of the length of the tape broach and its placement in the same zone;

in FIG. 6 - a mechanism for reading and determining the reference point of the length of the tape broach;

in FIG. 7 - punching unit with actuators and its placement in the same zone;

in FIG. 8 - groups of actuators, combined into one punching unit;

in FIG. 9 - zone profiling and pulling the tape, placed after the zone of perforation of the tape;

in FIG. 10 is a fragment of the profiling zone in the initial phase of capture and drawing of the tape by the first pair of profiling rolls;

in FIG. 11 - the mechanism of bending the edges of the profile with its conversion into a profile of a C-shaped section and the placement of this mechanism in the same zone;

in FIG. 12 - the mechanism of bending the edges of the profile with its conversion into a profile of a C-shaped section;

in FIG. 13 - the mechanism of punching holes in the sides of the C-shaped profile for fasteners and its placement in the same zone;

in FIG. 14 - the mechanism of punching holes in the sides of the C-shaped profile for fasteners;

in FIG. 15 - a mechanism for cutting flanges in a C-shaped profile and its placement in the same zone;

in FIG. 16 - a mechanism for cutting flanges in a C-shaped profile;

in FIG. 17 - crimping and trimming of the finished profile along the length and its placement in the same zone;

in FIG. 18 - combined crimping and trimming mechanism of the finished C-shaped profile in length;

in FIG. 19 is a fragment of a C-shaped profile with examples of certain types of various perforations, technological cuts, holes, punching and punching of various service holes and windows;

in FIG. 20 is a construction of a truss made of individual elements of a C-shaped profile, performed on this automated device.

in FIG. 21 is an initial assembly drawing of a structure.

An automated device for the manufacture of a C-shaped profile and individual elements of a C-shaped section with a multifunctional purpose comprises an uncoiler 1 of tape rolls, a rolling mill with an electric drive and working positions for profiling tape 2, a mechanism 3 for reading and determining a reference point for the length of the tape draw, a combined mechanism 4 crimping and cutting device, working on the signal of the mechanism 3 for reading and determining the starting point of the length of the tape draw, as well as a computer 5 with software HAND.

The software of the computer 5 is configured to locate and issue to the printer for printing the assembly drawing of a given prefabricated structure, automatically set and produce individual elements for a given prefabricated structure according to predefined algorithms, and the automated device itself is equipped with a printer marker for marking each element of the prefabricated structure indicating the number, its length, weight, location coordinates of this element on the drawing of the prefabricated structure.

The device is equipped with additional working positions with equipment and tools. Additional working positions are built in operationally in the rolling mill and form a roll-bending line 6 with it for the manufacture of individual profiled elements of the C-shaped profile according to the program set by computer 5. And the working and additional working positions of the roll-bending line 6 are closed by a movable screen 7 and divided into zones, namely: zone I of tape loading, zone II of reading and determining the starting point of the length of the tape draw, zone III of punching the tape, zone IV profiling and pulling the tape, zone V of edge bending, zone VI of punching holes for fasteners, zone VII of flange cutting, zone VIII of crimping and trimming the profile along the length, zone IX of unloading the finished profile.

The tape loading zone I is equipped with a guide tray 8, and the reading and determining zone II of the tape drawing length reference point is equipped with a mechanism for reading and determining the reference point of the tape drawing length 3, which is made in the form of two rollers, upper 9 and lower 10. Upper roller 9 made clamping, its end face is covered with friction material, and the lower roller 10 is installed with the possibility of contact with the end face of the upper roller 9.

Zone III of perforation of the tape is placed after zone II of reading and determining the reference point for the length of the tape broach, equipped with an actuator block with a set of tools (Fig. 7, 8) for cutting service holes and / or cutting edges and / or window cuts for cross connections, and / or cutting for punches, and / or cutting at an angle depending on the program for manufacturing certain blanks of individual elements of the C-shaped profile embedded in computer 5. Moreover, the block of actuators for punching is made in the form of a horizontal base, on which the drive hydraulic cylinders with a set of interchangeable cutting tools are placed.

Zone IV profiling and broaching the tape (Fig. 9, 10) is made in the form of a series of profiling rolls, lower 11 and upper 12, the lower 11 of which are forming. Profile rolls are installed in pairs and have an electric drive.

The first pair of profiling rolls 11 and 12 is installed with the possibility of capturing the tape 2 and transmitting a signal to activate the reading mechanism and determining the reference point of the length of the tape broach, and the remaining pairs of profiling rollers are installed with the possibility of pulling the tape 2.

The zone V of the bending of the edges (Fig. 11, 12) is located after the zone IV of profiling and pulling the tape and is intended for bending of the edges and the final obtaining of the C-shaped section of the profile through the mechanism 13 of the bending of the edges. The mechanism 13 of the bending of the edges is made in the form of a horizontal base 14, from the bottom of which the guides 15 with the rollers 16 are placed on the sides, by means of which rolling with the bending of the edges is carried out.

Zone VI punching holes for fasteners (Fig. 13, 14) is intended for punching holes in the sides of the obtained C-shaped profile for self-tapping screws and / or for tubular rivets for connecting individual elements of the C-shaped profiles in a prefabricated frame structure and is equipped with a punching mechanism 17 holes. The mechanism 17 for punching holes for fasteners is made in the form of a base 18, on which hydraulic cylinders 19 are located as an actuator with interchangeable punching tools in the form of either a truncated cone for receiving recesses for the head of self-tapping screws, or in the form of a cylinder for receiving holes for tubular rivets.

Zone VII cut flanges (Fig. 15, 16) is equipped with a mechanism 20 cut flanges. The flange cutting mechanism 20 is made in the form of a spatial structure on which two hydraulic cylinders 21 are installed and mounted at an angle to each other and to the base of the C-shaped profile as actuators, the working bodies of which are equipped with a cutting tool.

Zone VIII crimping and trimming the profile along the length (Fig. 17, 18) is intended for local crimping of the obtained C-shaped profile and is equipped with a combined crimping mechanism 4 and a cutting device, in the form of a rigid spatial structure with a hydraulic cylinder 22 as an actuator and with a cutting tool in the form of a flat knife 23.

Crimping is performed by two punches 24 and 25 placed on both sides of the C-shaped profile to effect cross-connection of individual elements of the prefabricated structure.

An automated device for the manufacture of a C-shaped profile and individual elements of a C-shaped section with a multifunctional purpose works as follows.

Previously, before starting the production of elements of a given prefabricated structure, the operator selects the appropriate program on computer 5, according to which the initial assembly drawing of the structure goes to the printer. The drawing shows the number of the element and the coordinates of its location in the prefabricated structure. After checking and approving the information received, the operator starts the roll-bending line 6.

At the beginning, a roll of tape 2 is installed in the unwinder 1 of the automated device.

Next, the roll of tape 2 in the unwinder 1 is rotated, the tape 2 is manually tucked into the guide tray 8, then it is pulled between the upper pinch roller 9 and the lower reading roller 10 of the reading mechanism 3 and determining the length of the tape broach, and then pulled bypassing the zone III of punching the tape to zone IV profiling and pulling the tape to the first pair of profiling rolls 11 and 12 that capture it. At the moment of capture of the tape 2 by the first pair of profiling rolls 11 and 12, a signal is sent to turn on the reading mechanism 3 and determine the starting point of the length of the tape 2 and an enable signal to turn on the start of the program selected by the operator. The automated device is ready for use and is in standby mode for starting the program.

The operator starts the selected program. The place of the beginning of the technological processing of the tape 2 by the specific working positions of the roll-bending line 6 is set by the mechanism 3 for reading and determining the reference point for the length of the pulling tape according to the specifically selected program, namely: in the zone III of punching, by means of the block of actuating mechanisms for punching, the service holes are cut down, and / or cutting edges and / or window cuts for cross-connection, and / or cutting for punches, and / or cutting at an angle depending on the program embedded in computer 5 we manufacture of various preparations of individual elements of the C-shaped profile.

After cutting and cutting out the laid service holes, a still flat tape 2 is pulled into the profiling zone IV. Here, by means of profiling rolls, it is stretched from one pair of rolls to another and at the same time they are profiled and a U-shaped section is obtained.

After the profiling zone IV, the obtained U-shaped profile is moved to the edge bending zone V to perform edge bending and finally obtaining the C-shaped profile through the edge bending mechanism 13, the rollers 16 of which roll the profile with simultaneous edge bending. The desired C-shaped profile is thus obtained.

For the final receipt of the given individual elements, it is still necessary to carry out several technological operations.

To do this, in zone VI, holes are punched for fasteners in the sides of the obtained C-shaped profile or for self-tapping screws, and / or for tubular rivets by punching or in the form of a truncated cone to obtain recesses for the head of the self-tapping screws, or in the form of a cylinder for receiving holes for tubular rivets.

In the next zone VII, by means of the flange cutter 20, they are cut with a cutting tool.

In zone VIII, local crimping of the obtained C-shaped profile is carried out by means of two punches 24 and 25 placed on both sides of the C-shaped profile, and the profile is cut along the length using the combined crimping mechanism 4 and the cutting device, by a signal from the reading and determining mechanism 3 the starting point of the length of the tape broach, they trim the finally obtained profile in length and, thereby, receive a separate profiled element from the C-shaped profile according to the program set by computer 5.

And in the last zone IX of unloading of finished products, the obtained separate finished element of a C-shaped profile is moved along the live table to the zone of finished products.

In the same way, the required number of individual elements is manufactured according to the size required for the manufacture of the selected prefabricated structure.

Then, bearing flat and spatial structures are assembled from the obtained individual elements, which are used later in the frame construction of buildings and structures as, for example, load-bearing walls, partitions, in the form of trusses of ceilings and coatings.

Using the proposed technical solution, it was possible to create an automated device with wide functional capabilities, which allows to obtain various elements from a C-shaped profile for multifunctional purposes with various designs of specific elements, from which concrete flat, three-dimensional and light, but rigid supporting structures are assembled according to the initial assembly drawing used later in the frame construction of buildings and structures.

The construction of prefabricated buildings is best suited to industrialization, lower costs and construction time. All assembled elements of structures are manufactured at enterprises where technological processes are fully mechanized and, to a large extent, automated. At the construction site, only the assembly of structures for buildings from prefabricated elements of factory production is carried out. This allows you to improve the quality of work while reducing the complexity of construction.

The claimed automated device allows you to develop a single structural and functional model of an automated control system and production of installation works, which includes information support and automation tools for controlling the design, manufacture and delivery of finished structures to the assembly and installation site.

Claims (11)

1. An automated device for the manufacture of a C-shaped profile and individual elements of a C-shaped section with a multifunctional purpose, including a computer with software, an electric rolling mill for profiling a metal strip with working positions and an edge flanging device, roll unwinder, strip length determinant metal, a cutting device that operates on the signal of the determinant of the length of the metal strip, characterized in that it is equipped with additional working positions with snap and a tool, additional operating positions are built in operationally in the rolling mill and form a roll-bending line with it for the manufacture of individual profiled C-shaped section elements according to a computer program, and the working and additional working positions of the rolling-bending line are closed by a movable screen and divided into zones, namely : tape loading zone, zone for reading and determining the reference point for the length of the tape broach, zone for punching the tape, zone for profiling and broaching the tape, bending zone for edges, punching zone holes for fasteners, a zone for cutting flanges, a zone for crimping and trimming a profile along a length, an unloading zone for a finished profile, the metal strip length determiner made in the form of a reading mechanism and determining a reference point for the length of the tape broach and placed in the reading zone and determining a reference point for the drawing length tapes. 2. The device according to p. 1, characterized in that the computer software is capable of locating and issuing to the printer for printing an assembly drawing of a given prefabricated structure, automatically set and produce individual elements for a given prefabricated structure according to predefined algorithms on a bending line, and the automated device itself is equipped with a printer marker for marking each element of the prefabricated structure, indicating the number, its length, weight, location coordinates of this element coagulant in the drawing of the assembly. 3. The device according to claim 1, characterized in that the tape loading zone is equipped with a guide tray, and the reading and determining zone of the tape broaching length reference point is equipped with a mechanism for reading and determining the reference point of the tape broaching length, which is made in the form of two rollers, lower and upper , the lower roller is made reading, its end is covered with friction material, and the upper roller is made clamping and installed with the possibility of contact with the end of the lower roller. 4. The device according to claim 1, characterized in that the punching zone of the tape is located after the reading zone and determining the reference point for the length of the tape’s broaching, equipped with an actuator block for punching with a set of tools for punching service holes, and / or punching edges, and / or window cutting for cross-connection, and / or cutting for punches, and / or cutting at an angle, and the actuator block for punching is made in the form of a horizontal base on which the drive hydraulic cylinders are placed on boron interchangeable cutting tools. 5. The device according to p. 1, characterized in that in the zone of profiling and pulling the tape, which is made in the form of a series of profiling rolls, lower and upper, the lower ones of which are forming, the first pair of profiling rolls is installed with the ability to capture and transmit a signal to activate the mechanism reading and determining the reference point of the length of the tape, and the remaining pairs of profiling rolls are installed with the possibility of drawing the tape. 6. The device according to claim 1, characterized in that the zone of the bending of the edges is located after the zone of profiling and pulling the tape and is designed to bend the edges and obtain, mainly, a C-shaped section of the manufactured profile by means of a bending mechanism. 7. The device according to claim 1, characterized in that the punching area for the fasteners is designed for punching holes in the sides of the obtained C-shaped profile for self-tapping screws and / or for tubular rivets for connecting individual elements of the C-shaped profile into a prefabricated frame structure and equipped with a punching mechanism. 8. The device according to claim 1, characterized in that the flange cutting area is equipped with a flange cutting mechanism, which is made in the form of a spatial structure on which two hydraulic cylinders are placed and mounted at an angle to each other and to the base of the C-shaped profile whose working bodies are equipped with a cutting tool. 9. The device according to p. 1, characterized in that the crimping and trimming profile along the length is intended for local crimping of the obtained C-shaped profile and is equipped with a combined crimping mechanism and a cutting device in the form of a rigid spatial structure with a hydraulic cylinder as an actuator and a cutting tool in the form of a flat knife. 10. The device according to p. 6, characterized in that the mechanism of bending of the edges is made in the form of a horizontal base, from the bottom of which guides with rollers are placed on the sides, by means of which rolling is performed with bending of the edges. 11. The device according to p. 7, characterized in that the punching mechanism of the holes for the fasteners is made in the form of a base on which hydraulic cylinders with interchangeable punching tools or in the form of a truncated cone for receiving recesses under the head of the screws are placed, or in the form cylinder for receiving holes for tubular rivets.

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