WO2009076625A1 - Cintrage de profils metalliques dans un processus en ligne continu - Google Patents

Cintrage de profils metalliques dans un processus en ligne continu Download PDF

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Publication number
WO2009076625A1
WO2009076625A1 PCT/US2008/086655 US2008086655W WO2009076625A1 WO 2009076625 A1 WO2009076625 A1 WO 2009076625A1 US 2008086655 W US2008086655 W US 2008086655W WO 2009076625 A1 WO2009076625 A1 WO 2009076625A1
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WO
WIPO (PCT)
Prior art keywords
profile
steel
metallic
turkshead
arching
Prior art date
Application number
PCT/US2008/086655
Other languages
English (en)
Inventor
Jack Curless
Ted Smyth
John Martinez
Daniel Nelson
Will Cromer
Ted Wilk
Original Assignee
Allied Tube & Conduit Corporation
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Allied Tube & Conduit Corporation filed Critical Allied Tube & Conduit Corporation
Priority to CA2707394A priority Critical patent/CA2707394A1/fr
Priority to US12/811,593 priority patent/US20120131974A1/en
Priority to EP08859291.0A priority patent/EP2234738A4/fr
Priority to MX2010006294A priority patent/MX2010006294A/es
Priority to BRPI0821659A priority patent/BRPI0821659A8/pt
Priority to AU2008334969A priority patent/AU2008334969A1/en
Publication of WO2009076625A1 publication Critical patent/WO2009076625A1/fr
Priority to IL206064A priority patent/IL206064A0/en

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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

Definitions

  • the present invention generally relates to a method and apparatus for roll forming steel. More particularly, the present invention relates to a process and machine for forming arch configurations of metallic profiles from roll- formed steel during a continuous in-line process.
  • Continuous in-line processing of steel provides an efficient and relatively quick method for transforming flat strip steel into steel profiles to accommodate high volume production with greater uniformity and consistency.
  • This continuous in-line process is well known in the art as disclosed in, for example, United States Patent Nos. 3,122,1114 and 3,696,503, both to Krengel et. al.; 3,468,145 to Ostrowski; and 3,667,095 to Ostrowski et. al., the disclosures of which are incorporated herein by reference.
  • U.S. Patent No. 3,122,114 disclosed the continuous formation of steel profiles and the galvanized treatment of the external surfaces of the formed profiles.
  • 3,696,503 disclosed a method for continuously galvanizing strip steel in which a forming roll operation, a galvanizing section and a reforming roll operation were used to produce steel profile having all exposed surface areas of the strip steel galvanized.
  • U.S. Patent No. 3,468,145 a method is disclosed for processing steel having a relatively thick cross-section and producing steel having a desired cross-section by moving the stock through a mill multiple times.
  • U.S. Patent No. 3,667,095 disclosed an apparatus for the continuous forming, galvanizing and application of a protective coating to steel profiles.
  • a continuous in-line process first forms strip steel into a desired profile having a cross-section configuration, for example, C-shaped, "U" shaped, etc.
  • the particular steel profile is formed as straight pieces within a continuous in-line machine and cut to a desired length. If the cut steel profiles require a particular radius of curvature, the cut profile sections undergo a separate secondary process to form arched sections using, for example, a standard three roll bending machine.
  • this additional arching step of the formed and cut profile sections requires additional labor, separate process machines and consumes valuable process time.
  • a steel profile having a "U" shaped cross-section essentially comprises a pair of vertically opposed wall members connected by a lower transverse member. At each longitudinal (i.e. lengthwise) end portion of the steel profile, these vertically opposed wall members ideally have a common transverse plane. Once this "U" shaped profile is arched, one of the vertically opposed wall members extends beyond this transverse plane.
  • Exemplary embodiments of the present invention are directed to an apparatus and method for manufacturing arched metallic profiles, particularly steel profiles, using a continuous in-line process.
  • the method includes forming the metallic profile; and arching the formed metallic profile in a continuous in-line process.
  • the apparatus includes a roll forming station configured to receive flat metallic composition and output a given profile.
  • An arching device is configured to receive the metallic profile and bend the metallic profile having a desired radius of curvature wherein a portion of the arching device is displaced with respect to the roll forming station vertically and/or horizontally.
  • FIG. IA is a block diagram illustrating the steps included in a continuous in-line process in accordance with the present invention.
  • FIG. IB illustrates a diagrammatic view of a continuous in-line arrangement for forming an arch in a steel profile embodying the various steps shown in FIG. IA;
  • FIG. 2A is a side view of a process for bending a steel profile in a continuous in-line process in accordance with the present invention
  • FIG 2B is a top plan view of the process for bending a steel profile in a continuous in-line process shown in FIG. 2A in accordance with the present invention
  • FIG. 2C is a top plan view of the process for bending a steel profile in a continuous in-line process shown in FIG. 2A in accordance with the present invention
  • FIG. 2D illustrates a cross sectional view of a portion of an arching device including an exemplary top insert roller in accordance with the present invention
  • FIGs. 3 A and 3B are perspective views of arched metallic profiles formed as part of a continuous in-line forming process in accordance with the present invention.
  • the present invention is directed to a method and apparatus for manufacturing an arched or curved steel profile as part of a continuous in-line forming process.
  • the method roll forms a steel profile from strip steel and bends this formed steel profile during the continuous movement of the steel through the in-line process in a desired cross-section configuration.
  • Applications of the present continuous in-line process include, for example manufacture of profiles for storage buildings, greenhouses, boat hulls, canopies, awnings, garages, ponds, swimming pool, structural enclosure elements, furniture, etc.
  • Fig. IA generally illustrates the continuous in-line roll forming process or method in accordance with the present invention.
  • the method includes the functions of roll forming strip steels into a desired profile at step 100, bending the formed steel profile at step 200 and shearing or cutting the arched steel profile into individual units for shipping at step 300.
  • the bending step 200 employs apparatus 200A and forming device 200B.
  • Fig. IB illustrates a diagrammatic view of a continuous in-line arrangement for forming an arch in a steel profile embodying the various steps shown in FIG. IA.
  • step 100 in which strip steel is roll formed into a desired profile may be accomplished through the use of an uncoiler 102, end welder 104, accumulation pit 106, punching station 108 and roll forming station 110.
  • Uncoiler 102 is configured to stream out long sections of steel sheet or strips from coils.
  • the end welder 104 is used to mate the individual steel sheet sections into a continuous steel sheet length.
  • the accumulation pit 106 provides excess length of steel sheet for end welder 104 to work.
  • the punching station 108 is configured to punch holes or other voids into the continuous steel sheet if desired.
  • the formed profile may be an open or closed profile. Typical open profiles include, for example, "C" shape (most common), "U" shape and angled configurations. Typical closed profiles may include such configurations as polygons, e.g., square, rectangle, triangle and the like, or curved configurations such as oval, circle, and the like. The formed profile may be either welded or non- welded.
  • the roll forming station 110 roll forms the continuous steel sheet into a particular steel profile.
  • the step of bending or arching the steel profile includes utilizing Turkshead 202, Turkshead 204 and cutoff guide 206.
  • the step of shearing or cutting 300 the bent steel profile is accomplished using, for example, a flying cutoff assembly 302.
  • a Turkshead may remain stationary in an angular or vertically displaced position relative to roll forming station 110 as the steel is feed through the process line to provide a constant radius of curvature to the formed steel profile prior to cutting.
  • the Turksheads 202 and 204 may be synchronized for linear and/or angular displacement with respect to the roll forming station 110 as the steel profile is shaped, providing a variable radius of curvature.
  • variable radii may be formed within a single cut steel profile or different radii may be formed in different cut lengths of steel profile.
  • the bent formed steel profile forms an arch, which may include either a singular arch or multiple arches. Multiple arches may also be formed where the arches are within the same plane having different radii, or arches within different planes of formations, whether the arch has the same radius or different radii than other arches in different planes.
  • the steel profile may be arched by the bending profile step 200 to form: (i) a consistent arch, (ii) multiple arches within more than two dimensions, (iii) different arches in the same direction, (iv) different arches in different directions, or (v) a spiral configuration. In this manner, various combinations or arch radii, profile forms and section lengths may be implemented using the present invention as described below.
  • Fig. 2A illustrates an exemplary process line 10 mounted on a base 5 for forming steel profiles from strip steel.
  • strip steel is supplied by an uncoiler which rotates to feed the continuous flat steel 111 to roll forming station 110.
  • the strip steel may include a plurality of holes, varying in hole location, size, shape, or combinations thereof.
  • Roll forming station 110 defines a steel profile forming device and includes a plurality of roll forming stands 115i - 115 N in which the strip steel is roll formed to a profile.
  • the roll forming stands are positioned along the process line aligned with a central axis (denoted as "A" in Fig. 2B) to produce a straight rolled steel profile.
  • Each roll forming stand includes a plurality of rolls which engage both the upper and lower surfaces of the strip steel 111 and apply pressure thereto to bend the steel.
  • the axis of rotation of each roll is transverse to the direction that the strip steel moves through process line 10.
  • Certain of the plurality of roll forming stands 115i - 115 N may be configured to have either an upper or lower combination of rolls which remain fixed relative to the direction of movement through the process line.
  • the number of roll forming stands 115i - 115 N will depend on the desired shape of the steel profile where each stand works or bends the flat steel progressively until the desired shape or profile is achieved.
  • strip steel 111 is supplied to first roll forming stand 115i where it is rolled and output as steel H l 1 .
  • the next roll forming stand in the process 115 2 receives the formed steel 111 1 where it is again rolled to output steel 111 2 .
  • the next roll forming stand in the process 1153 receives the formed steel 111 2 where it is again rolled to output steel 1113.
  • the steel outputted by each roll forming stand produces a changed profile which is rolled in progressive increments by the next successive roll forming stand in station 110. This process continues until the desired cross-section of steel profile 11 I N is outputted by the last roll forming stand 115 N in the process line 10.
  • a simple "U" shaped steel profile or cross-section may require six roll forming stands (115i - 115 6 ) and a more complex shape such as a "U" shape with channel edges may require twelve to 18 roll forming stands (115i - 115 is).
  • the rollers in each stand also act to move or advance the strip steel through the process line 10.
  • a pair of Turksheads 202 and 204 are disposed between the last roll forming stand 115 N and the cutoff assembly 302.
  • the Turksheads 202 and 204 define an arch forming device (200B of Fig. IA).
  • Turkshead 202 receives the formed steel profile 11 I N from roll forming stand I H N -
  • the Turksheads 202 and 204 impart sufficient force to the steel profile to arch the profile in a desired direction.
  • Each Turkshead 202 and 204 includes individual rollers or roll clusters rigidly held within a rotary housing.
  • Representative Turksheads include, for example without limitation, Turksheads similar to Model Number TH-500-SSU available from Addison Machine Engineering Inc.
  • either Turkshead 202 and/or Turkshead 204 may be disposed linearly in the vertical Y direction through the use of movable platforms 225 and 228 respectively.
  • platform 228 displaces Turkshead 204 vertically with respect to Turkshead 202 which remains stationary.
  • This displacement of Turkshead 204 defines a bend point incident on Turkshead 202 causing an arching of steel profile 11 l ⁇ along its longitudinal axis to produce profile 11 IA.
  • Turkshead 202 may be disposed on a movable platform 226 such that Turkshead 202 is disposed linearly in the vertical Y direction with respect to roll station 11 I N and Turkshead 204.
  • This displacement of Turkshead 202 defines a bend point incident on the last roll stand 11 I N -
  • the displacement (linearly or angularly) of either Turkshead 202 and/or 204 with respect to last roll station 11 I N causes an arching of steel profile 11 l ⁇ along its longitudinal axis to produce steel profile 1 1 1 A which is supplied to cut-off assembly 302 where it is cut into desired lengths.
  • Turksheads 202 and 204 may also be configured to be displaced angularly a distance in direction X off the central axis "A" formed by the roll forming stands 115i...l 15 N in process line 10 as described in greater detail with reference to Figs. 2B and 2C. In this manner, the Turksheads 202 and 204 provide a constant radius of curvature for the steel profile formed by roll forming station 110 prior to cutting by cut-off assembly 302 within the continuous in-line process. Alternatively, the Turksheads 202 and 204 may be synchronized to move as the steel profile is shaped by the roll assembly 110 thereby providing a variable radius of curvature.
  • cut-off assembly 302 is also movable on platform 301 such that cut-off assembly 302 must be in-line with Turkshead 204 to provide an end cut along a common transverse plane.
  • cutoff assembly 302 is perpendicular to the steel profile being roll formed by station 110.
  • An exemplary C-shaped steel profile was formed using the above described continuous in-line process with a web width of 70mm, a leg height of 50mm, and a return length of 10mm. Once formed, and as a part of the in-line continuous process, the steel profile was driven through a Turkshead to create an arch with an outer radius of 12.5 meters, and an overall length of 4.2 meters. Once bent, the steel profile was cut to the desired length.
  • the Turkshead 202 and/or 204 may also include a forming device 200B to provide support and/or restrain the desired profile in critical locations during the arching process.
  • a support guide or guide plate is used to alleviate these bend forces incident on the formed profile.
  • a guide plate or a Turkshead guide roll cut device has the corresponding shape of profile 11 I N undergoing the arching process and may be positioned within Turkshead 202. This device is used to support the steel profile during arching while avoiding damage to the given cross-section of the profile as it passes through the process line.
  • the forming device (200B) is positioned to best enhance the structural integrity of the steel profile and provides a stabilizing effect while the steel profile is being arched or bent.
  • These forming devices may be provided in specified shapes, or contact along specified locations of the steel profile and are generally used in the formation of bends in open profiles, such as being shaped to fit in, and conform to, a given internal space within the steel profile.
  • This forming device 200B may be separate from or incorporated into the Turkshead(s) to contribute to the forming of the prescribed curve while maintaining the desired profile.
  • the forming device 200B may be part of or in juxtaposition to cutoff assembly 302 to contribute to the forming of the prescribed curve while maintaining the desired profile and to promote the unimpeded operation of the cutoff assembly 302.
  • a forming device may be used in bending a C-shape in conjunction with a Turkshead by providing a resistive force to pull against the inside of the C-shape during bending, e.g., having four rolls providing pressure on a side member of the steel profile to force it in a certain direction while minimizing wrinkles in the steel profile.
  • Fig. 2B is a top plan view of the process line 10 shown in Fig. 2A having a plurality of roll forming stands 115i - 115 N centrally disposed along axis A to better illustrate the angular displacement feature of bending or arching step 200.
  • Strip steel 111 is supplied to first roll form stand 115i and the process of roll forming proceeds as described above to produce a desired steel profile I H N - Turkshead 202 remains stationary and Turkshead 204 is displaced angularly a distance ⁇ from the central axis "A" such that a bend radius "R" is formed in the steel profile.
  • the distance may be varied during the forming of the steel profile using roll forming station 110 to form a profile with multiple radius of curvatures.
  • the process may be used to create dissimilar sets of steel profiles, where each set of profiles are formed as a set, that may be used together, e.g., the left and right rails (mirror sides) of a slide, etc. In this manner, the constituents of a particular steel profile set are manufactured with a high degree of accuracy for use together.
  • cut-off assembly 302 is angularly aligned with Turkshead 204 to cut the arched steel profiles into desired lengths.
  • Fig. 2C is a top plan view of the process line 10 shown in Fig. 2B where both Turksheads 202 and 204 are displaced angularly with respect to axis "A" to form another arched configuration of steel profile.
  • Turkshead 202 is displaced angularly a distance A 1 from the central axis "A” such that a bend radius is formed in the steel profile with respect to bend station 115 N - Turkshead 204 may also be displaced angularly a distance A 2 from the central axis "A".
  • a steel profile having an arching radius of curvature "R" may be tailored to a particular configuration.
  • Cutoff assembly 302 receives the arched steel profile and cuts the profiles into desired lengths. Again, cutoff assembly 302 is aligned with Turkshead 204 to provide an end cut along a common transverse plane of the steel profile. The relationship of the distances Ai and A 2 will depend on the desired radius of curvature of the profile to be arched.
  • Fig. 2D illustrates a cross sectional view of a profile through Turkshead 204 and an exemplary top insert roller 250 disposed with Turkshead 204. Insert roller 250 is included in the top section of Turkshead 204 to maintain the shape of the roll formed profile 11 l ⁇ during the arching step to equalize the longitudinal stress on the profile during arching to prevent kinking/warping thereof.
  • roll formed profile 11 IT is disposed between Turkshead side rollers 25 IA and 25 IB for bending.
  • Insert roller 250 is configured to engage profile 11 IT such that as the profile is being arched, end 250A of insert roller 250 cooperates with the profile to maintain shape thereof.
  • Insert roller 250 shown in Fig. 2D is an exemplary shape for profile 11 IT and may be exchanged within Turkshead 204 to accommodate other profile shapes.
  • the degree of bend or arch within the steel profile is determined by the vertical and/or angular displacement of Turkshead 202 and/or Turkshead 204.
  • Representative bends include, for example, arch ranges in radius from about 3 meters to about 24 meters.
  • the formed arch may include a bend along the sides of the steel profile, such as that shown as a simple arch in FIG. 3 A, or a reverse arching structure with varying degrees of arch, shown in FIG. 3B.
  • Representative dimensions of the steel profile may include a web width of from about 1.5 inches to about 6 inches.
  • Representative arch ranges have a radius from about 3 meters to about 24 meters.
  • the bent formed steel profile preferably forms an arch.
  • the formed arch preferably has a consistent radius. Consistent radius include those radii having a minimal deviation along a given length of formed steel profiled with representative deviations ranging from about 1/8* of an inch to about 1 A inch.
  • the arch may be in the form of a singular arch or multiple arches, with a singular arch preferred. Representative multiple arches include multiple arches within more than two dimensions, different arches in the same direction and different arches in different directions.
  • the arch may be formed into a full circle structure, which may be formed using guides that offset the feed out of the bending steel profiles outside of the plane of the circle, prior to being cut. Examples of the final steel profiles, include for example without limitation, spirals, circles, slides, S-shapes, and the like.
  • the arched steel profile is cut or severed by assembly 302 after the steel profile has been arched.
  • This avoids drawbacks associated with prior methods where the steel profiles were first cut to length and then arched or bent to a desired radius of curvature pursuant to a secondary process.
  • the method and apparatus of the present invention forms a bent steel profile product continuous in-line at high production rates.
  • Representative production rates include, for example, from about 50 ft/min to about 500 ft/min, with rates of from about 60 ft/min to about 2040 ft/min preferred, and rates from about 60 ft/min to about 90 ft/min most preferred.
  • Supports at the cutoff assembly may be located on the side rail to move the weight load of the steel profile off of the blade. Additionally, these supports may be used to push at the bottom or top of the steel profile to reduce twist, or increase the arch.
  • steel profiles are preferred and referred to herein, other metallic compositions may be used in the formed profiles to be arched. For example, when aluminum profiles are manufactured, formed profiles may result from an extrusion process prior to being bent in the continuous in-line process. Other metals may be used, which are generally designed as specific functional components.

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

Abstract

L'invention concerne un procédé et un appareil de fabrication d'un profil métallique cintré dans un processus en ligne continu. Le procédé consiste à former le profil métallique et à cintrer le profil formé dans un processus en ligne continu. L'appareil comprend une station de formage aux galets configurée pour recevoir une composition métallique plate et former un profil donné. Un dispositif de cintrage est configuré pour recevoir le profil métallique et le plier selon un rayon de courbure souhaité, une partie du dispositif de cintrage se déplaçant verticalement et/ou horizontalement par rapport à la station de formage aux galets.
PCT/US2008/086655 2007-12-12 2008-12-12 Cintrage de profils metalliques dans un processus en ligne continu WO2009076625A1 (fr)

Priority Applications (7)

Application Number Priority Date Filing Date Title
CA2707394A CA2707394A1 (fr) 2007-12-12 2008-12-12 Cintrage de profils metalliques dans un processus en ligne continu
US12/811,593 US20120131974A1 (en) 2007-12-12 2008-12-12 Arching metallic profiles in continous in-line process
EP08859291.0A EP2234738A4 (fr) 2007-12-12 2008-12-12 Cintrage de profils metalliques dans un processus en ligne continu
MX2010006294A MX2010006294A (es) 2007-12-12 2008-12-12 Arquear perfiles metalicos en proceso continuo en linea.
BRPI0821659A BRPI0821659A8 (pt) 2007-12-12 2008-12-12 arqueamento de perfis metálicos em processo contínuo em linha
AU2008334969A AU2008334969A1 (en) 2007-12-12 2008-12-12 Arching metallic profiles in continuous in-line process
IL206064A IL206064A0 (en) 2007-12-12 2010-05-30 Arching metallic profiles in continuous in-line process

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US1292907P 2007-12-12 2007-12-12
US61/012,929 2007-12-12

Publications (1)

Publication Number Publication Date
WO2009076625A1 true WO2009076625A1 (fr) 2009-06-18

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ID=40755904

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2008/086655 WO2009076625A1 (fr) 2007-12-12 2008-12-12 Cintrage de profils metalliques dans un processus en ligne continu

Country Status (8)

Country Link
US (1) US20120131974A1 (fr)
EP (1) EP2234738A4 (fr)
AU (1) AU2008334969A1 (fr)
BR (1) BRPI0821659A8 (fr)
CA (1) CA2707394A1 (fr)
IL (1) IL206064A0 (fr)
MX (1) MX2010006294A (fr)
WO (1) WO2009076625A1 (fr)

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DE102009033135A1 (de) * 2009-07-15 2011-01-27 Elringklinger Ag Verfahren zum Herstellen von Profildichtringen

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Also Published As

Publication number Publication date
BRPI0821659A2 (pt) 2017-04-04
BRPI0821659A8 (pt) 2018-05-08
EP2234738A4 (fr) 2013-09-18
AU2008334969A1 (en) 2009-06-18
MX2010006294A (es) 2010-08-02
US20120131974A1 (en) 2012-05-31
CA2707394A1 (fr) 2009-06-18
IL206064A0 (en) 2010-11-30
EP2234738A1 (fr) 2010-10-06

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