WO2012113127A1 - 嵌套式复合型材构件的制造方法及其制造设备 - Google Patents

嵌套式复合型材构件的制造方法及其制造设备 Download PDF

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Publication number
WO2012113127A1
WO2012113127A1 PCT/CN2011/002040 CN2011002040W WO2012113127A1 WO 2012113127 A1 WO2012113127 A1 WO 2012113127A1 CN 2011002040 W CN2011002040 W CN 2011002040W WO 2012113127 A1 WO2012113127 A1 WO 2012113127A1
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WO
WIPO (PCT)
Prior art keywords
profile
nesting
cutting
punching
base
Prior art date
Application number
PCT/CN2011/002040
Other languages
English (en)
French (fr)
Inventor
朱建华
Original Assignee
宁波邦达智能停车设备股份有限公司
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 宁波邦达智能停车设备股份有限公司 filed Critical 宁波邦达智能停车设备股份有限公司
Priority to JP2013553759A priority Critical patent/JP5694572B2/ja
Publication of WO2012113127A1 publication Critical patent/WO2012113127A1/zh
Priority to US13/971,880 priority patent/US9427831B2/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P13/00—Making metal objects by operations essentially involving machining but not covered by a single other subclass
    • 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
    • B21D35/00—Combined processes according to or processes combined with methods covered by groups B21D1/00 - B21D31/00
    • 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
    • B21D35/00—Combined processes according to or processes combined with methods covered by groups B21D1/00 - B21D31/00
    • B21D35/001—Shaping combined with punching, e.g. stamping and perforating
    • 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
    • B21D47/00—Making rigid structural elements or units, e.g. honeycomb structures
    • B21D47/04—Making rigid structural elements or units, e.g. honeycomb structures composite sheet metal profiles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P19/00—Machines for simply fitting together or separating metal parts or objects, or metal and non-metal parts, whether or not involving some deformation; Tools or devices therefor so far as not provided for in other classes
    • B23P19/10—Aligning parts to be fitted together
    • B23P19/107—Aligning parts to be fitted together using oscillating, rotating or vibrating movements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P19/00—Machines for simply fitting together or separating metal parts or objects, or metal and non-metal parts, whether or not involving some deformation; Tools or devices therefor so far as not provided for in other classes
    • B23P19/10—Aligning parts to be fitted together
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49826—Assembling or joining
    • Y10T29/49908—Joining by deforming
    • Y10T29/49925—Inward deformation of aperture or hollow body wall
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/51—Plural diverse manufacturing apparatus including means for metal shaping or assembling
    • Y10T29/5176—Plural diverse manufacturing apparatus including means for metal shaping or assembling including machining means

Definitions

  • the present invention relates to a method of manufacturing a load bearing member, and more particularly to a method of manufacturing a nested composite profile member for a three-dimensional garage and a manufacturing apparatus therefor.
  • the nested composite profile member is composed of a first member ⁇ and a second member 2', and the first member 1' and the second member 2' are respectively equal-length elongated members having the same shape and size.
  • the so-called nested composite means the first member ⁇ is rotated 180 degrees and the second member 2 ′ is mutually entangled into a cylinder; wherein the cross section of the first member 1 ′ includes two first crosses arranged in parallel with each other
  • the side 11' further includes a first vertical side 12' which is perpendicularly connected to one of the two first lateral sides 1 ⁇ , and the other ends of the two first lateral sides 11' are vertically bent and formed to be opposite each other.
  • a first inset flange 13' and a first outer flange 14' the first member 1' forming an inwardly folded first bend 13" at the end of the first inset flange 13', the first member An inward concave is formed on the first vertical side 12' of 1' a first reinforcing rib 121';
  • a cross section of the second member 2' includes two second lateral edges 21' disposed parallel to each other, and further comprising a vertical connection with one of the ends of the second lateral edge 21'
  • the second vertical side 22', the other ends of the two second lateral sides 21' are vertically bent and formed into opposite second inlaid folded edges 23' and second outer folded edges 24', and the second member 2'
  • a second bent portion 231' which is folded inward is also formed at the end of the second inscribed flange 23', and a second reinforcing rib is formed on the second vertical side 22' of the second member 2'.
  • the first lateral side 11' of the first member ⁇ is respectively engaged with the second lateral side 21' of the second member 2', the first inset flange 13' and the second member 2
  • the inner side of the second vertical side 22' is fitted, and the first outer folded side 14' and the outer side of the second vertical side 22' of the second member 2' are fitted together, the first bent portion 131' and the first reinforcing rib
  • the inner convex portion 122' of the 121' is fitted;
  • the second inner folding edge 23' is fitted to the inner side of the first vertical side 12' of the first member, the second outer folded portion 24' and the first member 1'
  • the first vertical side 12' is affixed to the outer side, and the second bent portion 23'' is joined to the inner raised portion 222' of the second rib 22''; when the first member ⁇ and the second member 2' are nested and combined,
  • the first member ⁇ is folded inward at the end of the first outer hem 14' to
  • the first vertical side 12' is further formed with a first groove 124' having a C-shaped cross section on the first reinforcing rib 121', the opening direction of the first groove 124' and the first member ⁇
  • the opening direction is the same
  • the second vertical side 22' is also formed on the second reinforcing rib 221' with a C-shaped second groove 224' whose opening direction coincides with the opening direction of the second member 2'.
  • the first lateral side 1 ⁇ A first rib 111' is further disposed thereon, and a second rib 211' is further disposed on the second lateral side 2 ⁇ .
  • the geometry and structure of the cross-section of the profile of the first member and the second member of the nested composite profile member are not limited to the structures disclosed in the above patents, and may also be other structural forms.
  • the method for manufacturing the above-mentioned patented composite profile member generally adopts the following process steps: In the first step, two separate members are produced; the cutting of the material is performed on the profile, the through hole processing (multi-station) and the pressing of the rib ( Multi-station) These two steps; the second step, the first horizontal side, the second horizontal side, the first vertical side, the second vertical side, the outer folded side and the inlaid folded side are respectively performed on two separate members The second step of the work The undercut process of the folded portion. ,
  • the above process steps are all carried out at different stations, and are operated off-line, which causes multiple discrete processes and multiple stations to be transferred throughout the manufacturing process.
  • the disadvantages are: First, not only consumes a lot of man-hours and Labor, and will affect the positioning error between each station and its processing accuracy. For example, the disadvantage of pressing the rib after punching is that the extension deformation of the profile produced after pressing the rib will affect the original through hole processing.
  • the first technical problem to be solved by the present invention is to provide a nested composite profile member capable of significantly reducing raw material consumption and ensuring processing precision, and having high degree of mechanization and high production efficiency in view of the above-mentioned state of the art. Production method.
  • a second technical problem to be solved by the present invention is to provide a manufacturing apparatus of a nested composite profile member capable of realizing the above manufacturing method.
  • a method for manufacturing a nested composite profile member characterized in that all the process steps for manufacturing a nested composite profile member are continuous on the same production line Automated, the manufacturing method includes the following process steps: (1), leveling process, firstly feeding the metal strip into the profile leveling machine for leveling, and then, the metal strip is automatically conveyed along the production line to the latter process direction;
  • the profile is sent to the cutting device for cutting, and the first member is fed into the nesting and holding device after being cut, and rotated by 180 degrees in the cross-sectional direction of the first member, and then The first member after the rotational positioning is inserted into the second member obtained after the second cutting, and the first member and the second member are nested and hung to form a composite piece.
  • the first member The outer edge of the member is attached to the side of the second member, and the outer edge of the second member is attached to the side of the first member;
  • the composite one piece is fed into a third roll pressing die set, and the third roll pressing die set is respectively formed with the corresponding side on the outer folded edges of the first member and the second member
  • the snap-fit fastening hem is formed into the desired nested composite profile member and exits the production line after the affixing process.
  • the nesting and holding process in the step (5) specifically includes the following steps:
  • the profile conveyed in the direction of the production line is fed into the rotary positioning device of the nesting holding device, and when the profile touches the first detection control contact, the cutting device moves synchronously with the profile and cuts Obtaining the first member with the profile;
  • the rotary positioning device moves rapidly along the nested base in the nested holding device, and leaves a required separation distance from the profile in the rear conveyance;
  • the rotary positioning device drives the first member to rotate 180 degrees, and at the same time, the cutting device and the device Resetting the rotary positioning device;
  • the profile in the rear conveyance enters the rotary positioning device and realizes nesting and holding with the first member
  • the cutting device moves synchronously with the profile again, and cuts the profile again to obtain the second component. Continuing the conveying of the profile against the second member such that the second member continues to nest with the first member;
  • the first member and the second member form the composite piece, and the continuous conveying profile is placed against the composite piece to the next Process delivery; when the profile in the continuous conveyance hits the first detection control contact again, return to step a to continue the next nesting Process.
  • the technical solution adopted by the present invention to solve the above second technical problem is: a manufacturing device of a nested composite profile member, wherein the manufacturing device includes in turn along the direction of the production line
  • first roll pressing die set fixedly disposed on the ground, the first rolling die set comprising a plurality of first roller sets for roll forming the reinforcing ribs;
  • the punching device comprises a punching bed fixedly disposed on the ground and a punching machine capable of horizontally sliding along the punching bed;
  • the second roll stamping die set fixedly disposed on the floor, the second roll stamping die set comprising a plurality of second roller sets for roll forming the profile having a desired cross-sectional shape;
  • a cutting device having a die for cutting the profile to form the first member and the second member; a nesting holding device for positioning the first member 180 degrees and interlacing with the second member Forming the composite piece;
  • the third roll pressing die set is fixedly disposed on the ground, and the third roll pressing die set includes a third roller set for roll forming the fastening hem.
  • the nesting and holding device comprises a nested bed fixedly disposed on the ground; the nesting base is disposed on The nesting bed is horizontally slidable relative to the nested bed; the rotary positioning device includes a seat disposed on the nesting base and horizontally slidable relative to the nesting base,
  • the vehicle seat is connected with a first cylinder capable of driving the rotary positioning device to slide along the nesting base, and the seat is fixed with two fixed brackets spaced apart and oppositely disposed, and the fixing bracket is provided with a length direction a rotator that runs through and is rotatable relative to the bracket, the rotator is provided with a square hole that is adapted to the shape and size of the profile, and the rotator is further provided with a plurality of peripheral edges along the square hole a jig disposed, the jig includes a guide rail and a collet, the guide
  • the rotator is provided with spaced-apart slots along the circumferential surface, the rotator is opposite The corresponding slots on both sides of the 180-degree direction are interposed with positioning pins that define the rotational orientation of the rotator. After the rotator is rotated by 180 degrees, the positioning pins are respectively inserted into the corresponding positioning grooves on both sides of the rotator, so that the position of the rotator relative to the fixed bracket can be defined, the offset of the rotator relative to the fixed bracket bracket can be prevented, and the nesting can be ensured. The accuracy and reliability of the hug.
  • the cutting device comprises a cutting base disposed on the nesting bed and capable of being opposite The bed is horizontally slid, the cutting base is fixedly connected to the nesting base, and the cutting base is connected to drive the a second cylinder that slides along the nesting bed; a die is fixedly disposed on the cutting base; wherein the nesting base is provided with a cutting block and a control for controlling the die cutting along the length direction a positioning stop rotated by the rotary positioning device, and the nesting bed is provided with a reset stop on a side of the cutting base to restrict movement of the cutting base. Since the cutting base and the nesting base are fixedly connected, when the cutting device is reset, the nesting base is simultaneously reset, ensuring that the positioning reference and the cutting length of the second member and the first member are the same.
  • the metal strip and the member can be smoothly conveyed along the production line.
  • the cutting stopper and the positioning stopper are respectively stoppers that can be vertically expanded and contracted.
  • the cutting block and the positioning block are used for detecting the position of the metal strip or the component after cutting on the production line, and for controlling the action of the die and the rotator, wherein the cutting block and the positioning block can be respectively
  • the cylinder control realizes the expansion and contraction.
  • the punching device includes a punching bed fixedly disposed on the ground and a punching machine horizontally slidable along the punching bed, and the punching bed is further provided with A fifth cylinder that drives the punch to slide along the punching bed.
  • the punching machine can move along with the metal strip 3 ⁇ 4", and when the punching is completed, the punching machine is reset by the fifth cylinder.
  • the punching device further comprises a pressing device, which comprises a pressing plate and a driving platen. Pressing a cylinder and a pressing base that drives the pressure plate to slide horizontally along the punching bed, the pressing base and the punching machine are fixedly connected, the piston rod of the fifth cylinder and the pressing The base is fixedly connected.
  • the bottom of the pressure plate is further provided with a positioning pin which can penetrate into the formed punching hole on the metal strip. After the punching of the front metal strip is completed, the positioning pin on the pressure plate can be inserted into the punched through hole for positioning to ensure the accuracy of the subsequent punching position.
  • the advantages of the invention are as follows: Firstly, the roll forming process of the reinforcing rib structure such as the rib and the groove is performed before the punching process, thereby ensuring the hole size precision after the punching process, Significantly improve product quality; Secondly, metal strips are automatically transported along the production line, all processes are carried out continuously on the same production line, realizing the automated production of composite profile components, saving a lot of man-hours and auxiliary man-hours, greatly improving Production efficiency; Furthermore, from the metal strip into the production line to the molding of the composite profile, the metal strip completes a product processing process through each process, and each process is online and uninterrupted.
  • Fig. 1 is a schematic view showing the structure of an apparatus assembly line for the production of nested composite profile members.
  • Fig. 2 is a schematic, partially enlarged schematic view showing the cutting device and the nesting holding device in the line shown in Fig. 1.
  • 3 is a schematic diagram showing the axial structure of a nesting and holding device in the equipment line of FIG.
  • Fig. 4 is a schematic diagram showing the A-A structure of the nesting and holding device shown in Fig. 3.
  • Fig. 5 is a schematic diagram showing the transmission structure of the nesting and holding device shown in Fig. 4.
  • Fig. 6 is a perspective structural view of a nested composite profile member in the prior art.
  • Figure 7 is a schematic cross-sectional view (after assembly) of a nested composite profile member of the prior art.
  • Figure 8 is a plan view of the first member shown in Figure 7 (before assembly).
  • Figure 9 is a plan view of the second member shown in Figure 7 (before assembly). detailed description
  • FIG. 1 to FIG. 5 it is a schematic structural view of an embodiment of the present invention.
  • the manufacturing device of the nested composite profile member is an automated production line for continuous production in multiple steps.
  • the processing material of the embodiment is a feeding feeder.
  • the continuous metal strip A, the metal strip A can be automatically transported to the next process along the pipeline.
  • the nested composite profile manufacturing equipment includes the order of the production line process.
  • Profile leveler 1 used to flatten the metal strip A fed into the production line.
  • the first roll pressing die set 2 is fixedly disposed on the ground, and the first rolling die set 2 includes a plurality of first roller sets for rolling the required reinforcing ribs of the nested composite profile member;
  • the punching device 3 includes a punching bed 31 fixedly disposed on the ground 9 and a punching machine 32 horizontally slidable along the punching bed 31.
  • the punching machine 32 is fixedly disposed on the punching bed 31 and can drive the punching
  • the fifth cylinder T5 and the pressing device 8 of the hole machine 32 are slid along the punching bed 31.
  • the pressing device 8 includes a pressing plate 81, a pressing cylinder 83 for driving the pressing plate 81, and a driving platen 81 along the punching hole.
  • the pressing base 84 of the bed 31 is horizontally slid, the pressing base 84 and the punching machine 32 are fixedly connected, the piston rod of the fifth cylinder T5 is fixedly connected with the pressing base 84, and the bottom of the pressing plate 81 is further provided with a metal penetrating
  • the positioning pin 82 can be inserted into the punched through hole for positioning, and the punching machine 32 is reset by the fifth cylinder T5.
  • the second roll stamping die set 4 is fixedly disposed on the floor 9.
  • the second roll stamping die set includes a plurality of cross-sectional shapes (including lateral and vertical sides) for roll forming a nested composite profile member. Second roller set with inset hem, outrigger hem and bend, etc.).
  • a cutting device 5 for cutting the profile B and forming a first member and a second member, the cutting device 5 comprising: a cutting base 51 disposed on the nesting bed and capable of horizontally sliding relative to the nested bed 61, cutting The base 51 is fixedly connected to the nesting base 62, and the cutting base 51 is connected with a second cylinder T2 for driving the cutting base 51 to slide along the nesting bed;
  • a die 52 is fixedly disposed on the cutting base 51;
  • the nesting base 62 is provided with a cutting stopper 621 and a positioning stopper 622 along the length direction, wherein the cutting stopper 621 serves as a first detecting control contact for detecting the position of the profile B and controlling the cutting action of the die 52.
  • the positioning stop 622 serves as a second detection control contact for detecting the position of the first member and controlling the rotation of the rotary positioning device;
  • the nesting bed 61 is provided with a restriction on the cutting base on a side of the cutting base 51 51 moving reset stop 611. Since the cutting base 51 and the nesting base 62 are fixedly coupled, when the cutting device 5 is reset, the nesting base 62 is simultaneously reset, ensuring that the positioning reference and the cutting length of the second member and the first member are the same.
  • the cutting block 621 and the positioning block 622 are respectively upper and lower telescopic stoppers, wherein the cutting stopper 621 is connected to the piston rod of the third cylinder T3, and the positioning stopper 622 is connected to the piston rod of the fourth cylinder T4.
  • the cutting stopper 621 and the positioning stopper 622 can detect the position of the metal strip A or the cut member on the production line, and control the cutter action of the cutting device 5 when it is necessary to detect the position of the metal strip A or the cut member
  • the stopper can be pushed up by the cylinder piston rod; when the position of the metal strip A or the cut member has been detected, the stopper can be retracted downward by the cylinder piston rod.
  • the nesting and holding device 6 is configured to position the first member rotation 180 and to form a composite unit with the second member.
  • the nesting and holding device comprises:
  • Nested bed 61 fixedly placed on the ground 9;
  • a nesting base 62 disposed on the nesting bed 61 and horizontally slidable relative to the nesting bed 61; a rotary positioning device including a nesting base 62 and capable of being embedded relative to the nesting base 62 a seat 63 that slides horizontally on the base 62.
  • the seat 63 is connected to a first cylinder T1 that can drive the rotary positioning device to slide along the nesting base 62.
  • the seat 63 is fixed with a space and opposite thereto.
  • Two fixing brackets 64 are disposed, and the fixing bracket 64 is provided with a rotator 65 extending through the length direction and rotatable relative to the bracket 64; wherein the rotator 65 is provided with spaced-apart slots 651 along the circumferential surface, when the rotator 65 After being rotated by 180 degrees, the rotator 65 is respectively inserted with positioning pins 68 in the corresponding tooth grooves 651 on opposite sides of the 180-degree direction, and the positioning pins 68 can define the rotational position of the rotator 65 relative to the fixed bracket 64.
  • the reaper 65 is provided with a square hole 652 which is matched with the shape of the profile ⁇ in the axial direction, and the rotator 65 is further provided with a plurality of square holes 652 on the end surface.
  • Peripheral clip The jig includes a guide rail 66 and a collet 67.
  • the guide rail 66 is fixedly disposed on the end surface of the rotator 65.
  • the collet 67 can slide along the guide rail 66 and is in contact with the first member (the cut profile ⁇ ).
  • the relative position of the collet 67 along the guide rails 66 enables the rotator 65 to accommodate the clamping of profile members of different geometries and sizes.
  • the third roll stamping die set 7 is fixedly disposed on the floor 9.
  • the third roll stamping die set 7 includes a third roller set for fastening the required crimping of the nested composite profile member.
  • the manufacturing method of the nested composite profile member of the present embodiment includes the following process steps, which are successively completed in sequence on the same production line:
  • the leveling process first, the metal strip is fed into the profile leveler 1 for leveling, and the metal strip Material A is automatically transported along the production line in the direction of the latter process.
  • the metal strip A is continuously fed into the second roll pressing die set, and the second roll pressing die set is roll-formed to form a lateral side, a vertical side, an inset folding edge, and an outer wrapping The edge and the bent portion, the metal strip A is roll-formed by the second roll-pressing die set to form a profile B;
  • the nesting and holding process the cutting device 5 cuts the profile B to form the first member and the second member, and the first member and the second member are automatically nested and held together by the nesting and holding device into a composite piece C, the automatic embedded
  • the nesting process specifically includes the following steps:
  • the profile B is automatically conveyed in the direction of the production line, when the profile B hits the cutting block 621, the cutting device 5 moves with the profile B, and cuts the profile B to obtain the first member;
  • the first cylinder T1 drives the rotary positioning device to move rapidly along the nesting base 62, and leaves a certain separation distance from the profile B in the rear conveyance;
  • the rotation positioning device drives the first member to rotate 180 degrees, and at the same time, the cutting device 5 is in the Resetting under the driving of the second cylinder, the rotary positioning device is reset under the action of the first cylinder T1;
  • the profile B in the rear conveyance enters the first component clamped and positioned in the rotary positioning device to realize nesting and holding;
  • the first member and the second member form a composite unit C, and the profile B in the rear conveyance is pressed against the composite unit C to the next Process delivery; when the profile B in the subsequent conveyance hits the cutting baffle again, return to step a to continue the next nesting and holding process.
  • the outer wrap of the first member is in contact with the side surface of the second member, and the outer wrap of the second member is in contact with the side surface of the first member.
  • the composite unit C is fed into the third roll pressing die set 7, and the third roll die set 7 is formed on the outer folded edges of the first member and the second member, respectively.
  • the fastening flange which is engaged with the corresponding side surface, after the bonding process C, forms the final product, the nested composite profile member D, and then leaves the production line.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Punching Or Piercing (AREA)
  • Forging (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
  • Shearing Machines (AREA)
  • Shaping Metal By Deep-Drawing, Or The Like (AREA)

Description

嵌套式复合型材构件的制造方法及其制造设备 技术领域
本发明涉及一种承载构件的制造方法，特别是一种用于立体车库的嵌套式复合型材 构件的制造方法及其制造设备。 背景技术
普通的承载横梁、连接立柱等梁柱构件一般多釆用标准型材，但市场上直接采购的 标准型材往往形式简单， 结构单一， 而在标准型材上切割钻孔等工序往往需要人工划线 放样， 不仅加工速度慢， 效率低， 孔槽的尺寸几何精度与形位公差难以保证， 还会造成 原材料浪费， 材料利用率低。
为了减少生产过程中的原材料等资源消耗， 降低生产成本，本人在先申请的专利号 为 ZL201020191781.4的中国实用新型专利 《嵌套式复合型材构件》 公开了这样一种型 材， 如图 6〜图 9所示， 该嵌套式复合型材构件由第一构件 Γ和第二构件 2'组成， 第一 构件 1'和第二构件 2'分别为形状与尺寸相同的等断面长条形构件，所谓嵌套式复合是指: 第一构件 Γ旋转 180度后和第二构件 2'相互交错合抱成一柱体； 其中， 第一构件 1'的横 截面包括有两条相互平行设置的第一横边 11'， 还包括有一条分别和两个第一横边 1Γ的 其中一端垂直相连的第一竖边 12'， 两个第一横边 11'的另一端分别垂直弯折成型为相对 而设的第一内嵌折边 13'和第一外包折边 14'，第一构件 1'在第一内嵌折边 13'的末端形成 向内翻折的第一弯折部 13Γ,第一构件 1'的第一竖边 12'上形成有向内凹设的第一加强筋 121'； 第二构件 2'的横截面包括有两条相互平行设置的第二横边 21'， 还包括有一条分别 和第二横边 21'的其中一端垂直连接的第二竖边 22',两个第二横边 21'的另一端分别垂直 弯折成型为相对而设的第二内嵌折边 23'和第二外包折边 24'， 第二构件 2'在第二内嵌折 边 23'的末端同样形成向内翻折的第二弯折部 231'， 第二构件 2'的第二竖边 22'上形成有 向内凹设的第二加强筋 221'。上述专利的型材安装时，第一构件 Γ的第一横边 11'分别和 第二构件 2'的第二横边 21'贴合，第一内嵌折边 13'和所述第二构件 2'的第二竖边 22'内侧 面贴合，第一外包折边 14'和第二构件 2'的第二竖边 22'外侧面相贴合， 第一弯折部 131' 和第一加强筋 121'的内侧凸起部 122'贴合； 第二内嵌折边 23'和第一构件 Γ的第一竖边 12'内侧面贴合， 第二外包折边 24'和第一构件 1'的第一竖边 12'外侧面贴合， 第二弯折部 23Γ和第二加强筋 22Γ的内侧凸起部 222'贴合； 当第一构件 Γ和第二构件 2'嵌套组合后， 第一构件 Γ在第一外包折边 14'的末端向内翻折形成第一咬边 141'，第二构件 2'在第二外 包折边 24'的末端同样向内翻折形成第二咬边 241'，从而使得第一咬边 14Γ和第一加强筋
- 1 一
'认本 12Γ的外侧凹陷部 123'贴合， 第二咬边 24Γ和第二加强筋 22Γ的外侧凹陷部 223'贴合， 实现第一构件 Γ和第二构件 2'沿竖边方向的限位; 为了增强型材强度和刚度， 第一竖边 12'在第一加强筋 121'上还成型有截面呈 C形的第一凹槽 124',第一凹槽 124'的开口方向 和第一构件 Γ的开口方向相一致，第二竖边 22'在第二加强筋 221'上也成型有开口方向和 第二构件 2'的开口方向相一致的 C形第二凹槽 224', 第一横边 1Γ上还设置有第一凸筋 111'， 第二横边 2Γ上还设置有第二凸筋 211'。
在现有技术中，嵌套式复合型材构件的第一构件和第二构件的型材横截面的几何形 状和结构形式不限于上述专利中公开的结构， 还可以为其他结构形式， 具体可以参见如 本人在先申请的专利号为 ZL201020191801.8 的中国实用新型 《一种嵌套式型材构件》 和专利号为 ZL201020191783.3的中国实用新型 《一种嵌套式工字型立柱》。
目前， 针对上述专利复合型材构件的制作方法一般是采用以下工艺步骤： 第一步， 制作两个单独构件； 在型材上分别进行下料切割、 通孔加工 （多工位）和压制凸筋（多 工位）这几个工序； 第二步， 对两个单独构件分别进行第一横边、第二横边、第一竖边、 第二竖边、 外包折边和内嵌折边等多工位的辊压成型工序； 第三步， 将两个单独构件进 行人工嵌套式复合工序； 第四步， 采用辊压方法对该嵌套式复合构件进行第三弯折部、 第四弯折部的咬边弯折工序。 、
上述工艺步骤均在不同的工位上进行，并且是离线操作，这使得整个制造工艺过程 中有多个分立工序与多工位的转移， 其缺陷是： 其一， 不仅要消耗大量的工时与劳力， 而且会影响各工位间的定位误差及其加工制作精度， 例如， 采用通孔加工后再压制凸筋 的缺点是，在压制凸筋后产生的型材延伸变形将影响到原先通孔加工后的孔距尺寸精确 度； 其二， 多工位的单独加工工序使得每个工序均要增添调整与装夹的辅助工序， 则会 消耗大量的辅助工时以及由此产生的工序累积误差； 其三， 加工、 切割、 钻孔、 压制等 工序需要人工划线放样， 不仅加工速度慢、 效率低， 而且几何尺寸精度与形位公差难以 控制， 造成材料利用率与成品率低。 发明内容
本发明所要解决的第一个技术问题是针对上述现有技术现状而提供一种能显著降 低原材料消耗和保证加工制作精度， 并且， 机械化程度和生产效率高的用于嵌套式复合 型材构件的制造方法。
本发明所要解决的第二个技术问题是提供一种能实现上述制造方法的嵌套式复合 型材构件的制造设备。
本发明解决上述第一个技术问题所采用的技术方案为： 一种嵌套式复合型材构件的 制造方法， 其特征在于， 制造嵌套式复合型材构件的全部工艺步骤均在同一条生产线上 连续自动完成， 所述的制造方法包括有如下工艺步骤： (1)、 平整工序， 首先把金属带材送入型材平整机进行平整， 接着， 该金属带材沿生 产线自动向后一工序方向输送；
(2)、加强筋成型工序， 所述金属带材接着送入第一辊压模具组， 并经该第一辊压模 具组辊压成型所需的加强筋；
(3)、 冲孔工序， 具有所述加强筋的金属带材再送入冲孔装置加工成型所需的通孔；
(4)、截面成型工序， 将上述冲孔后的金属带材继续送入第二辊压模具组， 经该第二 辊压模具组辊压成型为具有所需横截面形状的型材，该型材具有嵌套复合所需的内嵌折 边和外包折边；
(5)、 嵌套合抱工序， 将所述型材送入切割装置切断， 切断后获得第一构件送入嵌套 合抱装置， 并在该第一构件的横截面方向内旋转 180度定位， 然后， 该旋转定位后的所 述第一构件插入到再次切断后获得的第二构件进行嵌套合抱，所述第一构件和第二构件 嵌套合抱后成为复合一体件，此时，所述第一构件的外包折边与第二构件的侧面相贴合， 所述第二构件的外包折边与第一构件的侧面相贴合；
(6)、 紧贴工序， 所述复合一体件送入第三辊压模具组， 该第三辊压模具组在所述第 一构件、 第二构件的外包折边上分别成型有与相应侧面相咬合的紧固折边， 所述复合一 体件经该紧贴工序后成型为所需的嵌套式复合型材构件并脱离生产线。
为了提高工作效率， 保证前后工序的连贯性， 确保生产线能够连续不间断地工作， 作为优选， 所述步骤 (5)中的嵌套合抱工序具体包括有以下步骤：
a、 沿生产线方向输送的所述型材送入所述嵌套合抱装置的旋转定位装置中， 当该 型材碰到第一检测控制触点时， 所述切割装置随所述型材同步移动， 并切断该型材而获 得所述第一构件；
b、 所述旋转定位装置沿所述嵌套合抱装置中的嵌套底座快速移动， 并与后面输送 中的型材之间留出所需的间隔距离；
c、 当所述第一构件随所述旋转定位装置移动并碰到第二检测控制触点时， 所述旋 转定位装置驱动所述第一构件旋转 180度定位， 同时， 所述切割装置和所述旋转定位装 置复位；
d、 所述旋转定位装置复位过程中， 后面输送中的型材进入到所述旋转定位装置中 并与所述第一构件中实现嵌套合抱；
e、 当后面输送中的型材再一次碰到所述第一检测控制触点时， 所述切割装置再一 次随该型材同步移动， 并再次切断该型材而获得所述第二构件， 此时， 继续输送中的型 材顶住所述第二构件使得所述第二构件继续和所述第一构件进行嵌套合抱；
f、 在所述第一构件和第二构件完全嵌套合抱完毕后， 该第一构件和第二构件形成 所述的复合一体件， 继续输送中的型材顶着将该复合一体件向下一个工序输送； .当继续 输送中的型材再次碰到所述第一检测控制触点时， 回到步骤 a， 继续下一次的嵌套合抱 过程。
本发明解决上述第二个技术问题所采用的技术方案为： 一种嵌套式复合型材构件的 制造设备， 所述的制造设备沿生产线方向依次包括有
型材平整机， 固定设置于地面上；
第一辊压模具组， 固定设置于地面上， 该第一辊压模具组包括有多个用于辊压成型 所述加强筋的第一辊轮组；
冲孔装置，包括有固定设置于地面上的冲孔床身和能沿该冲孔床身水平滑移的冲孔 机；
第二辊压模具组， 固定设置于地面上， 该第二辊压模具组包括有多个用于辊压成型 具有所需横截面形状的所述型材的第二辊轮组；
切割装置， 具有将所述型材切断而形成所述第一构件和第二构件的刀模； 嵌套合抱装置，用于将所述第一构件旋转 180度定位并和所述第二构件交错合抱成 所述的复合一体件； 以及
第三辊压模具组， 固定设置于地面上， 该第三辊压模具组包括有用于辊压成型所述 紧固折边的第三辊轮组。
为了提高嵌套合抱的质量， 避免嵌套合抱后的复合型材构件变形， 作为优选， 所述 的嵌套合抱装置包括有嵌套床身， 固定设置于所述地面上； 嵌套底座， 设置于所述嵌套 床身上并能相对于该嵌套床身水平滑移； 旋转定位装置， 包括有设置于所述嵌套底座上 并能相对于该嵌套底座水平滑移的车座，所述车座连接有能驱动该旋转定位装置沿所述 嵌套底座滑移的第一气缸， 该车座上固定有间隔且相对而设的两固定支架， 所述的固定 支架内设置有沿长度方向贯穿且能相对该支架旋转的旋转器，所述旋转器开设有和所述 型材的形状大小相适配的方孔，所述旋转器在端面上还设置有多个沿所述方孔的周边布 置的夹具， 所述夹具包括有导轨和夹头， 所述导轨固定设置于所述旋转器端面上， 所述 夹头能沿所述导轨滑移并与所述第一构件相紧抵。 于是， 夹具能够顶紧型材， 保证第一 构件和第二构件之间的可靠合抱。
为了确保第一构件在 180度范围内旋转， 防止旋转不到位或转过头导致无法实现嵌 套合抱， 作为优选， 所述旋转器沿圆周面开设有间隔设置的齿槽， 所述旋转器在相对而 设呈 180度方向的两侧相应齿槽内插设有限定该旋转器旋转方位的定位插销。当旋转器 旋转 180度后， 旋转器两侧相应的定位槽内分别插入定位销， 就能够限定旋转器相对于 固定支架的位置， 防止旋转器相对于固定支架支架定位的偏移， 保证嵌套合抱的准确性 和可靠性。
为了实现切割装置和嵌套合抱装置的联动， 同时保证切割和嵌套合抱两个工序的连 贯性， 作为进一步优选， 所述切割装置包括有切割底座， 设置于所述嵌套床身上并能相 对于该床身水平滑移， 所述切割底座和嵌套底座固定相连， 该切割底座上连接有驱动该 切割底座沿所述嵌套床身滑移的第二气缸； 刀模， 固定设置于所述切割底座上； 其中， 所述嵌套底座沿长度方向设置有控制刀模切割的切割挡块和控制所述旋转定位装置转 动的定位挡块，所述嵌套床身在位于所述切割底座的一侧设置有限制该切割底座移动的 复位挡块。 由于切割底座和嵌套底座之间是固定连接的， 当切割装置复位时， 嵌套底座 同时复位， 保证第二构件和第一构件的定位基准和切割长度都相同。
为了避免挡块和金属带材发生干涉，使得金属带材和构件均能够顺利的沿着生产线 输送， 作为进一步优选， 所述切割挡块和定位挡块分别为可上下伸缩的挡块。 其中， 切 割挡块和定位挡块既用来检测金属带材或切割后构件在生产线上的位置， 又用于控制刀 模和旋转器的动作， 所述切割挡块和定位挡块可以分别由气缸控制实现伸缩， 当需要检 测金属带材或切割后构件的位置时， 可以通过气缸活塞杆将挡块向上顶出； 当已经检测 到金属带材或切割后构件的位置时， 可以通过气缸活塞杆将挡块向下缩进。
为了提高冲孔的准确度，所述冲孔装置包括有固定设置于地面上的冲孔床身和能沿 该冲孔床身水平滑移的冲孔机，所述冲孔床身上还设置有驱动所述冲孔机沿该冲孔床身 滑移的第五气缸。 于是， 在冲孔过程中， 冲孔机能够随着金属带 ¾"一起移动， 当冲孔完 成后， 冲孔机在第五气缸作用下复位。
为了给金属带材的前端提供一定的压紧力， 避免金属带材在冲孔过程中发生变形， 所述冲孔装置还包括有压紧装置， 该压紧装置包括有压板、 驱动压板动作的压紧油缸和 带动所述压板沿所述冲孔床身水平滑移的压紧底座，所述压紧底座和所述冲孔机固定连 接， 所述第五气缸的活塞杆和所述压紧底座固定连接。
为了进一步提高冲孔的位置精确度，所述压板的底部还设置有能穿入所述金属带材 上的成型冲孔中的定位销。 当前面金属带材的冲孔完毕后， 压板上的定位销能够插入冲 完的通孔中进行定位， 确保后续冲孔位置的精确度。
与现有技术相比， 本发明的优点在于： 首先， 在冲孔工序之前先进行凸筋和凹槽等 加强筋结构的辊压成型工序，保证了冲孔加工后的孔距尺寸精度，可显著提高产品质量; 其次， 金属带材是沿生产线自动输送， 所有工序都是设置在同一条生产线上连续进行， 实现了复合型材构件的自动化生产， 节约了大量的机动工时与辅助工时， 大大提升了生 产效率； 再者， 从金属带材送入生产线到复合型材的成型， 金属带材经过每一道工序都 会完成一种产品加工工艺， 而且前后每一道工序之间都是在线的、 不间断地相互连接， 能够显著降低原材料等资源消耗，使得材料的利用率大大提高， 降低了生产成本；最后， 全部工序的自动化还大大降低了工人的劳动强度， 同时改善了生产环境与作业面积的利 用率。 附图说明
图 1为本发明用于嵌套式复合型材构件生产的设备流水线结构示意简图。 图 2为图 1所示流水线中的切割装置和嵌套合抱装置的局部放大结构示意简图。 图 3为图 1所示设备流水线中的嵌套合抱装置的轴向结构示意简图。
图 4为图 3所示嵌套合抱装置的 A-A向结构示意简图。
图 5为图 4所示嵌套合抱装置的传动结构示意简图。
图 6为现有技术中的嵌套式复合型材构件的立体结构图。
图 7为现有技术中的嵌套式复合型材构件的横截面示意图 (组装后)。
图 8为图 7所示第一构件的平面结构示意图 (组装前)。
图 9为图 7所示第二构件的平面结构示意图 (组装前)。 具体实施方式
以下结合附图实施例对本发明作进一步详细描述。
如图 1〜图 5所示， 为本发明实施例的结构示意图， 该嵌套式复合型材构件的制造 设备为一条多工序连续生产的自动化流水线，本实施例的加工原料为一送入送料器的连 续金属带材 A， 该金属带材 A能够沿流水线向下一个工序自动输送，本实施例嵌套式复 合型材制造设备按生产线工序的先后次序依次包括有
型材平整机 1， 用于平整送入生产线的金属带材 A。
第一辊压模具组 2， 固定设置于地面上， 该第一辊压模具组 2包括有多个用于辊压 成型嵌套式复合型材构件所需加强筋的第一辊轮组；
冲孔装置 3， 包括有固定设置于地面 9上的冲孔床身 31、 能沿该冲孔床身 31水平 滑移的冲孔机 32、 固定设置在冲孔床身 31上并能驱动冲孔机 32沿该冲孔床身 31滑移 的第五气缸 T5以及压紧装置 8; 其中， 压紧装置 8包括有压板 81、 驱动压板 81动作的 压紧油缸 83和带动压板 81沿冲孔床身 31水平滑移的压紧底座 84，压紧底座 84和冲孔 机 32固定连接， 第五气缸 T5的活塞杆和压紧底座 84固定连接， 压板 81的底部还设置 有能穿入金属带材 A的成型冲孔中的定位销 82; 在冲孔过程中， 冲孔机 32能够随着金 属带材 A—起移动， 当前面金属带材 A的冲孔完毕后， 压板 81上的定位销 82能够插 入冲完的通孔中进行定位， 冲孔机 32则在第五气缸 T5作用下复位。
第二辊压模具组 4， 固定设置于地面 9上， 该第二辊压模具组包括有多个用于辊压 成型嵌套式复合型材构件所需横截面形状（包括有横边、 竖边、 内嵌折边、 外包折边和 弯折部等） 的第二辊轮组。
切割装置 5， 用于切断型材 B并形成第一构件和第二构件， 该切割装置 5包括有： 切割底座 51， 设置于嵌套床身上并能相对于嵌套床身 61水平滑移， 切割底座 51 和嵌套底座 62固定相连， 该切割底座 51上连接有驱动该切割底座 51沿嵌套床身滑移 的第二气缸 T2;
刀模 52， 固定设置于切割底座 51上； 并且， 嵌套底座 62沿长度方向设置有切割挡块 621和定位挡块 622， 其中， 切割 挡块 621作为第一检测控制触点用于检测型材 B的位置并控制刀模 52的切割动作， 定 位挡块 622作为第二检测控制触点用于检测第一构件的位置并控制所述旋转定位装置的 转动; 嵌套床身 61在位于所述切割底座 51的一侧设置有限制该切割底座 51移动的复 位挡块 611。 由于切割底座 51和嵌套底座 62之间是固定连接的， 当切割装置 5复位时， 嵌套底座 62同时复位， 保证第二构件和第一构件的定位基准和切割长度都相同。
切割挡块 621和定位挡块 622分别为可上下伸缩的挡块，其中，切割挡块 621和第 三气缸 T3的活塞杆相连， 定位挡块 622和第四气缸 T4的活塞杆相连。 切割挡块 621 和定位挡块 622可以检测金属带材 A或切割后的构件在生产线上的位置，并且控制切割 装置 5的刀模动作， 当需要检测金属带材 A或切割后构件的位置时，可以通过气缸活塞 杆将挡块向上顶出； 当已经检测到金属带材 A或切割后构件的位置时，可以通过气缸活 塞杆将挡块向下缩进。
嵌套合抱装置 6，嵌套合抱装置用于将所述第一构件旋转 180定位并和所述第二构 件交错合抱成复合一体件， 嵌套合抱装置包括有：
嵌套床身 61， 固定设置于地面 9上；
嵌套底座 62， 设置于所述嵌套床身 61上并能相对于该嵌套床身 61水平滑移； 旋转定位装置，包括有设置于所述嵌套底座 62上并能相对于该嵌套底座 62水平滑 移的车座 63，所述车座 63连接有能驱动该旋转定位装置沿所述嵌套底座 62滑移的第一 气缸 Tl， 该车座 63上固定有间隔且相对而设的两固定支架 64， 固定支架 64内设置有 沿长度方向贯穿且能相对该支架 64旋转的旋转器 65;其中，旋转器 65沿圆周面开设有 间隔设置的齿槽 651 , 当旋转器 65旋转 180度后， 旋转器 65在相对而设呈 180度方向 的两侧相应齿槽 651内分别插设有定位销子 68，定位销子 68能够限定旋转器 65相对于 固定支架 64的转动位置， 保证嵌套合抱的准确性和可靠性； 旋转器 65沿轴向开设有和 型材 Β的形状大小相适配的方孔 652， 旋转器 65在端面上还设置有多个沿方孔 652的 周边布置的夹具， 夹具包括有导轨 66和夹头 67， 导轨 66固定设置于述旋转器 65端面 上， 夹头 67能沿导轨 66滑移并与第一构件 （切断后的型材 Β) 相紧抵， 通过调节夹头 67沿导轨 66的相对位置，使得旋转器 65能够适应不同几何形状和尺寸的型材构件的夹 持。
第三辊压模具组 7, 固定设置于地面 9， 该第三辊压模具组 7包括有用于辊压成型 嵌套式复合型材构件所需紧固折边的第三辊轮组。 本实施例的嵌套式复合型材构件的制造方法包括有如下工艺步骤，该工艺步骤在同 一条生产线上依次连续完成：
(1)、 平整工序， 首先把金属带材 Α送入型材平整机 1进行平整， 并且， 该金属带 材 A沿生产线自动向后一工序方向输送。
(2)、 加强筋成型工序， 所述金属带材 A接着送入第一辊压模具组， 并经该第一辊 压模具组辊压成型所需的加强筋。
(3)、 冲孔工序， 金属带材 A送入冲孔装置 3冲制通孔。
(4)、 截面成型工序， 所述金属带材 A继续送入第二辊压模具组， 并经该第二辊压 模具组辊压成型出横边、 竖边、 内嵌折边、外包折边和弯折部， 所述金属带材 A经该第 二辊压模具组辊压成型后形成型材 B;
(5)、 嵌套合抱工序， 切割装置 5切断型材 B形成第一构件和第二构件， 第一构件 和第二构件通过嵌套合抱装置自动嵌套合抱为一复合一体件 C， 该自动嵌套合抱过程具 体包括如下步骤：
a、 型材 B沿生产线方向自动输送， 当该型材 B碰到所述切割挡块 621时， 所述切 割装置 5随型材 B移动， 并切断该型材 B而获得所述第一构件；
b、 第一气缸 T1驱动所述旋转定位装置沿所述嵌套底座 62快速移动， 并与后面输 送中的型材 B之间留出一定的间隔距离；
c、 当第一构件随所述旋转定位装置移动并碰到所述定位挡块 622时， 所述旋转定 位装置驱动所述第一构件旋转 180度定位， 同时， 所述切割装置 5在所述第二气缸的驱 动下复位， 所述旋转定位装置在所述第一气缸 T1作用下复位；
d、 所述旋转定位装置复位过程中， 后面输送中的型材 B进入夹持定位在所述旋转 定位装置中的第一构件中实现嵌套合抱；
e、 当后面输送中的型材 B再一次碰到所述切割挡板时， 所述切割装置 5随型材 B 移动， 并再次切断该型材 B而获得所述第二构件， 此时， 后面输送中的所述型材 B顶 住所述第二构件使得所述第二构件继续和所述第一构件进行嵌套合抱；
f、 在所述第一构件和第二构件完全嵌套合抱完毕后， 该第一构件和第二构件形成 复合一体件 C,后面输送中的型材 B顶着将该复合一体件 C向下一个工序输送； 当后面 输送中的型材 B再次碰到所述切割挡板时， 回到步骤 a， 继续下一次的嵌套合抱过程。
完成嵌套合抱工序后， 此时， 所述第一构件的外包折边与第二构件的侧面相贴合， 所述第二构件的外包折边与第一构件的侧面相贴合。
(6)、 紧贴工序， 所述复合一体件 C送入第三辊压模具组 7， 该第三辊压模具组 7 在所述第一构件、 第二构件的外包折边上分别成型有与相应侧面相咬合的紧固折边， 复 合一体件 C经该紧贴工序后，形成最终产品——嵌套式复合型材构件 D， 然后脱离生产 线。

Claims

权 利 要 求
1、 一种嵌套式复合型材构件的制造方法， 其特征在于， 制造嵌套式复合型材构件 的全部工艺步骤均在同一条生产线上连续自动完成，所述的制造方法包括有如下工艺步 骤：
(1)、 平整工序， 首先把金属带材 (A)送入型材平整机 (1)进行平整， 接着， 该金属带 材 (A沿生产线自动向后一工序方向输送；
(2)、 加强筋成型工序， 所述金属带材 (A)接着送入第一辊压模具组， 并经该第一辊 压模具组辊压成型所需的加强筋；
(3)、 冲孔工序， 具有所述加强筋的金属带材 (A)再送入冲孔装置 (3)冲制成型所需的 通孔；
(4)、 截面成型工序， 将上述冲孔后的金属带材 (A)继续送入第二辊压模具组， 经该 第二辊压模具组辊压成型为具有所需横截面形状的型材 (B)， 该型材 (B)具有嵌套复合所 需的内嵌折边和外包折边；
(5)、 嵌套合抱工序， 将所述型材 (B)送入切割装置 (5)并切断， 切断后获得第一构件 送入嵌套合抱装置， 并在该第一构件的横截面方向内旋转 180度定位， 然后， 该旋转定 位后的所述第一构件插入到再次切断后获得的第二构件进行嵌套合抱，所述第一构件和 第二构件嵌套合抱后成为复合一体件 (C)， 此时， 所述第一构件的外包折边与第二构件 的侧面相贴合， 所述第二构件的外包折边与第一构件的侧面相贴合；
(6)、 紧贴工序， 所述复合一体件 (C)送入第三辊压模具组 (7)， 该第三辊压模具组在 所述第一构件、 第二构件的外包折边上分别成型有与相应侧面相咬合的紧固折边， 所述 复合一体件 (C)经该紧贴工序后成型为所需的嵌套式复合型材构件 (D)并脱离生产线。
2、 根据权利要求 1所述的嵌套式复合型材构件的制造方法， 其特征在于所述步骤 (5)中的嵌套合抱工序具体包括有以下步骤：
a、沿生产线方向输送的所述型材 (B)送入所述嵌套合抱装置的旋转定位装置中， 当 该型材 (B)碰到第一检测控制触点时， 所述切割装置 (5)随所述型材 (B)同步移动， 并切断 该型材 (B)而获得所述第一构件； - b、 所述旋转定位装置沿所述嵌套合抱装置中的嵌套底座 (62)快速移动， 并与后面 输送中的型材 (B )之间留出所需的间隔距离；
c、 当所述第一构件随所述旋转定位装置移动并碰到第二检测控制触点时， 所述旋 转定位装置驱动所述第一构件旋转 180度定位， 同时，所述切割装置 (5)和所述旋转定位 装置复位；
d、所述旋转定位装置复位过程中， 后面输送中的型材 (B)进入到所述旋转定位装置 中并与所述第一构件中实现嵌套合抱； 、 e、当后面输送中的型材 (B)再一次碰到所述第一检测控制触点时，所述切割装置 (5) 再一次随该型材 (B)同步移动， 并再次切断该型材 (B)而获得所述第二构件， 此时， 继续 输送中的型材 (B)顶住所述第二构件使得所述第二构件继续和所述第一构件进行嵌套合 抱；
f、 在所述第一构件和第二构件完全嵌套合抱完毕后， 该第一构件和第二构件形成 所述的复合一体件 (C), 继续输送中的型材 (B)顶着将该复合一体件 (C)向下一个工序输 送； 当继续输送中的型材 (B)再次碰到所述第一检测控制触点时， 回到步骤 a， 继续下一 次的嵌套合抱过程。
3、 一种实现如权利要求 1或 2所述制造方法的制造设备， 其特征在于所述的制造 设备沿生产线方向依次包括有：
型材平整机 (1)， 固定设置于地面 (9)上；
第一辊压模具组 (2)， 固定设置于地面 (9)上， 该第一辊压模具组 (2)包括有多个用于 辊压成型所述加强筋的第一辊轮组；
冲孔装置 (3)， 包括有固定设置于地面 (9)上的冲孔床身 (31)和能沿该冲孔床身 (31)水 平滑移的冲孔机 (32);
第二辊压模具组， 固定设置于地面 (9)上， 该第二辊压模具组包括有多个用于辊压 成型具有所需横截面形状的所述型材 (B)的第二辊轮组；
切割装置 (5)， 具有将所述型材 (B)切断而形成所述第一构件和第二构件的刀模 (52); 嵌套合抱装置，用于将所述第一构件旋转 180度定位并和所述第二构件交错合抱成 所述的复合一体件 (C); 以及
第三辊压模具组 (7)， 固定设置于地面 (9)上， 该第三辊压模具组 (7)包括有用于辊压 成型所述紧固折边的第三辊轮组。
4、 根据权利要求 3所述的制造设备， 其特征在于所述的嵌套合抱装置包括有： 嵌套床身 (61)， 固定设置于所述地面 (9)上；
嵌套底座 (62)， 设置于所述嵌套床身 (61)上并能相对于该嵌套床身 (61)水平滑移； 旋转定位装置， 包括有设置于所述嵌套底座 (62)上并能相对于该嵌套底座 (62)水平 滑移的车座 (63)，所述车座 (63)连接有能驱动该旋转定位装置沿所述嵌套底座 (62)滑移的 第一气缸 (Tl)， 该车座 (63)上固定有间隔且相对而设的两固定支架 (64)， 所述的固定支架 (64)内设置有沿长度方向贯穿且能相对该支架旋转的旋转器 (65)，所述旋转器 (65)上开设 有和所述型材 (Β)的形状大小相适配的方孔 (652)，所述旋转器 (65)在端面上还设置有多个 沿所述方孔 (652)的周边布置的夹具，所述夹具包括有导轨和夹头，所述导轨固定设置于 所述旋转器 (65)端面上， 所述夹头能沿所述导轨滑移并与所述第一构件相紧抵。
5、 根据权利要求 4所述的制造设备， 其特征在于： 所述旋转器 (65)沿圆周面开设 有间隔设置的齿槽 (651)，所述旋转器 (65)在相对而设呈 180度方向的两侧相应齿槽 (651) 内插设有限定该旋转器 (65)旋转方位的定位插销 (68)。
6、 根据权利要求 4所述的制造设备， 其特征在于， 所述切割装置 (5)包括有： 切割底座 (51)， 设置于所述嵌套床身 (61)上并能相对于该床身水平滑移， 所述切割 底座 (51)和嵌套底座 (62)固定相连， 该切割底座 (51)上连接有驱动该切割底座 (51)沿所述 嵌套床身 (61)滑移的第二气缸；
刀模 (52)， 设置于所述切割底座 (51)上；
其中， 所述嵌套底座 (62)沿长度方向设置有控制刀模 (52)开始切割的切割挡块 (621) 和控制所述旋转定位装置开始转动的定位挡块 (622)， 所述嵌套床身 (61)在位于所述切割 底座 (51)的一侧设置有限制该切割底座 (51)移动的复位挡块。
7、 根据权利要求 6所述的制造设备， 其特征在于： 所述切割挡块 (621)和定位挡块 (622)分别为可上下伸缩的挡块。
8、 根据权利要求 3所述的制造设备， 其特征在于： 所述冲孔装置 (3)包括有固定设 置于地面 (9)上的冲孔床身 (31)和能沿该冲孔床身 (31)水平滑移的冲孔机 (32)，所述冲孔床 身 (31)上还设置有驱动所述冲孔机 (32)沿该冲孔床身 (31)滑移的第五气缸 (T5)。
9、 根据权利要求 8所述的制造设备， 其特征在于： 所述冲孔装置 (3)还包括有压紧 装置 (8)， 该压紧装置 (8)包括有压板 (81)、 驱动该压板 (81)上下移动的压紧油缸 (83)和能 沿所述冲孔床身 (31)水平滑移的压紧底座 (84)， 所述压紧底座 (84)和所述冲孔机 (32)固定 连接， 所述第五气缸 (Τ5)的活塞杆和所述压紧底座 (84)固定连接。
10、 根据权利要求 9所述的制造设备， 其特征在于： 所述压板 (81)的底部还设置有 能穿入所述金属带材 (Α)上的成型冲孔中的定位销 (82)。
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