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
  • B21D5/02—Bending sheet metal along straight lines, e.g. to form simple curves on press brakes without making use of clamping means
• • 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
  • B21D13/00—Corrugating sheet metal, rods or profiles; Bending sheet metal, rods or profiles into wave form
  • B21D13/02—Corrugating sheet metal, rods or profiles; Bending sheet metal, rods or profiles into wave form by pressing

Definitions

• the invention relates to a device for producing a profiled metal plate, which device comprises a lower die and multiple upper dies.
• the invention relates to a method for producing a profiled metal plate, which method comprises the use of such a device.
• the invention relates to a profiled plate produced by means of such a device, or according to such a method.
• the invention relates to a construction part for a truck comprising such a profiled plate.
• Profiled plates are very suitable as construction parts being required to withstand high forces.
• a profiled plate can be used as a bearing structure in a truck, that may or may not be associated with one or two flat plates.
• Such a bearing structure must carry the weight of the load as well as the weight of the heavy equipment required for loading and unloading.
• the bearing structure should be able to withstand the high forces while the truck is in motion and while the load is being loaded or unloaded. See, for example, US 6,408,586, in which a profiled plate is described that is produced by a press braking technique. With this technique an upper die, that is moving towards the plate with a high speed, pushes a section of a plate into a recess of a lower die.
• a disadvantage of the press braking technique is that for each bending being formed in the plate, in other words, each setting, the plate should be inverted and re-arranged. This is time-consuming and increases the risk of mistakes and accidents. More specifically, inverting and repositioning metal plates having a relatively high weight requires supplementary heavy duty manipulators, like robot arms, as a consequence of which the total costs increase.
• JP 60003921 a device for producing a profiled plate is described, which is also based on the press braking technique. The upper die pushes the plate in a recess of the lower die such that the plate becomes V-shaped. However, in this case the legs of the V-shaped section of the plate will be pushed towards each other.
• Profiled plates are specifically suitable when they are associated with two flat plates generating a sandwich structure. Such a sandwich structure can withstand relatively high forces. See US 5,007,225 for use thereof as a construction part.
• the cold rolling technique is mentioned.
• this technique is not appropriate for metal plates having a relative high thickness, or having a relative high rigidity, plates having a thickness of more than 7 mm, and plates produced from a material having a higher rigidity than the conventional steel types, respectively.
• the device for producing profiled plates described in GB 1450235 comprises one single upper die that moves back and forth, multiple times, from a starting position above the lower die to an end position in the proximity of the lower die.
• the device for producing profiled plates described in US 3,421 ,279 comprises one lower die and one upper die, wherein the lower die and upper die, consisting of multiple upper and lower die members, are engaged such that an upper die member in its end position is located between two lower die members.
• a disadvantage of this technique is that releasing the plate from the lower die and/or upper die can be arduously, in particular when the bendings enclose a right or almost right angle. This is a particular problem using metal plates having a thickness of more than 7 mm or plates produced from a material having a higher rigidity than the conventional steel types.
• patent documents US 1,431 ,175, US 24,689, and WO 2006/051842 each disclose a device according to the preamble of claim 1.
• most upper dies if not each one of the upper dies, are shaped such that the use of a single upper die results in multiple curvatures in the plate.
• These devices are intended specifically for thin metal plates, for instance metal plates having a thickness lower than 7 mm.
• the relation of the ability for only one upper die to deform the metal plate to the rigidity of the metal plate is such that use of that upper die results in multiple curvatures in the metal plate.
• the use of upper dies in patent document US 1 ,431,175 results in multiple curvatures in the metal plate.
• the middle part of the upper die described in this document creates a main convex curvature.
• the side areas of the upper dies are shaped such that they create a second curvature in the plate at both sides of the convex curvature. Consequently, the plate as a whole remains horizontally with respect to the device.
• the upper dies in patent document WO 2006/051842 create in cooperation a waving pattern, wherein the upper area of the wave is formed by two upper dies that are positioned close to each other.
• the upper dies have a S-shaped contour at one side, forming one half of a upper area of the wave.
• the shape of the upper dies as shown in patent document US 24 689 have a more changeable contour but at least the use of one of those upper dies results in multiple curvatures in the metal plate.
• Retaining wall constructions for retaining soil and water during construction work have a plate thickness of 7 - 15 mm. Although they have the shape of a profiled plate, they consist of separate metal parts rolled at high temperature and form the retaining wall construction by engaging to each other. However, it is preferred for other applications, such as for construction parts required to withstand high forces, that profiled metal plates are produced from one piece. As mentioned above, construction parts for a truck having to bear loading and unloading means , having long arms for loading and unloading the load having, are required to withstand high forces.
• construction parts are used generally consisting of metal bars having a U-profile. The thickness of the material used to produce the metal bars is about 10 mm.
• the metal bars having a U-profile are welded together in a specific pattern.
• This production process is time-consuming, labor intensive and requires experienced personnel, because cutting the metal bars should be performed accurately, such that the bars have exactly the correct length, and, furthermore, positioning the metal bars and welding them together should be performed accurately.
• the costs of such construction parts it is desirable that they can be produced in a shorter time period with less specialized personnel.
• the object or the invention is to provide a device and a method for producing a profiled metal plate, which is especially advantageous for metal plates having a relatively high thickness, for instance having a thickness of 7-12 mm, or for metal plates having a relatively high rigidity. It is another object of the invention to provide a profiled plate, for instance having a thickness of 7-12 mm, that is able to withstand high forces. Furthermore, it is an object of the invention to provide construction parts for a truck that are easily producible, able to withstand high forces and reduced in weight compared to conventional construction parts.
• the invention provides a device according to claim .
• an advantage of such a device is that a relatively rigid plate can be deformed in multiple steps.
• an upper die is able, for instance in a first step, to move towards the lower die independently from the other upper die(s).
• the upper die is able to deform the plate in such a way that it makes it easier for another lower die to further deform the plate as required, in a second step, for instance using less power or with less shearing stress.
• an upper die can free the way for another upper die.
• the multiple upper dies are suitable for making one profile.
• This profile for example, can be a profile similar to the profile that can be produced using devices known in the art. Using these known devices one upper die can create a profile in a metal plate having a relatively low thickness, or having a relatively high flexibility.
• the expression "rigidity” is used to mean a property of the plate indicating the deformability or bendability. This means that with a plate having a high rigidity, more power is needed to deform or bend it compared to the power that is needed to deform or bend a plate having a lower rigidity. This property relates to factors such as temperature of the plate. Preferably, this device is suitable to deform a plate having a high rigidity under condition with substantial the same temperature as ambient temperature.
• the device is characterized by a relation of the ability for each one of the upper dies to deform the metal plate to a rigidity of the metal plate, this device is also suitable for metal plates being relatively less rigid, for instance metal plates having a thickness of 1-7 mm.
• An advantage of the invention is that the required ability for individual upper dies is lower than the required ability for existing devices as a whole to produce a profiled metaf plate. Therefore, the devices according to the invention can be produced with lower costs compared to similar devices according to the state of the art. Furthermore, it is an advantage that the ability, and deduced from that fact also the energy costs, can be reduced, as a consequence of which the profiled plates can be produced with lower costs.
• profile is used to mean a deformation of the plate, such as a ridge, groove, spherical form or recess having a V-shaped, trapezoid or partially spherical cross-section.
• the expression "profiled plate” is used to mean a plate having multiple profiles.
• the device comprises for each upper die separate driving means that are able to function independently from each other.
• the driving means can be adjusted to the required abilit each upper die should have to deform the plate. For example, it is possible that one upper die will be driven by driving means less powerful compared to the driving means for another upper die, for example because the latter deforms the plate in a lesser extend.
• the device comprises lifting means for lifting the metal plate after each one of the upper dies has returned from its end position to its starting position and a next profile should be created or when the plate is profiled completely.
• the lower die comprises an opening for passage of a lifting part to lift the plate upwardly away from the recess.
• the device comprises transporting means for transporting the metal plate through the device, such that the metal plate cgn be subjected to the forces of the upper dies for creating a profile on multiple locations.
• the lifting means and the transporting means are functionally coupled.
• the lower die comprises a recess
• the device comprises three Upper dies, a first upper die, a second upper die and a third upper die, that are moveable back and forth between a starting position, above the lower die, and an end position, in the close proximity of the lower die, wherein the first upper die in its end position is in the recess, wherein the first upper die comprises an oblong base section transitioning without abrupt changing into a tapered section.
• the plate can be deformed such that sections of the plate, hereafter further denoted as plate sections, extend freely from the recess of the lower die, for instance forming a U-shape or V-shape.
• the specific form of this deformation will be dependent on the walls of the lower die that confine the recess, on the form of the upper die and on the way in which and until how far the first upper die moves into the recess.
• the first upper die can push the metal plate fittingly in the recess. In the case of a plate having a relatively high thickness it can also be adequate to only partially push the metal plate in the recess.
• the plate section that is adjoining the first upper die in its end position and is present in the recess predominantly determines the shape of the profile. Furthermore, to produce a profiled plate it is required that the plate is deformed again later such that the plate sections surrounding the profile, or at both sides of the profile, are substantially aligned.
• the first upper die comprises an oblong base section that transitions without abrupt changing into a tapered section, in other words does not have a S-shaped side area, it can create only one curvature in the metal plate. In other words, the plate will not remain horizontally in the device.
• an advantage of the invention is that this curvature can be created in a metal plate having a relatively high thickness, or having a relatively high rigidity.
• the deformation mentioned above can be performed in two steps, the first step by movement of the second upper die, and the second step by movement of the third upper die.
• the first step the second upper die can move to an intermediate position, wherein the plate section or the plate sections, are moved in some degree towards the lower die.
• the third upper die possible together with the second upper die, can move to its, or their, end position(s), as a result of which the plate sections become substantially aligned, or the plate section become aligned with respect to the rest of the plate.
• the second upper die is able to deform the plate in such a way that the plate sections are arranged less slanting with respect to the third upper die, as a consequence of which the third upper die is able to deform the plate with more ease and is able to move to its end position.
• a part of the plate neighboring the profile at both sides is contacting the lower die in this end position. The movement of the first upper die from its starting position to its end position is comparable with press braking.
• An advantage of such a device is that with the same amount of force the upper dies are able to process a metal plate having a relatively high thickness, or having a relatively high ⁇ rigidity, and furthermore there is not too much shearing stress between the third upper die and the plate so mechanical deterioration of the third upper die or damage to the plate will be prevented.
• starting position is used to mean a position of an upper die, wherein the distance between the upper die and the lower is sufficient for allowing a profiled plate move further in order to form a new profile or in the case the profiling has been completed.
• end position is used to mean a position of an upper die wherein the distance between the respective upper die and the lower die is equal to, or slightly larger, than the thickness of the plate.
• intermediate position is used to mean a position of an upper die between its starting position and its end position, wherein the distance between the respective upper die and the lower die is sufficient to deform the plate after the first upper die has been in its end position or while the first upper die is still in its end position.
• first upper die, a second upper die and a third upper die, moveable back and forth between a starting position, above the lower die, and an end position, in the close proximity of the lower die is not used to mean that in all cases the second upper die and third upper die move to an end position as well. In some cases it can be preferred to have the second upper die or third upper die moved merely to an intermediate position. However, it is preferred that finally the first, the second, and the third upper die move to their end position.
• the first upper die comprises a tapered section transitioning into a blunt end, and the recess is confined by walls shaped such that they extend, in the end position of the first upper die, parallel to the tapered section and further than the blunt end.
• the distance between the tapered section and the recess confining walls is equal to or slightly higher than the thickness of the plate and the distance of the blunt end of the upper die to the recess confining walls is substantially higher than the thickness of the plate.
• At least one wall section of the walls of the lower die confining the recess is replaceable.
• An advantage of such a device is that after mechanical deterioration of the wall section this wall section can be replaced without the necessity to replace the whole lower die.
• Another advantage is that the thickness, or the form, of such replaceable wall section can be varied and as a consequence also the form, width and/or height of the profile that is created in the plate, can be varied.
• the second upper die comprises two second upper die members arranged at both sides of the first upper die and the third upper die comprises two third upper die members arranged at both sides of the first upper die, and the first upper is located centrally with respect to the second upper die and the third upper die.
• the advantage of such a device is that a profile can be created in the plate, wherein the shape of the profile is determined in such a way that the first upper die determines the shape of the central part of the profile, or the shape of the complete profile, and the second upper die and third upper die determine the shape of the plate at both sides of the central part, or the shape of the plate at both sides of the profile.
• the plate By moving the first upper die to its end position the plate shall be deformed such that two plate sections arise having substantially the same slope as the slope of the respective walls of the tapered section of the first upper die and the respective walls confining the recess.
• plate sections that are directed oblique upwardly towards the second and third upper die, are deformed by means of the second upper die members and by means of third upper die members, possibly together, moving towards, or until abutting, the lower die.
• the second upper die members and the third upper die members and the lower die are shaped such that the plate can be provided with a symmetric profile.
• the dimensions of the lower and upper dies are such that they can deform a plate along its total width and until the profile has the shape of a groove.
• the second upper die members are arranged between the third upper die members and the first upper die.
• the third upper die members are arranged between the second upper die members and the first upper die.
• the invention also provides a method for producing a profiled metal plate by means of a device for producing a profiled metal plate, which device comprises a lower die, and multiple upper dies, wherein the upper dies are moveable back and forth individually, in a substantially parallel movement, between a starting position, above the lower die, and an end position, in the close proximity of the lower die, which method comprises: deforming the plate by moving the first upper die to its end position, deforming the plate by moving the second upper die to an intermediate position, and deforming the plate by moving the third upper die to its end position.
• the step of deforming the plate by means of said upper die by moving the upper die to its end position also comprises moving said second upper die to its end position.
• the second upper die temporarily stops in its intermediate position until the third upper is spaced from the lower die with an distance that is almost equal to the distance between the second upper die and the lower die, and subsequently the second upper die and the third upper die move substantially synchronously to their end position.
• the invention also provides a profiled metal plate produced by a method according to the invention.
• the invention provides a profiled metal plate produced by means of a device according to the invention.
• the invention provides a construction part for a truck, comprising a profiled plate according to the invention, wherein the profiled plate is sandwiched between a first substantially flat plate and a second substantially flat plate.
• a construction part can be produced without much effort because positioning the profiled plate between the flat plates is not complicated.
• Another advantage of such a construction part is that while being able to withstand the same forces less material is required compared to the material required for a conventional construction part and a lower weight of a construction part in trucks means a decrease in fuel costs.
• the profiled plate in the construction part is connected to the first and second flat plate by means of plug weld joints.
• plug weld joints The way these plug weld joints can be produced is, for example, described in US 5,007,225. By generating regularly spaced openings on the projecting areas of the profiled plate, it may be possible to produce the plug weld joints automatically.
• the construction part consists, at least partially, of three plates that are substantially flat and arranged substantially parallel, wherein a profiled plate according to the invention is sandwiched between the second plate and a third plate.
• the location in which means for loading and unloading of goods are arranged the higher firmness is very advantageous.
• a sandwich structure as described above can be produced without difficulty, so therefore the extra firmness is being imparted relatively easy.
• both profiled plates are connected to the opposite substantially flat plates by means of plug weld joints
• Figures 1 A-F show a schematic representation of steps of an exemplary embodiment of a method according to the invention
• Figure 2 shows a perspective view of a non-limiting exemplary embodiment of a device according to the invention
• Figure 3 shows an enlargement of a lower die and a detail of an upper die of an exemplary embodiment of a device according to the invention
• Figure 4 shows an exemplary embodiment of a construction part according to the invention.
• FIG. 1 A F is demonstrated how a profile can be created in a metal plate that is already partially profiled, and of which only a part is shown, using a device according to the invention.
• two profiles (14) have been created and the third profile is being formed.
• a first upper die (5) a second upper die, comprising two second upper die members (6a and 6b) arranged at both sides of the first upper die (5), and a third upper die, comprising two third upper die members (7a and 7b) arranged at both sides of the first upper die (5), are all in their starting position.
• the second upper die members are located between the first upper die (5) and the third upper die members (7a and 7b).
• the plate (2) When the upper dies are in their starting position, the plate (2) can be transported with respect to the upper and lower dies to allow a third profile being formed such that said third profile to be formed and the second profile already formed are spaced appropriately. In this situation the plate (2) is supported by the lower die (3).
• the first upper die (5) has been moved to its end position, in the recess (4).
• the plate (2) is divided into two plate sections (2a and 2b) each having substantially the same slope as the slope of the two respective sides of the tapered section (8) of the first upper die (5).
• the second upper die members (6a and 6b) will be hindered in a lesser extend as they move to an intermediate position and because of the fact that they are much smaller than the third upper die members (7a and 7b) and move alongside the first lower die (5).
• the upper dies (5, 6a, 6b, 7a, 7b) are provided with slide strips (not shown) to smooth the movement of the upper dies with respect to each other.
• Figure 1C shows that the plate sections (2a and 2b), that are oriented both oblique upwardly to the second and third upper die, are deformed by means of the second upper die members (6a and 6b). The plate sections (2a and 2b) are bended towards the lower die (3).
• the second upper die members (6a and 6b) are in their intermediate position.
• the deformation described above, created by the second upper die members (6a and 6b), allows the third upper die members (7a and 7b) to move to their end positions. Because of this, the latter can have a larger width, as a consequence of which the abutting surface of the plate is larger and the plate can be deformed using relatively more power.
• both the second upper die members (6a and 6b) and the third upper die members (7a and 7b) are in their intermediate position.
• the second upper die members (6a and 6b) have been waiting in their intermediate position until the third upper die members (7a and 7b) are in their intermediate position too.
• second upper die members (6a and 6b) and the third upper die members (7a and 7b) are in their intermediate position such that they are equally spaced from the lower die (3). It is shown that the location of the third upper die members (7a and 7b) with respect to the plate sections (2a and 2b) has been improved and it is has become easier for the third upper die members (7a and 7b) to deform the plate sections (2a and 2b) such that they are aligned, supported by the upper surface of the lower die (3). In figure 1E, after the plate (3) has been provided with a third profile, all upper die(s) (members) (5, 6a, 6b, 7a, 7b) are again in their end position.
• the lower die (3) is provided with indentations for guiding lifting means for lifting the plate (2) for further transport of the plate for making a fourth profile in the plate (2) (see figure 2). These steps can be repeated until the plate (2) is profiled completely.
• Figure 2 shows a perspective view of the device (1) in which one of the two third upper die members (7b) are shown.
• the lower die (3) and the upper die(s) (members) extend; along the entire length of the device, wherein the length of the device determines the maximal width of the plate to be profiled.
• three small plates (2) are shown.
• This figure also shows indentations in the lower die allowing the lifting means (11) to lift the plate upwards away from the recess.
• the lifting means (1 ) also have the function of transporting the plate in order to re-position it such that a new profile can be formed.
• Figure 3 shows that the first upper die comprises an oblong base section (16) transitioning without abrupt changing into a tapered section (8).
• FIG. 1 shows that the oblong base section (16) extends further.
• FIG. 1 shows that the tapered section (8) of the first upper die (5) transitions into a blunt end (9), and the recess (4) is confined by walls (10) that are shaped such that they extend, in the end position of the first upper die (5), parallel to the tapered section (8) and further than the blunt end (9).
• the end of the profile does not contact the lower die (3).
• FIG 4A schematically shows a construction part (12) for a truck comprising a base sandwich structure along its entire length, in which a profiled plate (2) is sandwiched between a first flat plate (13a) and a second flat plate (13b).
• a profiled plate (2) is sandwiched between a first flat plate (13a) and a second flat plate (13b).
• One and of this construction part (12) is reinforced to a larger extend by an additional profiled plate (2) sandwiched between a second flat plate (13b) and a third flat plate (13c).
• the profiled plates (2) are connected to the adjacent flat plates (13a, 13b, 13c) by means of plug weld joints (15).

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

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Cited By (5)

Citations (11)

• 2013
  • 2013-01-23 NL NL1040017A patent/NL1040017C2/nl not_active IP Right Cessation
• 2014
  • 2014-01-22 WO PCT/NL2014/000003 patent/WO2014116103A1/en active Application Filing

Patent Citations (11)

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