DE102014116890A1 - Apparatus and method for producing profiles - Google Patents

Abstract

The invention relates to a device for producing a profile from a semifinished product (8) made of sheet metal, namely a profile with at least two extending in its longitudinal direction and in its cross-sectional plane angled legs, wherein the device is a desired profile predetermining lower mold bar (6) having full-surface supporting one of the legs and at least one roller (17) for roll profiling of the semifinished product (8) supported by the molding strip (6) to the desired profile. According to the invention, an upper mold bar (7) is adapted to clamp a part of the semifinished product (8) forming the first leg of the desired profile firmly between itself and the lower mold bar (6), the surfaces of the two moldings (6, 7) are complementary to each other and have the same shape as the first leg of the desired profile.

Description

The invention relates to a device and a method for producing a profile from a semifinished product made of sheet metal, according to the preambles of the independent claims.

Such a device and such a method for producing a U-profile with constant height and variable width are known from JP 61086031 A known. The device includes a desired width profile predetermining lower mold strip for full-surface planar support of the bottom of the desired U-profile and two movable in the horizontal direction tapered rollers for bending of the moldings projecting profile parts, ie the later leg, by roll forming, the mold bar together with the semi-finished product resting thereon is pulled through on a carriage between the rollers. After replacing the rollers against tapered rollers this process is repeated. The tapered rollers are arranged so that they also press the semi-finished against the mold bar, so that it must be fixed only in the horizontal direction, namely by means of two positioning holes.

The o. G. Technology only allows the production of U-profiles with variable width and level bottom. In addition, one needs a set of tapered rollers with different cross sections, and the tapered rollers for the first roll profiling step must be relatively flachkegelig, which is why they rub significantly on the semifinished product and leave corresponding traces.

From the DE 10 2009 022 829 B3 Although it is known per se to clamp a semi-finished product between rod-shaped clamping elements adapted to the desired profile and possibly also variable cross-sections, which then passes together with the semi-finished by stationary rollers of a roll forming, wherein the rollers support both the rods and the Shape semi-finished product. Here, however, not only the rods but also the rollers must be specially adapted to the profile to be produced, and if several Profilierschritte are required, you need for each Profilierschritt other roles.

The roll forming of U- or hat profiles with variable height is indeed possible without the use of forming or supporting strips, such. B. from the DE 10 2007 059 439 B3 known, but you need in addition to lateral roller stands for molding the profile legs a number of adjustable rollers for molding the tread.

The invention is based on the object to further develop the roll profiling of profiles supported on strips to the effect that with relatively little effort, a relatively large variety of profiles can be produced.

This object is achieved by an apparatus and a method having the features of the independent claims. Advantageous developments of the invention are specified in the dependent claims.

The invention enables a roll forming on moldings, which in particular U or hat profiles can be produced, but also other profiles, eg. B. L-profiles or Z-profiles.

The invention enables the production of profiles with constant height and / or width, d. h., with constant cross section.

A further development of the invention also makes it possible to produce profiles with variable height and / or width, and in particular a profile, in which at least one first leg has a shape which is not flat everywhere. For this development, the mutually facing surfaces of the two moldings are not flat, and the at least one roller is rotatably mounted on a vertically movable base. Thus, all profiles can be made in which at least one leg does not run anywhere in the same plane, but has any curvatures.

In the case of a U- or hat profile whose bottom is - deviating from the usual language, wherein only the sides of a U-profile are referred to as legs - formed by the first, curved leg, and the profile pages and possibly bends are each by a formed flat thighs.

Although you need different moldings for different profiles, but the cost of their production can be reduced by these modular builds, so that different profiles can be produced with differently shaped mold bar parts.

Otherwise, the effort to adapt the device to different profiles is relatively low. This is especially true for a preferred embodiment in which the lower mold bar and possibly also the upper mold bar, if not only attached to the lower mold bar, is mounted on a carriage which is horizontally movable on a platform along a straight path, wherein on at least on one side of the web a Verstellgerüst is mounted on the platform, each containing a base with a roller mounted thereon.

In an alternative to the aforesaid embodiment, the moldings and the crimped-in profile may be stationary, and instead the adjusting stands are moved along straight tracks along the platform horizontally.

The bending of the profile pages is preferably carried out in small steps, for example in angular increments of 5 ° or 10 °. For smaller quantities, the carriage can be moved back and forth on the platform, with the roller being adjusted accordingly at the end of each pass. For larger numbers, it is advantageous if on one side of the web or on both sides in each case a series of Verstellgerüsten are fixed at intervals on the platform, each containing a base with a roller, the rollers are each set so that each Verstellgerüst performs a deformation by an angular step.

Preferably, the or each roller is not driven, but freely rotatably mounted so that it can roll at the optimum rotational speed on the corresponding profile side, and preferably it is also pivotally mounted as a whole at its base, in a plane transverse to the profile longitudinal direction, so that the role can either adapt itself to the profile angle to be produced in the current profiling step, or alternatively, the role position can easily be adjusted by hand to suit it.

Unlike the generic device, the or each roller may be cylindrical or relatively tapered, e.g. B. with a cone angle of less than 30 °. In this case, one can produce a multitude of profiles with only one type of roller.

For the production of profiles with variable height, it is sufficient if the or each base on which a roll is mounted, is vertically movable.

For the production of profiles with variable height and width, the base usually has to be horizontally movable transversely to the longitudinal direction of the profile. However, certain types of profiles with variable height and width, especially those in which only the leg angle changes in profile longitudinal direction, can also be produced with one or more rollers, which are only vertically movable.

The adjusting stands can be positioning systems with integrated drive, for. B. so-called bipods, hexapods or hexaglides, as described in the DE 10 2007 011 849 B4 are described. The bipod allows movement of the base and thus the role in two degrees of freedom. For profiles with variable height and constant width is sufficient in itself a mobility of the role in one degree of freedom, namely vertical to the platform. A corresponding positioning system can be called Monopod.

Such adjustable stands are already available in many existing roll forming systems, so that the invention can thus be realized with very little effort.

The adjustable stands may alternatively be of a non-integrated drive type, as the position of the or each base is mechanically forcedly controlled by the moldings as they are moved across the platform with the carriage. For this purpose, one of the two moldings having one or more longitudinally extending, suitably curved to the desired profile bending control grooves or cams, in each of which engages a positive control element of a Verstellgerüstes or attacks. In this case, the device requires only a single drive, namely for the carriage, which thus brings the entire forming capacity. Such a drive is particularly easy to implement if only height-adjustable profiles are produced, because in this case the adjustment of the rollers and the carriage feed direction are perpendicular to each other and therefore the forces on a control cam on the mold bar can be relatively small.

In any case, only relatively few drives are required for the invention, which facilitates the construction of Walzprofilieranlagen with which height-variable U or hat profiles, as z. B. can be used as a side member in light trucks use, can be produced with very little effort.

The semi-finished product can be placed either in a preformed or a flat state between the two moldings, wherein the first leg of the desired profile forming part of the semifinished product is brought by the moldings in its final form, while the semifinished product is clamped between the two moldings.

The use of moldings as supporting elements during roll forming has the further advantage that the moldings can also be provided with structures which produce structures on the profile during clamping and / or roll forming, for. As indentations, imprints and gills that can not be produced by pure roll forming, or you can roll profiling with appropriate structures preformed semi-finished, which would be damaged by pure roll forming.

The use of moldings has the further advantage that the semifinished product during the rolling profiling by means of the moldings heat can be supplied or withdrawn in order to achieve an optimum forming temperature. For this purpose, the moldings z. B. be provided with coolant channels or electrical heating elements.

The following is a description of embodiments with reference to the drawings. Show:

1 a U-profile with variable depth;

2 another U-profile with variable depth;

3 a hat profile with variable depth;

4 a U-profile with variable depth and width;

5 an upper and a lower mold strip, between which a semi-finished sheet is clamped;

6 a device for producing a variable height profile with moldings and a monopod;

7 a device for producing a variable height profile with moldings and four monopods;

8th a device for producing a variable height profile with moldings and four bipods;

9 a molding strip for a U-profile with variable bending radii; and

10 a device for producing a profile of variable height with moldings and two hexapods or hexaglides.

The device described below is particularly suitable for the production of U-profiles with variable depth, as in 1 to 4 are shown by way of example, in particular of U- or hat profiles with variable depth and constant width, as in 1 to 3 are shown by way of example. In the case of hat profiles, the corresponding folds can be formed either on a semi-finished product before it is processed with the device described, or in a post-processing step after forming a U-profile.

With adjustable scaffolds, which allow a roller adjustment in more than two dimensions, corresponding profiles with variable depth and width can be made, as in 4 shown by way of example The device described below is also suitable for the production of L or Z profiles with variable depth and possibly also variable width. Exemplary L or Z profiles can be recognized by looking at the profiles of 1 to 4 each thinks away one of the two vertical legs.

Using the same or similar reference numerals for the same or similar parts, the U or hat profiles shown each have a bottom 1 respectively. 1' , which is not everywhere flat over its length, two legs perpendicular to the profile cross-sectional plane 2 and 3 . 2 ' and 3 ' respectively. 2 '' and 3 '' , as well as possibly bends 4 and 5 ,

For the production of in 1 U-profiles with variable depth and width are two elongated moldings 6 and 7 provided, which in 5 top left in a side view, including in a vertical plan view, right next to it in a front view and bottom right in a perspective view are shown. The lower mold bar 6 is shaped on its top as well as the inside of the floor 1 and is a little longer, and the top molding 6 is shaped on its underside as well as the outside of the floor 1 and is a little longer. Thus, the facing surfaces of the two moldings 6 and 7 complementary to each other, except that the upper molding 6 slightly narrower than the lower molding 7 is to provide the later described roles more range of motion during roll forming available.

The moldings 6 and or 7 should be made of a wear-resistant, hardened and surface-treated material, which does not necessarily have to be steel. In particular, the moldings 6 and or 7 be composed of several parts, which may also consist of different materials. So can the moldings 6 and or 7 z. B. horizontally, namely in a supporting body made of an easy-to-work material such as aluminum and a hardened steel strip placed thereon.

A semi-finished product 8th sheet metal is between the two moldings 6 and 7 placed and clamped with means not shown in between, so that those portions of the semifinished product 8th that go to the thighs 2 . 3 should be bent, projecting laterally from it. The semi-finished product 8th can either match the contours of the moldings 6 . 7 and the later soil 1 be pre-bent, or it is brought by pinching in the appropriate form. In this state are also the side over the moldings 6 . 7 In addition, protruding portions of the semifinished product 8th not exactly everywhere in length, although later they will be.

The clamping can z. B. be generated mechanically, pneumatically, magnetically, by positive engagement, by screwing or by gluing.

As in 5 shown lower left in an enlarged section, the lower molding can 6 bending edges 9 with a defined bending radius, and the bending edges 9 may protrude slightly laterally to allow for overbending. Also in other places than the bending edges 9 can the form bar 6 have a slightly different shape than they should take the finished profile. For example, the side surfaces of the form bar 6 in the area of the bent sections of the soil 1 of the profile slightly deviate from the nominal cross section of the profile to counteract undesirable deformations of the finished profiles in these areas.

6 shows an apparatus for producing profiles with variable height and constant width, namely top left as a side view, top right as an end view, bottom left as a top view and bottom right perspective.

In this device is the lower mold bar 6 at the top of the mold 7 is attached while the semifinished product 8th sandwiched between, on a sledge 10 attached, by means of a drive, not shown, on a horizontal platform 11 horizontally movable, the guides 12 which has a straight path 13 pretend along the carriage 10 can move.

In 6 is on one side of the track 13 an adjusting frame 14 on the platform 11 attached. The adjustment frame 14 is a positioning system with integrated drive and contains a vertically movable base 15 How to best in the central section magnification in 6 recognizes. The base 15 carries a semicircular bracket 16 between the ends of which is a cylindrical roller 17 is mounted freely rotatable with a relatively small diameter.

The coat hanger 16 is pivotable relative to the base such that the axis of the roller 17 in a plane perpendicular to the web 13 is adjustable. In the exemplary embodiments it is provided that such a pivoting of the roller 17 either by hand or during the roll 17 unrolls on the sheet and adjusts its angular position by itself. If necessary, but also a separate drive for pivoting the role 17 in a plane perpendicular to the web 13 be provided.

In a first profiling step is the role 17 in the position shown, in which they are approximately at the height of the semi-finished product 8th is located and only slightly against the plane of the platform 11 is inclined. In this position, the slide 10 along the train 13 over its entire length along the Verstellgerüstes 14 procedure, the role 17 to the role 17 towards projecting portion of the semifinished product 8th z. B. Bends down by 5 ° or 10 ° while it rolls freely on it. This is the formleistenseitige end of the role 17 always kept close to the bending point. This is the role 17 by means of the adjustment frame 14 moved in the vertical direction, while away from the curved sections of the moldings 6 and 7 is happening.

After a passage, when the sled 10 from one end to the other end of the platform 11 has moved, becomes the base 15 and thus the role 17 from the adjustment frame 14 down a little, and the procedure described above is performed in the opposite direction.

All this is repeated until the one thigh 2 of in 1 profile shown finished rolled. In each passage, the role arises 17 by itself on the respectively necessary angle, because its formleistenseitiges end is always close to the bending point, or the roll angle is adjusted and fixed by hand each time.

Subsequently, the moldings 6 . 7 together with the intervening semi-finished product 8th on the sled 10 or it will be the whole sleigh 10 turned over in the same way as described above the other leg 3 roll profiling of the profile. Alternatively, on the the adjustment frame 14 opposite side of the track 13 another adjustment framework of the same type as the adjustment frame 14 on the platform 11 be attached to the two thighs 2 . 3 roll forming at the same time.

The above described further Walzprofilierschritte for the leg 3 or two adjustable stands 14 are of course not necessary if an L-profile is made, whose legs through the floor 1 and one thigh 2 of in 1 formed profile are formed.

Instead of moving the carriage back and forth 10 on the platform 11 with successive adjustment can be roll profiling with fewer passes or with only one pass, if several same Verstellgerüste 14 . 14 ' . 14 '' and 14 ''' one behind the other along the train 13 on the platform 11 are attached, as in 7 shown otherwise the 6 equivalent. This means, 7 also shows an apparatus for producing profiles with variable height and constant width top left as a side view, top right as an end view, bottom left as a top view and bottom right perspective, with an enlarged view of one of the adjusting frameworks in the middle.

A similar device is in just such a way 8th shown, with the only differences that the four adjusting frames 24 . 24 ' . 24 '' and 24 ' no monopods are like the adjusting frames 14 . 14 ' . 14 '' and 14 ''' in 7 but bipods, as in the DE 10 2007 011 849 B4 are described, and that the role is not cylindrical, but a tapered roller 27 with a relatively small cone angle of z. B. 20 °. The bipod allows a movement of the base, here a round disc 25 is, both vertically and in the middle axis. This allows the tapered roller 27 always positioned so as to avoid unwanted deformations as possible, which can occur especially in the curved profile sections, and the slightly tapered shape of the tapered roller 27 also contributes to this.

To be able to produce profiles of variable height and width with the device described above, the role 17 respectively. 27 not just vertical to the platform 11 , but also transversely to the profile longitudinal direction or the web 13 be movable. This can be achieved, for example, by the role 17 respectively. 27 is mounted on a monopod or bipod, which is mounted on the base of a monopod or bipod arranged perpendicular thereto, which on the platform 11 is attached. Alternatively one can use one or more adjusting frames with more than two degrees of freedom, as they are in 2c and 2d of the DE 10 2007 011 849 B4 are shown schematically.

9 shows a form bar 30 for a U-profile with over its length variable bending radii 31 and 32 , which also represents a profile with not everywhere flat thighs. The form bar 30 can z. B. in place of the lower mold bar 6 in the device of 6 be used. The upper molding can also in this case be complementary to the lower molding 30 be. In the case of relatively small variable bending radii 31 and 32 as in 9 but the top molding may possibly just be flat.

10 shows two perspective views of another device for producing profiles with variable height and constant width, which differs from the previous embodiments, the left and right of the carriage 10 , the carriage previously described 10 resembles and sits on a platform 41 located, the previously described platform 11 is similar, in each case a Verstellgerüst 44 is arranged in the form of a hexapod or hexaglide.

On the adjustable frame 44 is each a role 47 stored, and every role 47 can by means of their Verstellgerüstes 44 be moved in all three spatial directions and solid angles. Therefore, the roles must be 47 not pivotable on their adjustable scaffolding 44 be appropriate, as is the case in the previous embodiments

The two adjustable scaffolding 44 are each from an auxiliary platform 48 worn along one of the two longitudinal edges of the platform 41 extends. Every auxiliary platform 48 has a surface on which one of the adjustable scaffolding 44 is fixed, and this surface is inclined to the surface portion of the platform 41 on which the sled 10 at an angle of about 45 ° with respect to the plane of the auxiliary platform 48 diagonally outwards and upwards. Such support of Verstellgerüste 44 slants to the surface of the platform 41 is particularly advantageous in that on the one hand the roles 47 can easily be brought in all directions and angles, which are used to process the semi-finished product 8th are necessary, and that on the other hand, the Verstellgerüste 44 are easily accessible from all directions, z. B. for roll change and maintenance.

In the 10 The device shown works in a similar way to the devices of the previously described embodiments. During a passage of the carriage 10 the roles remain 47 angle fixed and are only where the profile height changes, perpendicular to the platform 42 and for the next round will be the rolls 47 by means of the adjusting frameworks 44 a little bit panned. For example, the in 10 from the position shown in the sketch at the top right to the position shown in the sketch at the bottom left.

Another advantage of in 10 shown device is that because of the mobility of the adjusting frameworks 44 In all three spatial directions and solid angles also profiles with variable width can be easily produced. It only needs to be from the sled 10 worn moldings are designed accordingly.

The skilled artisan recognizes that with the described devices not only profiles with variable height and / or width can be made, but also those with constant height and width, d. h., With a constant over its length cross-section. In this case, one uses planar moldings for clamping the profile, and the at least one roller is not moved vertically during a passage, but remains stationary.

Normally, other processes are used to mass-produce profiles with a constant cross-section, but it is an additional advantage that profiles with a constant cross-section can be produced quickly if you need them.

Another advantage of the invention, which is for both constant cross-section profiles and variable cross-section profiles, is that the process leaves very little machining marks on the sheet so as to obtain profiles with particularly high surface quality.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• JP 61086031 A [0002]
• DE 102009022829 B3 [0004]
• DE 102007059439 B3 [0005]
• DE 102007011849 B4 [0020, 0056, 0057]

Claims (10)

Device for producing a profile from a semifinished product ( 8th ) of sheet metal, namely a profile with at least two extending in its longitudinal direction and in its cross-sectional plane to each other angled legs ( 1 . 1'; 2 . 2 ' . 2 ''; 3 . 3 ' . 3 '' ), wherein the device has a lower profile strip which predetermines the desired profile ( 6 ) for supporting one of the legs ( 1 . 1' ) and at least one role ( 17 . 27 ) for roll profiling of the molding ( 6 ) supported semi-finished product ( 8th ) to the desired profile, characterized in that the device also comprises an upper molding ( 7 ), which is adapted to a first leg ( 1 . 1' ) of the desired profile forming part of the semifinished product ( 8th ) firmly between itself and the lower molding ( 6 ), wherein the mutually facing surfaces of the two moldings ( 6 . 7 ) are complementary to each other and the same shape as the first leg ( 1 . 1' ) of the desired profile. Apparatus according to claim 1, characterized in that the profile has a variable height and / or width that at least a first leg ( 1 . 1' ) of the profile has a shape that is not flat everywhere, that the mutually facing surfaces of the two moldings ( 6 . 7 ) are not even and that the at least one role ( 17 . 27 ) on a vertically movable base ( 15 . 25 ) is rotatably mounted. Apparatus according to claim 1 or 2, characterized in that at least the lower molding ( 6 ) on a sledge ( 10 ) mounted on a platform ( 11 ) along a straight path ( 13 ) is horizontally movable, and that on at least one side of the web ( 13 ) an adjusting framework ( 14 . 24 ) on the platform ( 11 ), which adjusting framework ( 14 ) the basis ( 15 . 25 ) at which the at least one roll ( 17 . 27 ) is stored. Apparatus according to claim 3, characterized in that on at least one side of the web ( 13 ) or on both sides of the track ( 13 ) a series of Verstellgerüsten ( 14 . 14 ' . 14 '' . 14 '''; 24 . 24 ' . 24 '' . 24 ' ) at intervals on the platform ( 11 ), each having a vertically movable base ( 15 . 25 ) on which a roll ( 17 . 27 ) is stored. Device according to one of the preceding claims, characterized in that the at least one roller ( 17 . 27 ) freely rotatable at its base ( 15 . 25 ) and / or that the at least one roll ( 17 . 27 ) as a whole pivotable at its base ( 15 . 25 ) and / or that the at least one roll ( 17 . 27 ) or every role ( 17 . 27 ) is either cylindrical or relatively pointed and / or that the or each base ( 17 . 27 ) Also horizontally transversely to the longitudinal direction of the profile is movable. Device according to one of claims 3 to 5, characterized by a mechanical positive control of the position of the or each base ( 17 . 27 ) through the moldings ( 6 . 7 ) while moving on the carriage ( 10 ) over the platform ( 11 ). Device according to claim 1, characterized in that it comprises a horizontal platform ( 41 ) from which the moldings ( 6 . 7 ) and that the base on which the at least one roll ( 47 ) is part of a Verstellgerüstes ( 44 ), that from an auxiliary platform ( 48 ), wherein a flat surface on which the adjusting framework ( 44 ) on the auxiliary platform ( 48 ) at an oblique angle to a flat surface of the horizontal platform ( 41 ) adjoins. Method for producing a profile from a semifinished product ( 8th ) of sheet metal, namely a profile with at least two extending in its longitudinal direction and in its cross-sectional plane to each other angled legs ( 1 . 1'; 2 . 2 ' . 2 ''; 3 . 3 ' . 3 '' ), one of the two legs ( 1 . 1' ) over its entire length and width of a desired profile, the lower molding ( 6 ) is supported and then from the molding ( 6 ) supported semi-finished products ( 8th ) is roll-profiled to the desired profile, characterized in that a first leg ( 1 . 1' ) of the desired profile forming part of the semi-finished product ( 8th ) firmly between the lower molding ( 6 ) and an upper mold bar ( 7 ) is clamped, wherein the mutually facing surfaces of the two moldings ( 6 . 7 ) are complementary to each other and the same shape as the first leg ( 1 . 1' ) of the desired profile, whereupon the between the two moldings ( 6 . 7 ) clamped semis ( 8th ) is roll profiled to the desired profile. A method according to claim 1, characterized in that the profile has a variable height and / or width that at least a first leg ( 1 . 1' ) of the profile has a shape that is not flat everywhere, that the mutually facing surfaces of the two moldings ( 6 . 7 ) are not exactly that the at least one role ( 17 . 27 ) according to the shape of the first leg ( 1 . 1' ) is moved vertically. A method according to claim 8 or 9, characterized in that a U- or hat profile is produced, the bottom of which by the first leg ( 1 . 1' ) is formed and / or that a profile with variable height and constant width is produced and / or that the semifinished product ( 8th ) in a flat state between the two moldings ( 6 . 7 ) and that the first leg ( 1 . 1' ) of desired profile is formed while the semi-finished ( 8th ) between the two moldings ( 6 . 7 ) or that the semifinished product ( 8th ) in a state between the two moldings ( 6 . 7 ) in which it is preformed such that the first leg ( 1 . 1' ) of the desired profile forming part of the semifinished product ( 8th ) essentially already has the desired not everywhere flat shape.

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