Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21D5/00—Bending sheet metal along straight lines, e.g. to form simple curves
  • B21D5/06—Bending sheet metal along straight lines, e.g. to form simple curves by drawing procedure making use of dies or forming-rollers, e.g. making profiles
  • B21D5/08—Bending sheet metal along straight lines, e.g. to form simple curves by drawing procedure making use of dies or forming-rollers, e.g. making profiles making use of forming-rollers
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21D5/00—Bending sheet metal along straight lines, e.g. to form simple curves
  • B21D5/06—Bending sheet metal along straight lines, e.g. to form simple curves by drawing procedure making use of dies or forming-rollers, e.g. making profiles
  • B21D5/08—Bending sheet metal along straight lines, e.g. to form simple curves by drawing procedure making use of dies or forming-rollers, e.g. making profiles making use of forming-rollers
  • B21D5/083—Bending sheet metal along straight lines, e.g. to form simple curves by drawing procedure making use of dies or forming-rollers, e.g. making profiles making use of forming-rollers for obtaining profiles with changing cross-sectional configuration

Definitions

• the present invention relates to a method for roll-forming from a plane sheet metal strip successively in a number of forming stations a hat beam with a profile that varies along its length, having a central flange, two webs and two side flanges.
• the invention relates also to a roll-forming machine with a number of forming stations for successively forming from a plane sheet metal strip a hat beam, having a central flange, two webs and two side flanges and a cross-section that varies along its length.
• each side flange is clamped in the forming stations between a pair of clamping rollers and all four corners of the hat beam are formed at the same time between the said two pairs of clamping rollers and at least one support roller for the central flange, the corners are folded on the peripheral edges of the clamping rollers and the peripheral edges of the support rollers and the webs extend between the respective corner at least one of the clamping roller pairs and the support roller is displaced during the forming process in order to change the profile of the hat beam.
• the roll-forming machine according to the invention is characterised primarily in that the forming stations have one pair of clamping rollers for each side flange and at least one support roller for the central flange, and the clamping roller pairs in the forming stations are arranged to be displaceable both horizontally and vertically during a forming operation.
• Figure 1 is a schematic cross-section of one of the intermediate roll-forming stations in a roll- forming machine according to the invention.
• Figure 2 is a schematic cross-section of the final roll-forming station in the roll-forming machine.
• Figure 3 is a side view of a beam with a hat-shaped profile roll-formed as specified by the invention.
• Figure 4 is a cross-section of the beam in Figure 3 taken as is shown by the arrows 4-4 in Figure 3.
• EP 1339508 Bl describes a complete roll-forming machine and is incorporated herein by way of reference. A complete roll-forming machine is not described below but only two of the roll- forming stations of the roll-forming section thereof are described.
• a roll-forming section has a support stand 10 that supports a number of roll-forming stations.
• Figure 1 shows one of the intermediate roll-forming stations that has the reference number 11.
• Figure 2 shows the final forming station 12 in the forming section. All forming stations may be similar, which give great flexibility when manufacturing different hat-shaped profiles.
• the two forming stations shown are the same and they are symmetrical. Each forming station forms the entire cross section of the metal strip. For this reason, only one half of the forming station 11 will be described in detail.
• the hat-shaped beam that is in the process of being formed has a central flange 13, two webs 14, 15 and two side flanges 16, 17.
• the forming station 11 has a frame 20 that supports a pair of clamping rollers 21, 22 that clamp, i.e. the rollers retain by friction, one side flange 16, and it has a pair of clamping rollers 23, 24 that clamp between them the other side flange 17.
• the forming station has also a pair of support rollers 25, 26 for the central flange 13.
• the webs 14, 15 are bent upwards around the peripheral edges of the support rollers 25, 26 such that the corners 27, 28 of the hat-shaped beam are formed.
• the two other corners 29, 30 of the hat-shaped beam are folded around the peripheral edges of the lower rollers 22, 24 by the pairs 21, 22; 23, 24 of clamping rollers.
• the webs 14, 15 are thus held freely stretched between the corners 29, 27 and 30, 28.
• the clamping rollers 23, 24 are supported by a vertical guide rail 35 for motion perpendicular to the horizontal axes I and II of the clamping rollers.
• the guide rail 35 is supported by a support 31, 32 and it can be rotated around a horizontal axis III that is parallel with the horisontal axes I and II of the clamping rollers.
• the lower part 32 of the support 31, 32 in turn is supported on a transverse horizontal rail 33 in the frame 13 in a manner that allows translation.
• the upper part 31 of the support 31, 32 is supported by the lower part 32 in a manner that allows rotation around a vertical axis IV.
• the distance between the clamping rollers can be adjusted by a manual screw setting 34 such that an appropriate clamping force against the side flange 17 is obtained.
• the pair of clamping rollers 21, 22 is supported in the same manner as the pair of clamping rollers 23, 24, as a mirror image.
• the two support rollers 25, 26 are supported by supports 40, 41 and 42, 43 that are supported by a transverse horizontal rail 44 in the frame 20 in a manner that allows translation.
• the lower parts 41 and 43 of the supports are supported in a manner that allows rotation by the upper parts 40, 42 such that they can be rotated around vertical axes V, VI that are perpendicular to the axes VII, VIII of the clamping rollers 23, 24.
• the lower parts 41, 43 of the supports can be also vertically displaced relative to the upper parts 40, 42.
• All displacements and all rotations (turnings) are carried out by power devices that may be hydraulic or electrical. These devices are not shown in the schematic drawings. The actions of the powers devices are controlled by a computer.
• a hat-shaped profile (a hat beam) from a plane sheet it is appropriate to use 5-6 roll-forming stations.
• the forming station 11 shown in Figure 1 can in this case be the third station, while that shown in Figure 2 is the final forming station 12.
• all forming stations are set to be fixed.
• the power devices are controlled by the computer during the forming operation following preprogrammed algorithms.
• the support rollers 25, 26 may have counter-rollers on the lower surface of the central flange 13 but such counter-rollers are not necessary.
• the beam shown in Figure 3 has straight side flanges 16, 17 that are plane, but lie in two different planes.
• the central flange 13 has a constant width, but the heights of the webs 14, 15 vary along the length of the beam.
• the support rollers 25, 26 are displaced in a vertical direction in the forming stations, while the pairs of clamping rollers 21, 22; 23, 24 are displaced both horizontally and vertically. It is appropriate that the angle of the webs is held constant in any one forming station, i.e. such that the forming station folds up the webs to equal degrees independent of variations in the heights of the webs.
• the support rollers 25, 26 are displaced along the guide rail 42 during the forming operation.
• the support rollers are turned (rotated) around the axes V and VI such that their axes are maintained always perpendicular to the corners 27, 28 of the hat-shaped beam.
• the pair of clamping rollers 23, 24 is turned in a similar manner around the axis IV such that the axes of the rollers are maintained always perpendicular to the edge 30 of the hat-shaped beam.
• the pair of clamping rollers 21, 22 is turned in an equivalent manner. It is even possible to manufacture a hat-shaped beam that is curved in a horizontal direction by displacing the support rollers 25, 26 in an asymmetrical manner along the guide rail 42.
• the pair 23, 24 of clamping rollers is turned around the axis III such that a line between the axes I and II of the clamping rollers is maintained always perpendicular to the side flange.
• An equivalent description is valid for the pair 21, 22 of clamping rollers.
• the strip is fed through the roll-forming section by the forming stations, which have computer controlled motors for driving the forming rollers.
• the rotational speed of the roller pairs must be varied individually to avoid slipping since a roller pair must have higher rotational speed when it is moved transversely than when it is held fixed.
• the roll-forming machine can be used to form pre-cut blanks in the form of short plane strips, and it can be used to form hat-shaped beams directly from a coil of metal strip.
• the edges of the metal strip can be cut to the shape desired using an edge-cutting unit in direct association with the first forming station. It is possible as an alternative to cut the edges of the strip after the forming operation, since the side flanges are directed outwards.
• the edge-cutting before forming is preferred, since the strip is always plane before the forming operation.
• the strip can be cut off completely or partially before the forming.

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• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Bending Of Plates, Rods, And Pipes (AREA)

Priority Applications (5)

Applications Claiming Priority (2)

Publications (1)

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ID=36480962

Family Applications (1)

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Cited By (4)

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Citations (4)

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• 2005
  • 2005-07-11 SE SE0501650A patent/SE527722C2/sv not_active IP Right Cessation
• 2006
  • 2006-07-10 EP EP06758039.9A patent/EP1904244B1/en not_active Not-in-force
  • 2006-07-10 CN CN2006800253136A patent/CN101218044B/zh not_active Expired - Fee Related
  • 2006-07-10 US US11/988,122 patent/US8181499B2/en not_active Expired - Fee Related
  • 2006-07-10 KR KR1020077031036A patent/KR101260867B1/ko not_active Expired - Fee Related
  • 2006-07-10 JP JP2008521355A patent/JP5435944B2/ja not_active Expired - Fee Related
  • 2006-07-10 WO PCT/SE2006/000854 patent/WO2007008152A1/en not_active Ceased
  • 2006-07-10 BR BRPI0612860-2A patent/BRPI0612860A2/pt not_active Application Discontinuation
  • 2006-07-10 RU RU2007148635/02A patent/RU2401710C2/ru not_active IP Right Cessation

Patent Citations (4)

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