WO2009080717A1

WO2009080717A1 - Device for a roll former for profiling a sheet-metal strip and method associated therewith

Info

Publication number: WO2009080717A1
Application number: PCT/EP2008/067941
Authority: WO
Inventors: Stefan Freitag; Albert Sedlmaier; André ABEE
Original assignee: Data M Sheet Metal Solutions Gmbh
Priority date: 2007-12-21
Filing date: 2008-12-18
Publication date: 2009-07-02
Also published as: DE102007062104B4; DE102007062104A1

Abstract

The present invention provides a device 1, 1' for a roll former 2 for profiling a sheet-metal strip 6. The device 1, 1' includes one or more mounting elements 4. The mounting elements 4 are disposed opposite to one another to form an interposed gap 5 for passing through the sheet-metal strip 6 to be profiled. In addition, the mounting elements 4 are designed in order to absorb forces transversely and/or vertically to the profiling direction. Profiles 7 of the sheet-metal strip 6 may thus be kept in position and/or shaped.

Description

Apparatus for a rollformer for profiling a sheet metal strip and associated method

description

The invention relates to a device for a rollformer for profiling a sheet-metal strip and an associated method according to the preambles of claim 1 or claim 10 or 11.

State of the art

Profiled sheets of metals, such as aluminum, zinc, copper or steel, are used, for example, for the cladding and covering of building exterior surfaces, walls and ceilings. The profiles are usually molded by means of roll forming, so that three-dimensionally shaped sheets arise. The rollforming devices have a plurality of profiling rollers (rollers) arranged in succession in the sheet-metal belt conveying direction, through which the sheet-metal strip to be processed is carried out in a continuous process. The pairs of rollers have at their outer periphery corresponding profiles and deform the band as it passes between the rollers. The deformation of the sheet is usually carried out in several stages with multiple pairs of rolls, each of which with a partial deformation to Total deformation contributes. The sheets have parallel extending profiles with triangular, trapezoidal or sinusoidal cross sections. Since, in the case of a multiplicity of profilings provided next to one another, the overall width of the sheet decreases with increasing deformation, the profiles are initially formed or shaped first in the middle region, and the lateral regions are formed only in the later stages. During the stepwise deformation of the sheet, the sheet should not be undesirable stressed and deformed. However, it comes in the profiling of thin sheets in the prior art to a deterioration in quality. The occurring during the deformation movements and / or displacements lead to the sheet material to surface damage, such. Eg scratches. Also deviations in the cross section, such. As unwanted flats and kinks can occur. Such surface damage gives an ugly appearance and reduce the sales value of the profile sheets. The surface damage is particularly disturbing when already painted, powder-coated, polished or otherwise surface-treated sheets are formed. At z. B. against corrosion protected sheets put the damage to the surface or of the coating the corrosion protection locally down or make it illusory. Furthermore, the detached from the coating parts have a further unpleasant effect: for example, detached from a galvanizing zinc particles can settle on the rollers and form on the roller surfaces undesirable deposits that can cause further surface damage and deformation. Accordingly, there is a need to be able to perform the desired deformations on sheets without unwanted secondary deformations.

task

The object of the present invention is to overcome the above-mentioned disadvantages of the prior art with regard to undesired deformations prevent the profiling of sheets and provide the desired deformation safely and with relatively little effort, without causing the sheet to be profiled sheet or its surface are unduly stressed.

This object is achieved by a device for a roll former for profiling a sheet-metal strip and an associated method according to the preambles of claim 1 or claim 10 or 11.

Advantageous developments of the invention are given in the appended claims.

Brief description of the drawings

Fig. IA shows a schematic plan view of an arrangement of several consecutive pairs of rollers in a roll former of the prior art;

Fig. IB shows a perspective view of the roller pairs of the roll former of Fig. IA;

FIG. 2 shows a schematic profile of a thin sheet metal material corresponding to the roller pairs of FIGS. 1A, 1B;

Fig. 3A shows a schematic plan view of a transformation of a thin sheet metal strip by an arrangement of several successive pairs of rollers in a roll former using the device according to the invention; -A -

Fig. 3B shows a perspective view of the deformation by the roller pairs of the roll former of Fig. 3A;

Figs. 3C-3H are enlarged sectional views, respectively, taken along lines A-A, B-B, C-C, D-D, E-E and F-F of the individual stages of forming by the roller pairs of the roll former of Fig. 3B;

4 shows a schematic and perspective view of a retaining element according to the invention designed as a holding shoe;

Fig. 5 shows structures according to the invention in and / or on the sheet-metal strip, which increase the transverse rigidity of the sheet-metal strip;

Fig. 6A shows the development of undesirable secondary deformations on the sheet metal strip in the simulation; and

6B shows the effects of holding elements according to the invention on the sheet metal strip in the simulation.

Detailed Description of the Preferred Embodiments

The present invention provides an apparatus and a method that can be used in the manufacture of cold rolled profiled trapezoidal sheets, and will be described in detail with reference to the special form corrugated sheet of thin sheet metal.

FIG. 1A shows, in a schematic plan view, an arrangement of a plurality of consecutive pairs of rollers 3 in a prior art roller former 2 and FIG. 1B shows a perspective view of the pairs of rollers 3 of FIG Rollformers 2 of Fig. IA, wherein the arrow indicates the Blechbandförderrichtung or the feed direction of the sheet metal strip respectively. In the construction of the roller pairs 3, the finished end cross section of the profiled sheet is used and the forming determined for each processing step. The finished profile is developed back into the flat sheet metal strip and the profile flower 8 is obtained with the individual forming stages. FIG. 2 shows a schematic profiled flower 8 of a thin sheet metal material corresponding to the roller pairs 3 of FIGS. 1A, 1B. Furthermore, exemplary profiles 7 and symmetrically developing profiles 7 "are shown in FIG. 2, which will be discussed in more detail below ,

Fig. 3A shows a schematic plan view of a deformation of a thin sheet metal strip 6 by an arrangement of several consecutive pairs of rollers 3 in a roll former 2 using the device 1 according to the invention, wherein the arrow indicates the Blechbandförderrichtung or the feed direction of the sheet metal strip 6. Furthermore, exemplary schematically drawn holding elements 4 are shown from the fourth pair of rollers in Blechbandförderrichtung. After the last pair of rollers, two holding elements 4 are arranged by way of example. The sections along lines A-A, B-B, C-C, D-D, E-E, F-F are shown in detail in Figs. 3C-3H.

FIG. 3B shows a perspective view of the deformation by the roller pairs 3 of the roll former 2 of FIG. 3A, wherein the arrow indicates the sheet metal band conveying direction or the feed direction of the sheet metal strip 6. The upper holding elements 4 are formed there as holding shoes 9. Further, by way of example, a profiling 7 in the middle of the sheet metal strip 6, two directly adjacent Profϊlierungen 7 "and each a profiling T at the edges (Edge element) to increase the transverse stiffness of the sheet metal strip 6 shown.

3C-3H are respectively enlarged sectional views taken along lines A-A, B-B, C-C, D-D, E-E and F-F of the individual stages of forming by the roller pairs 3 of the roll former 2 of Fig. 3B (see Fig. 3A). In Fig. 3C, a roller pair (or roller stand) 3 of the roll former 2 is shown along the section line A-A. The pair of rollers 3 comprises an upper roller group 22 and a lower roller group 22 '. Each roller group 22, 22 'is supported by a respective upper shaft 23 and a lower shaft 23'. The shafts 23, 23 'are supported by a framework 24. Further, each roller group 22, 22 'includes respective upper forming rollers 25, lower forming rollers 25', and upper leading rollers 26 and lower guiding rollers 26 '. In FIG. 3D, the next pair of rollers (or roller stand) 3 of the roll former 2 is shown along the section line B-B, wherein the section line B-B extends directly through the device 1, 1 'according to the invention. The holding elements 4 of the device 1, 1 'according to the invention are exemplarily designed as upper holding shoes 9 and lower holding shoes 9'. Further, the gap 5 is shown, which is formed by the upper and lower holding elements 4 and holding shoes 9, 9 'for the implementation of the sheet metal strip 6 to be profiled. In FIG. 3H, the last roller pair (or roller frame) 3 of the roll former 2 is shown along the section line F-F, the section line F-F extending directly through the device 1, 1 'according to the invention. By way of example, two upper and lower holding shoes 9, 9 'are shown.

A thin sheet metal strip 6 is, in the general understanding of one skilled in the art, one that has a thickness of about 0.4 to about 0.6 mm or less. This applies to broadband profiles, such as corrugated sheets or trapezoidal sheets. By way of example, six stages are shown from the profiling process of the thin sheet metal strip 6. In principle, each individual wave of the corrugated sheet can be formed in a single or several individual transformations and there are various strategies, such. Eg "2-bend" (simultaneous forming at two bending points), "4-bend" (simultaneous forming at four bending points) and "AIl-bend" (simultaneous profiling of all waves). FIGS. 3A-3H schematically show the 2-bend strategy from the very frequently used 2-bend and 4-bend strategies. In the strategies 2-bend and 4-bend first the inner waves and in subsequent steps the waves further out are formed, wherein one or more already shaped waves can be used to guide the sheet metal strip 6 by the roll former 2.

Due to the forces occurring during the profiling, the sheet metal strip 6 is pulled inwards toward the middle of the strip, since material of the width goes to the height of the individual waves, and the entire width of the sheet metal strip 6 decreases. In this case, the sheet metal strip 6 is pulled too far inward or toward the middle of the profile or pushed. As a result, there is too much material to be processed at one point. The excess material in the region of a finished shaped shaft directly in front of the next pair of rollers 3 causes the sheet to swerve into the height or depth. The already shaped shaft is deformed. In the subsequent forming step, the deformed shaft is pushed back to its original shape. This reciprocal deformation and a relative movement between the sheet and rolls produce the errors in the surface and the deviations in the cross section.

In one embodiment of the present invention, a device 1, 1 'is provided, which includes one or more holding elements 4. The holding elements 4 are arranged opposite each other to form an intermediate gap 5 for the implementation of the sheet metal strip 6 to be profiled. Furthermore, the holding elements 4 can absorb forces transversely and / or vertically to the profiling direction and thereby keep profiles 7 of the sheet-metal strip 6 in position and / or shape.

FIGS. 3A-3H schematically show some upper and lower holding elements 4 exemplary stages in the progressive continuous deformation of a thin sheet metal strip 6 by pairs of rollers 3. The holding elements 4 are preferably mounted at the point at which the unwanted deformation occurs, this is usually directly just before the roller plane. Thus, the support members 4 are mounted as close as possible before and / or after the roller pairs 3 to hold already preformed and / or finished shaped waves in position and / or shape. Before the first pair of rollers 3 in BandfÖrderrichtung holding elements can be provided or omitted. The following pairs of rollers 3 have iteratively increasing numbers of holding elements. 4

In this embodiment, the holding elements 4 are in the following pairs of rollers 3 only at the outermost, just preformed and / or finished shaped waves. Alternatively, the retaining elements 4 may be applied over all preformed and / or finished shafts. By the holding elements can absorb the forces occurring transversely to the Profilierrichtung, they have a stabilizing effect on the position and / or shape of the respective waves. The holding elements 4 can also absorb forces occurring vertically to the profiling and thus contribute in addition to their stabilizing effect. The holding elements 4 can be installed in a frame. Since all parts are identical or similar parts, the costs for manufacturing and installing the device 1, I ¹ on the roll former 2 are reduced. The holding elements 4 can be actuated by hydraulic, pneumatic, mechanical and / or electrical leverage a direction perpendicular to the feed direction of the sheet metal strip or Blechbandförderrichtung direction are applied to the sheet to be profiled at each predetermined positions. The positions of the holding elements 4 are to be selected according to the needs and are preferably determined by means of simulation software, such. B. Software of the assignee of the present invention. The simulation of the situation in the course of the forming steps in the profiling can be advantageously carried out to to determine the correct positions for the holding elements 4. Alternatively, it is also possible to carry out tests on the system.

In another embodiment, the upper and lower support members 4 include one or more upper and lower support shoes 9, 9 'and / or support rollers. The retaining shoes 9, 9 'and / or retaining rollers may be cylindrical, sinusoidal, triangular, trapezoidal or as combinations thereof for adaptation to the profiles to be stabilized. 4 shows a schematic and perspective view of a holding element 4 according to the invention designed as a wave-shaped upper and lower holding shoe 9, 9 '. The holding shoe 9, 9' optimally adapts to the profile to be stabilized above and below the plane of the sheet metal strip 6 , These holding shoes 9, 9 'can be brought closer to a pair of rollers 3 compared to holding rollers, since the holding shoes 9, 9' can be performed in a lower height. In the case of retaining rollers cost-effective storage is achieved because they only have to absorb relatively small forces. Furthermore, drive of the holding rollers is not required in most applications.

The holding elements 4 and holding shoes 9, 9 'and / or holding rollers are preferably made of a material such. As plastic, aluminum, Ampco (Cu alloy) and the like. Alternatively, combinations of these materials are provided.

In the case of holding shoes 9, 9 'is to pay attention to an advantageous Gleitfahigkeit in the choice of material, so that when adversely affecting the holding elements 4 with the profile to be stabilized frictional forces occur. Should in certain applications on a material that would cause high frictional forces can not be waived, so it is also possible to reduce the friction so-called. Friction reducer in the form of z. B. use lubricant compositions. Friction reducers are the Those skilled in the art well known and will not be discussed here. However, when using z. B. lubricant compositions are taken to ensure that the compositions undergo no (undesired) chemical reactions with the surface of particular already surface-treated sheets.

In a further embodiment, the device 1, T according to the invention further includes means with which one or more structures in and / or on the sheet metal strip 6 can be formed in order to increase the transverse rigidity of the sheet metal strip 6. FIG. 5 shows some of these structures according to the invention. The increase in transverse rigidity in the transverse direction can be achieved by profiling part of the profile cross-section of the sheet metal relatively early or directly at the beginning of the profiling process. This structuring according to the invention can take place externally on the edge (edge element) as a profiling 7 'or further inside the sheet as profiling 7 "Preferably, the structuring according to the invention takes place as a profiling T (edge element) on the edge This edge element T can be completely or partially shaped the sheet is stiffened in the transverse direction and can not be pulled or pushed so easily between the other pairs of rollers 3. The size, number and design of the structures depend on the space conditions on the profiling and in particular on the desired stiffness of the sheet Furthermore, in the case of structures on the edge, these edge elements T can advantageously already be used to guide the sheet-metal strip 6 through the roll former 2. The above embodiment can also be realized without the use of the holding shoes 9, 9 ', provided the quality requirements of the profile are lower.

Furthermore, the present invention provides a method of using a device 1, 1 'according to the invention in the production of a profiled sheet-metal strip 6. In step 1, a profile flower 8 (see Fig. 2) can be determined. As already mentioned, the determination of the profile flower 8 can be done by reverting the finished profile into the flat sheet metal strip.

In step 2, the individual steps of the profiling can be carried out without the holding elements 4 according to the invention and transverse stiffening in the simulation. This implementation can be done via finite element simulation, preferably by means of the simulation software of the applicant of the present invention. FIG. 6A shows the development of undesirable secondary deformations on the sheet metal strip 6 in the simulation. FIG. 6A shows the situation between two forming stages. The curve 1 shows the plate between pairs of rollers 3 just before entering the next forming stage. Curve 2 shows the sheet metal in the following pair of rollers 3. It can be clearly seen that the sheet metal strip 6 is pulled or pushed too far inward or toward the center of the profile. The excess material in the region of the finished shaped shaft directly in front of the next pair of rollers 3 causes the sheet to swerve upwards. The already shaped shaft is deformed. In the subsequent forming step, the deformed shaft is pushed back to its original shape.

In the next step 3, the individual positions for holding elements 4 in the simulation can be determined. If necessary, in this step 3 of the simulation, the size, number and position for transverse stiffeners can be further determined.

In step 4, the individual stages of the profiling can be carried out with holding elements 4 in the simulation. If necessary, in this step 4 of the simulation, furthermore, the individual steps of the profiling can be carried out with the additional effect of size, number and position of transverse stiffeners be performed. FIG. 6B shows the effects of inventive retaining elements 4 on the sheet-metal strip 6 in the simulation. An additional transverse reinforcement is not available here. The magnification shows how the metal strip 6 leaves this forming step. The almost perfect result is clearly visible.

In step 5, if necessary, the positions for holding elements 4 in the simulation can be optimized. If necessary, in this step 5 of the simulation, the size, number and position of transverse stiffeners can be further optimized.

In step 6, the individual steps of the profiling can be carried out with retaining elements 4 and, if necessary, transverse reinforcement in the installation. In the last step 7 of the method according to the invention, if necessary, the positions of the holding elements 4 and / or the transverse stiffeners in the system can be optimized.

With the above-described device 1, 1 'of the present invention, which can be integrated into any prior art rollformer, as well as the method according to the invention, in particular thin sheets can be profiled which do not exhibit the surface damage and cross-sectional deviations of the prior art. These sheets can be produced with consistent quality, in particular already painted, powder-coated, polished or otherwise surface-treated sheets, in which the coating has a special function to fulfill, such as corrosion protection.

When technical features mentioned in any of the claims are provided with a reference numeral, these reference numerals have been included only to enhance the intelligibility of the claims. Corresponding For example, these references do not have a limiting effect on the scope of protection of each element, which is exemplified by such reference numerals.

LIST OF REFERENCE NUMBERS

1, T device for a roll former

2 roll former

3 pairs of rollers (or roller stand)

22 upper roller group 22 'lower roller group

23 upper shaft 23 'lower shaft

24 scaffolding

25 upper forming roller 25 'lower forming roller

26 upper leading roller 26 'lower leading role

4 retaining element

5 gap

6 to be profiled sheet metal strip

7 profiling

7 'profiling to increase the transverse rigidity (edge element)

7 "profiling to increase the transverse stiffness

8 profile flower

9 upper shoe 'lower shoe

Claims

claims

1. Device (1, 1 ') for a roll former (2) with a plurality of successive pairs of rollers (3) for profiling a metal strip (6), wherein the device (1, 1') comprises one or more holding elements (4) , wherein the holding elements (4) opposite to each other to form an intermediate gap (5) for the implementation of the sheet metal strip to be profiled (6) between successive pairs of rollers (3) are arranged and configured to forces transverse and / or vertical to profiling take and thereby retain profilings (7) of the sheet metal strip (6) in position and / or shape.

2. Device (1, V) according to claim 1, wherein the holding elements (4) comprise one or more holding shoes (9, 9 ') and / or holding rollers, which are formed profile-dependent transversely to the feed direction of the sheet metal strip, in particular sinusoidal, arcuate, cylindrical , triangular, trapezoidal or combinations thereof.

A device (1, 1 ') according to any one of claims 1 or 2, wherein the holding members (4) are made of a material selected from the group consisting of plastic, aluminum, Ampco (Cu alloy) and the like or Combinations thereof.

4. Device (1, 1 ') according to one or more of claims 1-3, further comprising a first means for adjusting the height of the gap (5) of the holding element (4).

5. Device (1, V) according to one or more of claims 1-4, further comprising a second means for adjusting the distance of the holding element (4) in the feed direction of the sheet metal strip to the pair of rollers (3).

6. Device (1, 1 ') according to one or more of claims 2-5, wherein the holding rollers are driven.

7. roll former (2) in conjunction with the device (1, Y) according to one or more of claims 1-6, further comprising a first pair of rollers (3), which immediately after an insertion point of the metal strip (6) in the roll former ( 2) is arranged and which is formed to form at the respective edges of the sheet profilings (7 ') to increase the Quersteifϊgkeit the sheet metal strip.

8. roll former (2) in conjunction with the device (1, V) according to one or more of claims 1-6, further comprising a first pair of rollers (3), which immediately after an insertion point of the metal strip (6) in the roll former ( 2) and which is adapted to create a profiling (7) in the center of the sheet, and further comprising a second pair of rollers (3) disposed downstream of the first pair of rollers (3) and adapted to before a profiling (7 "), which is offset from the profiling (7) of the sheet in the middle, at the respective edges of the sheet profilings (7 ¹ ) to increase the transverse stiffness of the sheet metal strip to form.

9. roll former (2) in conjunction with the device (1, 1 ') according to one or more of claims 1-6, further comprising a first pair of rollers (3), immediately after an insertion point of the metal strip (6) in the roll former (2) is arranged and which is designed to produce a profiling (7) in the middle of the sheet, and further comprising a second pair of rollers (3), which is arranged downstream of the first pair of rollers (3) and which is formed in order to form profilings (7 ') in order to increase the transverse rigidity for stiffening the sheet-metal strip in front of a profiling (7 ") which is offset from the profiling (7) of the sheet in the middle.

10. A method for using a device (1, 1 ') according to any one of claims 1-6 or with a roll former (2) according to claims 7-9 in the manufacture of a profiled sheet metal strip (6), comprising the following steps:

1. determining a profile flower (8);

2. Transits of the individual steps of the profiling without holding elements (4) in the simulation;

3. determining positions for holding elements (4) in the simulation;

4. Transits of the individual steps of the profiling with holding elements (4) in the simulation;

5. Optimizing, if necessary, the positions for holding elements (4) in the simulation;

6. Passing through the individual steps of the profiling with holding elements (4) in the roll former (2); and

7. Optimize, if necessary, the positions of the holding elements (4) and in the roll former (2).

11. Method for using a device (1, 1 ') according to one of claims 1-6 or with a roll former (2) according to claims 7-9 in the production of a profiled sheet-metal strip (6), comprising the following steps:

1. determining a profile flower (8);

2. Transits of the individual steps of the profiling without holding elements (4) and without transverse stiffening in the simulation;

3. Determining positions for holding elements (4) and the transverse stiffening in the simulation;

4. Transits of the individual steps of the profiling with holding elements (4) and with the transverse stiffening in the simulation;

5. Optimizing, if necessary, the positions for holding elements (4) and, if necessary, the transverse reinforcement in the simulation;

6. Performing the individual steps of the profiling with retaining elements (4) and, if necessary, the transverse stiffening in the roll former (2); and

7. Optimize, if necessary, the positions of the holding elements (4) and, if necessary, the transverse reinforcement in the roll former (2).