KR20080110363A - Roll forming apparatus for simultaneous forming and method - Google Patents

Abstract

A roll forming apparatus for simultaneous forming and the method for roll forming-creating is provided to the fixed shape and to maintain the airtight of the air gap for the upper plate and lower plate. A roll forming apparatus for simultaneous forming includes a first uncoiler(101), a roll core molder(102), a second uncoiler(103), a roller electric resistance welding machine(105), and a roll former unit(R), and comprises a blanking press(106) processed between the roller electric resistance welding machine and roll former unit to the complex blank; a stamping press(107) pressing the leading end and backend of the complex blank ash supplied from the blanking press; a pressurized roller unit(108) pressing both side terminal of the complex blank ash through upper and lower pressure roller to the progressive direction; and a welding roller unit(109) which electrifies both side terminal of the complex blank ash with the progressive direction through upper and lower electrode roller and welded.

Description

ROLL FORMING SYSTEM FOR SIMULTANEOUS FORMING AND METHOD THEREOF}

1 is an exploded perspective view of a general vehicle bumper beam assembly.

2 is a conceptual diagram illustrating a roll forming apparatus and a step-by-step process for simultaneous molding according to the prior art.

3 is a perspective view showing an example of a bump forming beam formed by the roll forming apparatus and the method according to the prior art according to the prior art.

4 is a conceptual diagram illustrating a roll forming apparatus and a step-by-step process for simultaneous molding according to an embodiment of the present invention.

5 is a process conceptual diagram of a stamping step of the roll forming apparatus for simultaneous molding according to an embodiment of the present invention.

6 is a process conceptual view of the roll pressing step of the roll forming apparatus for simultaneous molding according to an embodiment of the present invention.

7 is a process conceptual view of the roll welding step of the roll forming apparatus for simultaneous molding according to an embodiment of the present invention.

8 is a perspective view showing an example of a roll forming apparatus and a bumper beam formed by the method for the simultaneous molding according to an embodiment of the present invention.

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a roll forming apparatus and a method for co-molding. The present invention relates to a roll forming apparatus for simultaneous forming and a method for forming a composite plate to be retained and allowing roll forming to be formed in a constant shape.

In general, the bumper beam assembly of a vehicle is elastically deformed at a low speed collision of the vehicle to minimize physical damage to the vehicle body, and in the event of a collision with another vehicle or a stationary body, the impact force is absorbed so that rider safety can be achieved. It is a cushioning means installed at the front and rear of the vehicle.

As shown in FIG. 1, the vehicle bumper beam assembly includes a bumper beam 51 disposed in the vehicle width direction from the front and the rear of the vehicle, and a stay for connecting the bumper beam 51 and the front side member to each other. 53, and a plurality of reinforcement 55 and brackets (57).

Accordingly, the bumper beam assembly for a vehicle absorbs some of the collision energy while the energy absorber is not shown during the collision of the vehicle, and the collision energy that is not absorbed by the energy absorber is not reflected by the bumper beam 51 and the rear of the rear bumper beam 51. 53 is dispersed and absorbed into the vehicle body.

Recently, a study has been conducted to produce a beam stream having a linear beam such as the bumper beam 51 in a sandwich-type composite sheet to improve its shock absorbing performance. As described above, Korean Patent Application No. 10-2006-0134444 filed by the present applicant discloses a roll forming apparatus and a method for simultaneous molding.

Referring to FIG. 2 with respect to such a co-molding roll forming apparatus, in the conventional co-forming roll forming apparatus, the first uncoiler 1 is formed on the process line in front of the coil panel for core panel 11. The roll core molding machine 2 which supplies and forms the zigzag-shaped core panel in the back of the said 1st uncoiler 1 is comprised.

In addition, a second uncoiler 3 is configured at the rear of the roll core forming machine 2 to release the upper coil 31 and the lower coil 33 supplied for the upper plate and the lower plate, and the second uncoiler 3. At the rear of the), guide rollers 4 are arranged to align both ends of each coil.

In addition, a roller electric resistance welding machine 5 is formed at the rear of the guide roller 4 to produce the composite plate 20 by welding the upper plate and the lower plate with the core panel 10, and the brake press 6 at the rear thereof. In the rear of the brake press 6, 10 or more stages of roll formers (R1 to R7; some not shown) are arranged in a row to sequentially form the composite plate 20, as shown in FIG. It consists of the roll former unit R which roll-forms into the bumper beam 51 using the sandwich type composite board material 20 as described above.

However, as shown in FIG. 3, the bumper beam 51 formed by using the sandwich type composite plate 20 from the conventional co-molding roll forming apparatus as described above is in an open state at each end. The air gap between the furnace upper plate 53 and the lower plate 55 is exposed to the outside, which is similar to an electrodeposition (undercoat) process in which a coating film is formed on the surface of the vehicle in the painting process of the vehicle body. In the immersion process, the electrodeposition liquid penetrates into the gap between the upper plate 53 and the lower plate 55 of the bumper beam 51 to coat even the portion where painting is unnecessary.

In this way, when the coating liquid such as electrodeposition liquid penetrates into the gap between the upper plate 53 and the lower plate 55 of the bumper beam 51, it takes a long time to dry the coating liquid, and the overall bumper beam 51 Problems such as increased weight.

Accordingly, the present invention has been made by the technical requirements as described above, and an object of the present invention is to integrally weld a bent core panel between an upper plate and a lower plate, and then press the edges of the pores between the upper plate and the lower plate to form a void. The present invention provides a co-molding roll forming apparatus and a method for forming a composite sheet having airtightness and allowing roll forming to be formed in a constant shape.

Simultaneous forming roll forming apparatus of the present invention for realizing the above object is a first uncoiler for releasing the coil is configured and supplied in the front on the process line; A roll core molding machine provided at a rear of the first uncoiler and bending the strip-shaped steel sheet released from the first uncoiler in a zigzag shape to form a core panel; A second uncoiler configured to be disposed behind the roll core forming machine on the process line and to release the coils supplied for the upper plate and the lower plate to the upper side and the lower side of the core panel formed and supplied from the roll core forming machine, respectively; A guide roller configured to align in a row by guiding both side ends of the core panel, the upper plate, and the lower plate coil, which are configured to be disposed on the rear of the second uncoiler and overlapped on the processing line; The roller which is configured to the rear of the guide roller on the process line and energizes the upper plate and the lower plate coil which are supplied to the upper side and the lower side of the core panel through the upper and lower roller electrodes to continuously weld to the sandwich type composite plate. Resistance welding machine; In the roll forming apparatus for a simultaneous forming comprising a plurality of roll formers are arranged in a row, a roll former unit for bending and sequentially forming a composite plate material supplied from the previous process to roll forming the predetermined shape,

Between the roller electric resistance welder and the roll former unit on the process line

A blanking press for cutting the sandwich type band-shaped composite sheet material supplied from the roller electric resistance welding machine to a predetermined standard to be processed into a composite blank material; A stamping press for press molding the front and rear ends of the composite blank material supplied from the blanking press; A pressure roller unit for pressing the both ends of the composite blank material of which the front end and the rear end are press-molded in the advancing direction through the upper and lower pressure rollers; It further comprises a welding roller unit for energizing both ends of the composite blank material pressed by the pressure roller unit in the advancing direction through the upper and lower electrode rollers.

The second uncoiler is mounted on the upper upper coil supplied for the upper plate, and the lower coil is supplied to the lower plate is installed in the lower portion of the upper coil spaced apart at regular intervals to pass through. It features.

The blanking press is cut into a composite blank material by cutting the composite plate material to the size of the length of the product to be molded, the stamping press is supported on the lower end and the rear end of the composite blank material to be supplied mounted to the lower bolster The lower mold; It is characterized by consisting of an upper mold mounted on the slider at the upper portion of the lower mold to press-form and press-form the front and rear ends of the composite blank material.

The pressurizing roller unit is configured to be rotatable in the lower portion on the frame, the lower pressurizing rollers are formed integrally with a pressurizing end having a large diameter at both ends; It is configured to be rotatable in the upper portion on the frame, the upper end is composed of an upper pressing roller which is integrally formed with a pressing end of a large diameter, the welding roller unit is configured to be rotatable in the lower portion on the frame is pressed from the pressing roller unit Two lower electrode rollers supporting both ends of the formed composite blank material from below; It is rotatably configured on the upper part on the frame, and consists of both upper electrode rollers which are continuously welded by energizing both ends of the composite blank material in the advancing direction together with the lower electrode rollers.

In addition, the upper electrode rollers on both sides are connected by an electrode rod rotatably installed on the frame.

And the roll forming method for the co-forming using the roll forming apparatus for co-forming as described above comprises a first uncoil step of releasing the coil to be supplied for the core panel through the first uncoiler, on the process line; S10) a core panel forming step of bending the strip-shaped steel sheet supplied from the first uncoiler step in a zigzag shape through a roll core forming machine to form a core panel at the rear of the first uncoiler; (S20) the roll core In the rear of the molding machine, a second uncoil step of releasing the upper plate and the lower plate coils to the upper side and the lower side of the core panel is formed and supplied from the core panel forming step through a second uncoiler; (S30) the second uncoil Aligning step of aligning in a row by guiding both side ends of the core panel and the upper plate and the lower plate coils which are supplied to overlap each other from the rear of the guide through the guide roller; 40) In the rear of the guide roller, the upper plate and the lower plate coil supplied to the upper and lower side of the core panel is energized through the upper and lower roller electrodes of the roller electric resistance welding machine to continuously weld to the sandwich type composite plate Welding step; (S50) In the rear of the roller electrical resistance welding machine, a blanking step of cutting the band-shaped composite plate material supplied from the roller electrical resistance welding machine by a blanking press to the standard of the beam flow to be formed into a blank processing step; ( S60) a stamping step (S70) of compression molding the front and rear ends of the composite blank material supplied from the blanking press through a stamping press; Roll pressing step (S80) for pressing both sides of the composite blank material press-formed from the stamping step by the upper and lower pressure rollers in the advancing direction through the upper and lower pressure rollers; Roll welding step (S90) of the two side ends of the composite blank material compression-molded by the upper and lower pressure rollers in the advancing direction through the upper and lower electrode rollers for welding; And a roll forming step (S100) of sequentially forming and bending the composite blank material supplied through the final upper and lower electrode rollers from the previous process to roll forming a beam of a predetermined shape.

Here, the second uncoil step (S30) is characterized in that to release the upper coil supplied for the upper plate to the upper portion of the core panel, the lower coil supplied for the lower plate to the lower portion of the core panel. do.

Hereinafter, with reference to the accompanying drawings, preferred embodiments of the present invention will be described in detail as follows.

4 is a conceptual diagram illustrating a roll forming apparatus and a step-by-step process for simultaneous molding according to an embodiment of the present invention.

In the configuration of the roll forming apparatus for simultaneous forming according to an embodiment of the present invention, as shown in FIG. 4, a coil is to be supplied for the core panel with a first uncoiler 101 formed on the front of the process line. 111) is provided to release.

At the rear of the first uncoiler 101, a band-shaped steel sheet released from the first uncoiler 101 is bent in a zigzag shape using a sawtooth upper roll 121 and a lower roll 123 to form a core panel ( The roll core molding machine 102 which molds with 100 is comprised.

In addition, an upper coil 131 and a lower coil are supplied to the upper and lower plates of the upper and lower sides of the core panel 100 which is formed and supplied from the roll core forming machine 102 at the rear of the roll core forming machine 102. The second uncoiler 103 is configured to release 133.

Here, the second uncoiler 103 is mounted on the upper upper coil 131 supplied for the upper plate, spaced apart a predetermined interval so that the core panel 100 passes through the lower portion of the upper coil 131. In the state, the lower coil 133 supplied for the lower plate is installed.

In addition, the guide roller 104 for aligning and arranging both ends of the core panel 100 and the upper and lower coils 131 and 133 which are superimposed on the rear of the second uncoiler 103 on the process line. Is composed.

At the rear of the guide roller 104, the upper and lower coils 131 and 133 supplied to the upper and lower sides of the core panel 100 are energized through the upper and lower roller electrodes 151 and 153, respectively, to the core panel 100. And a roller electric resistance welder 105 which is welded by an electric resistance and continuously welded to the sandwich type composite plate 200.

The blanking press 106 cuts the sandwich type band-shaped composite plate 200 supplied from the roller electric resistance welder 105 to a predetermined size at the rear of the roller electric resistance welder 105 to process the composite blank material 300. ) Is configured.

The blanking press 106 cuts the composite plate member 200 to a size as long as the length of the product to be molded and forms the composite blank member 300.

And behind the blanking press 106 is provided with a stamping press 107 for compression molding the front end and the rear end of the composite blank material 300 supplied from the blanking press 106.

Here, the stamping press 107, as shown in Figure 5, the lower mold 163 for supporting the lower surface with respect to the front end and the rear end of the composite blank material 300 is mounted and supplied to the lower bolster 161, And an upper mold 167 mounted on the slider 165 at the upper portion of the lower mold 163 to press-press and press-form the front and rear ends of the composite blank material 300.

In addition, a pressure roller unit 108 is provided at the rear of the stamping press 107, and the pressure roller unit 108 has upper and lower ends of both sides of the composite blank material 300 press-formed at the front end and the rear end. The press rollers 173 and 171 are configured to be press-molded in the advancing direction.

That is, the pressing roller unit 108, as shown in Figure 6, is configured to be rotatable in the lower portion on the frame, the lower pressing roller 171 is formed integrally with a pressing end (PR) having a large diameter at both ends. And, it is configured to be rotatable in the upper portion on the frame, both ends are composed of an upper pressing roller 173 is formed integrally with a large pressing end (PR) diameter.

A welding roller unit 109 is provided at the rear of the pressure roller unit 108. The welding roller unit 109 has upper and lower electrode rollers formed at both ends of the composite blank material 300 which is press-molded by the pressing roller unit 109. 177, 175 is configured to conduct the welding in the direction of travel.

That is, the welding roller unit 109 is configured to be rotatable in the lower portion on the frame, the lower electrode rollers on both sides to support the both ends of the composite blank material 300 press-molded from the pressure roller unit 108 from the bottom ( 175 and both upper electrode rollers rotatably configured on the upper part of the frame, and continuously welding both ends of the composite blank material 300 together with the lower electrode rollers 175 in the advancing direction from the upper side to be continuously welded ( 177).

Here, the both upper electrode rollers 177 are preferably connected by an electrode rod 179 rotatably installed in the frame.

At least 10 roll formers R1 to R7 (not shown) are arranged in a row at the rear of the welding roller unit 109 so that the first uncoiler 101, the roll core forming machine 102, and the second uncoiler are arranged in a row. The composite supplied through the curler 103, the guide roller 104, the roller electric resistance welding machine 105, the blanking press 106, the stamping press 107, the pressure roller unit 108, and the welding roller unit 109 A roll former unit R is formed by sequentially bending and forming the blank material 300, and forming a roll by forming the bumper beam 400 using the sandwich type composite blank material 300 as illustrated in FIG. 8.

Therefore, the roll forming method for co-molding for roll forming the bumper beam 400 formed by using the sandwich type composite sheet 200 using the co-forming roll forming apparatus having the above-described configuration, On the process line, the first uncoil step (S10) for releasing the coil 111 to be supplied to the roll core forming machine 102 for the core panel through the first uncoiler 101 is performed.

At the rear of the first uncoiler 101, a core panel is bent into a core panel 100 by bending the strip-shaped steel sheet supplied from the first uncoiler step S10 in a zigzag shape through a roll core forming machine 102. Proceed with the molding step (S20).

Subsequently, the core panel 100 formed by the roll core molding machine 102 in the core panel forming step S20 passes through the second uncoiler 103 and the upper coil 131 on the second uncoiler 103. ) And the lower coil 133 is unrolled so as to overlap the upper and lower plates for the upper plate and the lower plate to proceed with the second uncoil step (S30).

Here, in the second uncoil step S30, the upper coil 131 supplied for the upper plate is released to the upper portion of the core panel 100, and the lower coil 133 supplied for the lower plate is the core panel. Loosen to the bottom of (100).

As described above, in the second uncoiler 103, the core panel 100, the upper plate and the lower plate coils (that is, the upper coil 131 and the lower coil 133) which are supplied to be overlapped with each other, have both ends thereof. The alignment step (S40) is guided by the guide roller 104 configured to the rear of the second uncoiler 103 and aligned in a line.

In the rear of the guide roller 104, the upper and lower coils supplied to the upper and lower sides of the core panel 100 are energized through the upper and lower roller electrodes 151 and 153 of the roller electric resistance welder 105. A welding step (S50) of continuously welding the sandwich type composite plate 200 is performed.

Subsequently, at the rear of the roller electric resistance welder 105, the band-shaped composite plate 200 supplied from the welding step S50 is cut to meet the specifications of the beams to be formed through the blanking press 106 to produce a composite blank material ( The blanking step S60 is processed to 300.

In addition, the composite blank material 300 supplied from the blanking press 106 performs a stamping step S70 of compression molding the front end and the rear end of the composite blank material 300 through the stamping press 107 in the advancing direction.

The composite blank material 300 press-formed from the stamping step S70 at the front end and the rear end is press-molded in the advancing direction through the upper and lower pressure rollers 173 and 171 of the pressure roller unit 108. Proceed with the roll pressing step (S80).

Subsequently, both ends of the composite blank material 300 press-molded by the upper and lower pressure rollers 173 and 171 again pass through the upper and lower electrode rollers 177 and 175 of the welding roller unit 109 to be energized. The roll welding step S90 in which the electric resistance welding is performed is performed.

As such, the composite blank material 300, each end of which is crimped or crimped welded from the welding roller unit 109, is bent and formed while sequentially passing through ten or more stages of roll formers R1 to R7 (not shown). The roll forming step (S100) of forming a beam stream such as the bumper beam 400 as shown in FIG. 8 is performed.

That is, as shown in FIG. 8, the bumper beam 400 formed by the roll forming apparatus for simultaneous molding according to the present embodiment has an upper plate 401 in a state where each end portion EL is crimped or pressed welded. ) And the lower plate 403 are hermetically sealed to form a beam flow in a state of airtightness.

As described above, according to the roll forming apparatus for simultaneous forming and the method according to the present invention, after bending the core panel of the bent shape integrally between the upper plate and the lower plate, it is squeezed along the end portion of the air gap between the upper plate and the lower plate. At the same time to form a composite plate to maintain the airtight, it is possible to roll-forming molding to a certain shape to improve the productivity of the beam flow and reduce the manufacturing cost.

In addition, by maintaining the airtightness of the gap between the upper plate and the lower plate, the beams formed by bumper beams, etc. are applied to the vehicle body, and in the process of locking the vehicle body into the deep tank, such as electrodeposition (undercoat) process on the surface of the vehicle body in the painting process. By preventing the electrodeposition liquid from penetrating into the gap between the upper plate and the lower plate of the bumper beam, it eliminates the problem that a long time is required to dry the conventional coating liquid, and prevents the conventional problem that the weight of the overall bumper beam is increased by unnecessary coating. You can do it.

Claims (9)

A first uncoiler on the process line, the first uncoiler configured to release a coil supplied to the front; A roll core molding machine provided at a rear of the first uncoiler and bending the strip-shaped steel sheet released from the first uncoiler in a zigzag shape to form a core panel; A second uncoiler configured to be disposed behind the roll core forming machine on the process line and to release coils supplied for the upper plate and the lower plate to the upper side and the lower side of the core panel formed and supplied from the roll core forming machine, respectively; A guide roller configured to align in a row by guiding both side ends of the core panel, the upper plate, and the lower plate coil, which are configured to be disposed on the rear of the second uncoiler and overlapped on the processing line; The roller which is configured to the rear of the guide roller on the process line and energizes the upper plate and the lower plate coil which are supplied to the upper side and the lower side of the core panel through the upper and lower roller electrodes to continuously weld to the sandwich type composite plate. Resistance welding machine; In the roll forming apparatus for a simultaneous forming comprising a plurality of roll formers are arranged in a row, a roll former unit for bending and sequentially forming a composite plate material supplied from the previous process to roll forming the predetermined shape, Between the roller electric resistance welder and the roll former unit on the process line A blanking press for cutting the sandwich type band-shaped composite sheet material supplied from the roller electric resistance welding machine to a predetermined standard to be processed into a composite blank material; A stamping press for press molding the front and rear ends of the composite blank material supplied from the blanking press; A pressure roller unit for pressing the both ends of the composite blank material of which the front end and the rear end are press-molded in the advancing direction through the upper and lower pressure rollers; And a welding roller unit for energizing and welding both ends of the composite blank material press-molded by the pressure roller unit in the advancing direction through the upper and lower electrode rollers. The method of claim 1, The second uncoiler is The upper coil to be supplied for the upper plate is mounted on the upper side, the lower portion of the upper coil in a state spaced apart by a predetermined interval so as to pass through, the lower coil supplied for the lower plate is installed Roll forming device. The method of claim 1, The blanking press And forming a composite blank material by cutting the composite sheet material to a length equal to the length of the product to be molded. The method of claim 1, The stamping press A lower mold for supporting the lower surface with respect to the front and rear ends of the composite blank material which is mounted and supplied to the lower bolster; And an upper mold mounted on a slider at an upper portion of the lower mold and configured to press-form and press-form the front and rear ends of the composite blank material. The method of claim 1, The pressure roller unit A lower pressurizing roller configured to be rotatable at a lower portion of the frame, and having both end portions integrally formed with a pressurized end having a large diameter; The upper forming roller rotatably configured on the upper portion on the frame, the upper end of the pressing end is formed integrally with a large diameter on both ends; Roll forming apparatus for a simultaneous forming. The method of claim 1, The welding roller unit Two lower electrode rollers rotatably configured at a lower portion on the frame to support both ends of the composite blank material press-molded from the pressing roller unit from below; Rotation is formed on the upper portion on the frame, the both sides of the upper electrode rollers for continuous welding by energizing both ends of the composite blank material in the advancing direction from the top with the lower electrode rollers; Device. The method of claim 6, The upper electrode rollers on both sides Roll forming apparatus for simultaneous molding, characterized in that connected by the electrode rod rotatably installed in the frame. In the roll forming method for simultaneous molding, A first uncoil step of releasing the coil to be supplied for the core panel through the first uncoiler on the process line; (S10) A core panel forming step of bending the strip-shaped steel sheet supplied from the first uncoil step in a zigzag shape through a roll core molding machine to form a core panel at the rear of the first uncoiler; (S20) A second uncoil step of releasing upper and lower coils, respectively, from the rear of the roll core forming machine to an upper side and a lower side of the core panel formed and supplied from the core panel forming step through a second uncoiler; (S30) In the rear of the second uncoiler, an alignment step of aligning the both ends of the core panel and the upper plate and the lower plate coils which are supplied to each other through a guide roller to align in a row; (S40) In the rear of the guide roller, the upper plate and the lower plate coil supplied to the upper side and the lower side of the core panel is energized through the upper and lower roller electrodes of the roller electric resistance welding machine to weld continuously to the sandwich type composite plate Step; (S50) A blanking step of cutting the belt-like composite plate material supplied from the roller electrical resistance welder through a blanking press to the size of the beam to be molded and processing it into a composite blank material at the rear of the roller electric resistance welder; (S60) A stamping step (S70) of pressing and molding the front and rear ends of the composite blank material supplied from the blanking press through a stamping press; Roll pressing step (S80) for pressing both sides of the composite blank material press-formed from the stamping step by the upper and lower pressure rollers in the advancing direction through the upper and lower pressure rollers; Roll welding step (S90) of the two side ends of the composite blank material compression-molded by the upper and lower pressure rollers in the advancing direction through the upper and lower electrode rollers for welding; And Simultaneous bending and molding of the composite blank material supplied through the final upper and lower electrode rollers from the previous step, the roll forming step (S100) comprising a roll forming step of forming a certain shape of the beam flow (S100) . The method of claim 3, The second uncoil step S30 is And releasing the upper coil supplied for the upper plate to the upper part of the core panel, and releasing the lower coil supplied for the lower plate to the lower part of the core panel.

Images