KR20090053081A - Roll forming system for sandwich panel and method thereof - Google Patents

Abstract

According to the present invention, in the process of integrally welding a mesh-shaped core panel between a top plate and a bottom plate to form a sandwich panel through a single roll forming process, the welding point is scanned after a welding step using a roller electric resistance welder. The present invention provides a roll forming apparatus for a sandwich panel and a method thereof, by performing additional high-speed laser welding to the welding spot by using a laser beam, thereby reinforcing the bonding force between the panels to roll forming a molded article of good quality.

Roll Forming, Co-Forming, Forming Beams, Sandwich Panels, Laser Welding

Description

Roll forming apparatus for sandwich panel and its method {ROLL FORMING SYSTEM FOR SANDWICH PANEL AND METHOD THEREOF}

The present invention relates to a roll forming apparatus for a sandwich panel and a method thereof, and more particularly, to form a sandwich type panel by integrally welding a mesh-shaped core panel between a top plate and a bottom plate through one roll forming process. At the same time, the present invention relates to a roll forming apparatus for a sandwich panel and to a method for forming a roll forming into a certain shape.

In general, a straight beam type such as a bumper beam of a vehicle is formed by a roll forming apparatus for bending and molding a panel supplied by a roll former consisting of an upper roll and a lower roll arranged in a row of 10 or more stages into various shapes.

Recently, a study of a bumper beam using a sandwich panel is being conducted to produce a straight beam type such as a bumper beam requiring excellent collision absorption performance as described above. Korean Patent Application No. 10-2006-0134444 (2006) (December 27, application) discloses a roll forming apparatus and a method for simultaneously forming a beam stream such as a vehicle bumper beam by applying such a sandwich panel.

Referring to FIG. 1, a roll forming apparatus and a method of applying the conventional sandwich panel will be briefly described. In the roll forming apparatus according to the related art, a first uncoiler 101 is formed on a process line in front of a coil to be supplied for a core panel. (111) is provided to release.

Behind the first uncoiler 101 by using a serrated upper roll 121 and the lower roll 123, the strip-shaped steel sheet released from the first uncoiler 101 is bent and trimmed in a zigzag shape to form a net shape. The roll core molding machine 102 which is shape | molded by the core panel 110 of this is comprised.

In addition, the upper coil 131 and the lower coil are supplied to the upper and lower plates of the upper and lower sides of the core panel 110 formed and supplied from the roll core molding machine 102 at the rear of the roll core molding 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 110 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, a guide roller 104 is formed at the rear of the second uncoiler 103 on the process line to guide and align both ends of the core panel 110 and the upper plate and the lower plate coils, which are supplied to each other in a row. .

At the rear of the guide roller 104, an upper plate and a lower plate coil supplied to the upper side and the lower side of the core panel 110 are energized through the upper and lower roller electrodes 51 and 53, respectively. A roller electric resistance welder 105 is welded by electric resistance and continuously welded to the sandwich panel 120.

A brake press 106 is formed at the rear of the roller electric resistance welder 105 to form holes for various applications for assembling bumper beams to be formed in the strip-shaped sandwich panel 120 supplied from the roller electric resistance welder 105. Is composed.

10 or more stages of roll formers R1 to R7 (not shown) are arranged in a row at the rear of the brake press 106 so that the first uncoiler 101, the roll core forming machine 102, and the second uncoiler ( 103, the sandwich panel 120 supplied through the guide roller 104, the roller electric resistance welder 105, and the brake press 106 are sequentially bent, and the sandwich panel 120 as shown in FIG. 2 is formed. Roll former unit (R) for forming a roll forming to the bumper beam 130 is configured.

The roll forming method for simultaneous forming for forming the bumper beam 130 to which the sandwich panel 120 is applied using the conventional roll forming apparatus is first formed on the process line in front of the first uncoiler ( The first uncoil step S110 for releasing the coil 111 to be supplied to the roll core molding machine 102 through the core panel 101 is performed.

At the rear of the first uncoiler 101, the strip-shaped steel sheet supplied from the first uncoiler step S110 is bent and trimmed in a zigzag shape through a roll core molding machine 102 to form a mesh core panel 110. The core panel molding step (S120) of molding to proceed.

Subsequently, in the core panel forming step S120, the core panel 110 formed by the roll core molding machine 102 passes through the second uncoiler 103 and the upper coil 131 on the second uncoiler 103. ) And the lower coil 133 is released so as to overlap the upper plate and the lower plate for the upper plate and the lower plate to proceed with the second uncoil step (S130).

As described above, in the second uncoiler 103, the core panel 110, the upper plate and the lower plate coils (ie, the upper coil 131 and the lower coil 133) which are supplied to overlap each other, have both ends thereof. The alignment step (S140) is guided by the guide roller 104 is formed in 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 110 are energized through the upper and lower roller electrodes 151 and 153 of the roller electric resistance welding machine 105. The welding step (S150) of continuously welding to the sandwich panel 120 is performed.

Subsequently, at the rear of the roller electric resistance welder 105, various uses for assembling the bumper beam 130 to be molded through the brake press 106 on the strip-shaped composite plate 120 supplied from the welding step S150. The piercing step (S160) of piercing the hole of the proceeds.

As described above, the bands undergoing the first uncoil step S110 and the core panel forming step S120, the second uncoil step S130, the alignment step S140, the welding step S150, and the piercing step S160 are performed. Sandwich panel 20 of the upper is guided to the roll former unit (R) to be sequentially formed in the course of passing through each of the roll former (R1 ~ R7; not shown), as shown in Figure 2, bumper beam 130 The roll forming step (S170), which is roll forming with a beam flow such as), is performed.

However, the bumper beam 130, which is roll-formed into a sandwich panel through the conventional co-molding roll forming apparatus as described above, is welded (S150) to the upper coil 131 on the upper side and the lower side of the core panel 110. ) And the lower coil 133 are overlapped, and simply welded by energizing the upper and lower roller electrodes 151 and 153 of the roller electric resistance welding machine 105, as shown in FIG. 3, the core panel 110. With respect to the welding points of the upper coil 131 or the lower coil 133, almost no weld joints W are formed, and thus the bonding strength is weak, so that the upper plate 131 is formed from the core panel 110 during the forming in the roll forming step S170. The lower plate 133 is easily separated and broken, which causes a problem of product defects.

Accordingly, the present invention has been invented to solve the problems of the prior art as described above, an object of the present invention sandwich the core panel of the mesh shape between the upper plate and the lower plate by integrally welding through a single roll forming process sandwich In the process of forming the panel, following the welding step through the roller electric resistance welding machine, the welding spot is scanned and further high-speed laser welding of the welding spot is performed by using a laser beam to reinforce the bonding strength between the panels to provide good quality. The present invention provides a roll forming apparatus for a sandwich panel and a method thereof, which enable roll forming of a molded article.

The roll forming apparatus for a sandwich panel of the present invention for realizing the above object comprises: a first uncoiler releasing a coil configured and supplied at a front side on a process line; A roll core molding machine provided at a rear of the first uncoiler to bend and trim a strip-shaped steel sheet released from the first uncoiler into a zigzag mesh structure 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; A roller electric resistance welding machine configured to be connected to the upper and lower coils of the upper and lower plates of the core panel, which are configured behind the guide rollers on the process line, and are continuously welded to the sandwich panel through the upper and lower roller electrodes; A laser welding unit scanning a welding point of the sandwich panel welded by the roller electric resistance welding machine on the processing line, and irradiating a laser beam to each welding point according to the scan information to perform laser welding; A brake press configured at the rear of the laser welding unit on the processing line to form holes for various uses for assembling the forming beam to be formed in a strip-shaped sandwich panel supplied from the laser welding unit; And a roll former unit, in which a plurality of roll formers are arranged in a row at the rear of the brake press, sequentially bending and forming a strip-shaped sandwich panel supplied through the final brake press from the previous process, and roll forming the rolled beam with the forming beam. .

The second uncoiler is mounted on the upper upper coil supplied to the upper plate, and the lower coil 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.

And the laser welding unit is mounted on one side of the welder frame on the process line scanner for scanning the welding point of the sandwich panel welded by the roller electric resistance welder to output the scan information; A long distance laser welder which performs laser welding by irradiating a laser beam to each welding point on the upper and lower plates of the sandwich panel according to the control signal; And a controller for analyzing the scan information of the welding spot output from the scanner and outputting a control signal to the remote laser welder.

And the roll forming method of the sandwich panel using the roll forming apparatus for a sandwich panel as described above, the first uncoil step of releasing the coil to be supplied for the core panel through the first uncoiler is configured on the process line; S1) the core panel forming step of bending the belt-shaped steel sheet supplied from the first uncoiler step into a zigzag mesh structure through a roll core forming machine to form a core panel at the rear of the first uncoiler; (S2 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 which is formed and supplied from the core panel forming step through a second uncoiler at the rear of the roll core forming machine; At the rear of the second uncoiler, both side ends of the core panel, the upper plate, and the lower plate coil, which are supplied to each other, are guided through a guide roller. Alignment step of aligning in a row; (S4) 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 welder to the sandwich panel Welding step of continuous welding; (S5) In the back of the roller electrical resistance welding machine, the welding spot of the welded sandwich panel is scanned, and the long-range laser welder irradiates a laser beam to each welding spot according to the scan information A laser welding step of performing laser welding; (S6) In the rear of the remote laser welding machine, a piercing processing of various uses for the assembly of the forming beam to be formed in the strip-shaped sandwich panel supplied from the remote laser welding machine with a brake press Piercing step; (S7) In the rear of the brake press, the final bra from the previous step That in the sandwich panel on the strip supplied through the bending press molding sequentially comprising a roll former step (S8) for forming a roll forming the shaped beam it is characterized.

The second uncoil step (S3) is characterized in that the upper coil supplied for the upper plate is released to the upper part of the core panel, and the lower coil supplied for the lower plate is released to the lower part of the core panel.

And the laser welding step (S6) is a step of outputting the scan information by scanning the welding point of the sandwich panel welded by the roller electric resistance welder through a scanner mounted on one side of the welder frame on the process line; Analyzing the position coordinates of each welding point on the upper plate and the lower plate of the sandwich panel from the welding point scan information output from the scanner and outputting a control signal to the remote laser welder; (S62) Remote laser welder in accordance with the control signal Irradiating a laser beam to each welding point on the upper plate and the lower plate of the sandwich panel to perform laser welding; (S63) characterized in that consisting of.

As described above, according to the roll forming apparatus and method for a sandwich panel according to the present invention, a mesh panel core panel between the upper plate and the lower plate is integrally welded through a single roll forming process to form a sandwich panel. In the process, following the welding step through the roller electric resistance welding machine, the welding spot is scanned and further high-speed laser welding is performed on the welding spot using a laser beam to sufficiently form a fusion joint at the welding spot between the sandwich panels. It reinforces the bonding force, and thus has the effect of producing a roll forming molded article of good quality.

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 for a sandwich panel and a step-by-step process according to an embodiment of the present invention, Figure 5 is a block diagram of a laser welding unit applied to a roll forming apparatus for a sandwich panel according to an embodiment of the present invention, 6 is a detailed flowchart of a laser welding step applied to a roll forming method of a sandwich panel according to an exemplary embodiment of the present invention.

In the configuration of the roll forming apparatus for a sandwich panel according to an embodiment of the present invention, as shown in FIG. 4, a coil to be supplied for the core panel is configured with a first uncoiler 1 formed on the front of the process line. 11) is provided to release.

Behind the first uncoiler (1) trims a band-shaped steel sheet released from the first uncoiler (1) using a sawtooth upper roll (21) and a lower roll (23) in a zigzag mesh structure. The roll core molding machine 2 which shape | molds and shape | molds to the core panel 10 is comprised.

In addition, an upper coil 31 and a lower coil supplied to the upper and lower plates of the upper and lower sides of the core panel 10 which are molded and supplied from the roll core forming machine 2 are respectively located behind the roll core forming machine 2. The second uncoiler 3 is configured to release 33).

Here, the second uncoiler (3) is mounted on the upper coil 31, which is supplied for the upper plate on the upper side, spaced apart a predetermined interval so that the core panel 10 passes through the lower portion of the upper coil (31) In the state, the lower coil 33 supplied for the lower plate is provided.

In addition, the guide roller for aligning the two ends of the core panel 10 and the upper coil 31 and the lower coil 33 which are supplied to each other at the rear of the second uncoiler 3 on the process line in a row. (4) is comprised.

At the rear of the guide roller 4, the upper coil 31 and the lower coil 33 supplied to the upper side and the lower side of the core panel 10 are energized through the upper and lower roller electrodes 51 and 53, respectively. The roller electric resistance welding machine 5 which welds by the core panel 10 and electric resistance, and continuously welds to the sandwich panel 20 is comprised.

Then, the welding spots by electric resistance welding of the sandwich panel 20 welded by the roller electric resistance welding machine 5 are scanned on the process line, and the laser beams are irradiated to the respective welding spots according to the scan information. A laser welding unit 6 for performing laser welding is provided.

Here, the laser welding unit 6 is, as shown in Figure 5, the scanner 61 is mounted on one side of the welder frame 64 on the process line, the sandwich welded by the roller electric resistance welder (5) It is configured to scan the welding point of the panel 20 and output the scan information.

In addition, the welder frame 64 is configured with a remote laser welding machine 630 in the upper and lower portions, respectively, in accordance with a control signal for each welding point on the upper coil 31 and the lower coil 33 of the sandwich panel 20. LB) is irradiated and laser welding is performed.

The scanner 61 and the remote laser welder 63 are electrically connected to the controller 65. The controller 65 analyzes the scan information of the welding spot output from the scanner 61 and the remote laser welder 63. Has a control logic to output a control signal.

In addition, a brake press 7 is formed at the rear of the laser welding unit 6 to form holes for various uses for assembling the forming beam to be formed in the strip-shaped sandwich panel 20 supplied from the remote laser welding machine 63. do.

10 or more stages of roll formers R1 to R7 (some not shown) are arranged in a row at the rear of the brake press 7 so that the first uncoiler 1, the roll core forming machine 2, and the second uncoiler ( 3), the sandwich panel 20, which is supplied through the guide roller 4, the roller electric resistance welding machine 5, the laser welding unit 6 and the brake press 7, is sequentially bent and molded, as shown in FIG. The roll former unit R which roll-forms by the shaping | molding beam 30 using the sandwich panel 20 as described above is comprised.

Therefore, the roll forming method of the sandwich panel for roll forming the forming beam 30 using the sandwich panel 20 by using the roll forming apparatus for sandwich panels having the above-described configuration is as shown in FIG. 4. Similarly, first, on the process line, a first uncoiled step S1 for releasing the coil 11 to be supplied to the roll core forming machine 2 for the core panel through the first uncoiler 1 is performed. Proceed.

At the rear of the first uncoiler 1, the strip-shaped steel sheet supplied from the first uncoiler step S1 is bent and trimmed into a zigzag mesh structure through a roll core forming machine 2 to form a core panel 10. The core panel molding step S2 is performed.

Subsequently, the core panel 10 formed by the roll core molding machine 2 in the core panel forming step S2 passes through the second uncoiler 3 and the upper coil 31 on the second uncoiler 3. ) And the lower coil 33 are unrolled so as to overlap the upper plate and the lower plate for the upper plate and the lower plate to proceed with the second uncoil step S3.

Here, in the second uncoil step S3, the upper coil 31 supplied to the upper plate is released to the upper portion of the core panel 10, and the lower coil 33 supplied to the lower plate is the core panel. Loosen to the bottom of (10).

As described above, in the second uncoiler 3, the core panel 10, the upper coil 31, and the lower coil 33, which are supplied overlapping with each other, are both rear ends of the second uncoiler 3. Guided by the guide roller (4) is configured to proceed to the alignment step (S4) aligned in a line.

At the rear of the guide roller 4, the upper coil 31 and the lower coil 33 supplied to the upper side and the lower side of the core panel 10 are supplied with upper and lower roller electrodes of the roller electric resistance welding machine 5. 51 and 53, the welding step (S5) of continuous welding to the sandwich panel 20 is conducted.

Subsequently, at the rear of the roller electric resistance welding machine 5, the welding spot of the welded sandwich panel 20 is scanned, and the remote laser welding machine 63 performs a laser beam (for the respective welding spot according to the scan information). The laser welding step S6 of irradiating the laser beam LB) is performed.

Here, the laser welding step (S6), as shown in Figure 6, welded by the roller electric resistance welder 5 through a scanner 61 mounted on one side of the welder frame 64 on the process line. The welding point of the sandwich panel 20 is scanned and the scan information is output (S61).

Then, the controller 65 analyzes the position coordinates of each welding point on the upper coil 31 and the lower coil 33 of the sandwich panel 20 from the welding point scan information output from the scanner 61. The control signal is output to the remote laser welding machine 63 (S62).

Subsequently, the remote laser welding machine 63 performs laser welding by irradiating a laser beam LB to each welding point on the upper coil 31 and the lower coil 33 of the sandwich panel 20 according to the control signal. (S63)

Here, when the laser welding step (S6) as shown in FIG. 6 is further performed by the above-described sandwich panel roll forming apparatus, as shown in FIGS. 7 and 8, the core panel 10 is attached to the core panel 10. With respect to each of the welding points of the upper coil 31 and the lower coil 33, the fusion joints W are sufficiently formed to improve the mutual bonding force, which is the core panel 10 during molding in the subsequent roll forming step S8. The upper coil 31 and the lower coil 33 are prevented from being broken apart from each other to ensure the quality of the molded article.

Subsequently, in the rear of the remote laser welding machine 63, various uses for assembling the shaping beam 30 to be molded through the brake press 7 to the sandwich panel 20 with the bonding force reinforced from the laser welding step S6. The piercing step (S7) of piercing the hole of is proceeded.

As such, the first uncoil step S1 and the core panel forming step S2, the second uncoil step S3, the alignment step S4, the welding step S5, the laser welding step S6, and the piercing are performed. The strip-shaped sandwich panel 20 which has undergone the step S7 is guided to the roll former unit R to be bent and sequentially formed in the course of passing through each of the roll formers R1 to R7 (not shown). The roll forming step (S8) is formed by roll forming the bumper beam 30 as shown.

1 is a roll forming apparatus for a sandwich panel according to the prior art and the process step by step conceptual view thereof.

2 is a perspective view showing an example of a roll forming apparatus for a sandwich panel and a bumper beam formed by the method according to the prior art.

3 is a cross-sectional view of the junction portion of the sandwich panel according to the prior art.

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

5 is a configuration diagram of a laser welding unit applied to the roll forming apparatus for a sandwich panel according to an embodiment of the present invention.

6 is a detailed flowchart of a laser welding step applied to a roll forming method of a sandwich panel according to an exemplary embodiment of the present invention.

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

8 is a cross-sectional view of the junction portion of the sandwich panel according to the present invention.

Claims (6)

In the roll forming apparatus for a sandwich panel, 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 to bend and trim a strip-shaped steel sheet released from the first uncoiler into a zigzag mesh structure 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; A roller electric resistance welding machine configured to be connected to the upper and lower coils of the upper and lower plates of the core panel, which are configured behind the guide rollers on the process line, and are continuously welded to the sandwich panel through the upper and lower roller electrodes; A laser welding unit scanning a welding point of the sandwich panel welded by the roller electric resistance welding machine on the processing line, and irradiating a laser beam to each welding point according to the scan information to perform laser welding; A brake press configured at the rear of the laser welding unit on the processing line to form holes for various uses for assembling the forming beam to be formed in a strip-shaped sandwich panel supplied from the laser welding unit; A roll former unit is formed by arranging a plurality of roll formers in a row at the rear of the brake press and sequentially bending and forming a strip-shaped sandwich panel supplied through the final brake press from the previous process to roll forming the rolled beam into the forming beam. Roll forming apparatus for a sandwich panel characterized by the above-mentioned. The method of claim 1, The second uncoiler is The upper coil to be supplied for the upper plate is mounted on the upper portion, sandwiching the lower coil is provided for the lower plate in a state spaced apart a predetermined interval so that the core panel passes through the lower coil Roll forming device. The method of claim 1, The laser welding unit A scanner mounted on one side of the welder frame on the process line and scanning a welding point of the sandwich panel welded by the roller electric resistance welding machine to output the scan information; A long distance laser welder which performs laser welding by irradiating a laser beam to each welding point on the upper and lower plates of the sandwich panel according to the control signal; Roll forming apparatus for a sandwich panel comprising a controller for analyzing the scan information of the welding point output from the scanner to output a control signal to the remote laser welder. In the roll forming method of the sandwich panel, A first uncoil step of releasing a coil to be supplied to the core panel through the first uncoiler on the process line; (S1) A core panel forming step of forming a core panel by bending and forming a strip-shaped steel sheet supplied from the first uncoil step into a zigzag mesh structure through a roll core forming machine at the rear of the first uncoiler; (S2) A second uncoil step of releasing the upper and lower coils, respectively, from the rear of the roll core forming machine to the upper and lower sides of the core panel which is formed and supplied from the core panel forming step through a second uncoiler; (S3) Aligning step of aligning the two end ends of the core panel and the upper plate and the lower plate coils which are supplied overlapping each other in a row in the rear of the second uncoiler through a guide roller; (S4) A welding step of continuously welding the upper plate and the lower plate coils supplied to the upper side and the lower side of the core panel through the upper and lower roller electrodes of the roller electric resistance welding machine at the rear of the guide roller and continuously welding them to the sandwich panel; (S5) A laser welding step of scanning a welding point of the welded sandwich panel at the rear of the roller electric resistance welding machine, and performing a laser welding by irradiating a laser beam to the respective welding point according to the scan information; (S6) A piercing step of piercing a hole for various uses for assembling a shaping beam to be formed in a strip-shaped sandwich panel supplied from the remote laser welder at the rear of the remote laser welder; (S7) In the rear of the brake press, a sandwich panel comprising a roll former step (S8) of sequentially bending and forming a strip-shaped sandwich panel supplied from the previous process via the final brake press to roll forming into the forming beam. Roll forming method. The method of claim 4, wherein The second uncoil step S3 is Roll forming method of the sandwich panel, 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. The method of claim 4, wherein The laser welding step (S6) Scanning a welding point of the sandwich panel welded by the roller electric resistance welding machine through a scanner mounted on one side of the welding machine frame on the process line and outputting the scan information; (S61) Analyzing position coordinates of each welding point on the upper plate and the lower plate of the sandwich panel from the welding point scan information output from the scanner, and outputting a control signal to a remote laser welding machine (S62) According to the control signal, a remote laser welding step of irradiating a laser beam to each welding point on the upper plate and the lower plate of the sandwich panel to perform laser welding; (S63) roll forming method of a sandwich panel, characterized in that consisting of.

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