KR20170133957A - Roll forming system and method thereof - Google Patents

Abstract

Disclosed are an apparatus for forming a roll including an uncoiler, a straightener, a brake press, a roll forming unit, capable of ensuring productivity, and a method thereof. According to an embodiment of the present invention, the apparatus for forming a roll comprises: a frequency heater heating a forming beam using a frequency output from a frequency generator at a rear side of the roll forming unit to preheat an adhesion part; and a laser welder performing welding by radiating a laser beam while supplying a filler wire to the pre-heated adhesion part of the forming beam from a rear side of the frequency heater. The method for forming a roll includes: a preheating step of, by the frequency heater, preheating the adhesion part by heating the forming beam unit using a frequency output from the frequency generator from a rear side of the roll forming unit; and a welding step of performing welding by radiating a laser beam while supplying a filler wire to a filler metal from the heated adhesion part of the forming beam using the laser welder from the rear side of the frequency heater.

Description

[0001] DESCRIPTION [0002] ROLL FORMING SYSTEM AND METHOD THEREOF [

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a roll forming apparatus and a roll forming method, and more particularly, to a roll forming apparatus and a roll forming apparatus for performing laser welding by supplying filler wires to a joining portion of an aluminum plate, Roll forming method.

Generally, the roll forming method is to produce a forming beam by bending a roll former unit in which a coil is loosened to form a pair of upper rolls and lower rolls in a row, A beam of a linear type that is bent and formed into various shapes such as a beam is manufactured.

FIG. 1 is a general roll forming system for forming a roll forming system and its conceptual stepwise process concept. In a general roll forming system and its process, an uncoiler 1 for uncoiling a supplied coil 10 is arranged in front of a processing line A straightener 2 which forms an uncoiling step S1 and spreads the coil 10 unwound from the uncoiler 1 to the flat panel 20 is provided on the rear side thereof to perform a straightening step S2, Respectively.

The panel 20 supplied from the straightener 2 is provided at the rear of the straightener 2 with a brake press 3 for forming holes for various purposes for assembling the formed beam, ).

The roll forming unit 4 composed of at least ten roll formers R1 to R10 (not shown) is disposed behind the brake press 3 to rotate the uncoiler 1, the straightener 2 ) And the panel 20 supplied through the brake press 3 are successively subjected to a roll forming step S4 in which a forming beam 30 to be obtained is subjected to roll forming.

When the shaping beam 30 has a closed end shape, a laser welding apparatus 5 for welding both ends of the shaping beam 30 is provided at the rear of the roll forming unit 4 to proceed the welding step S5.

2, a laser welding apparatus 5 such as a laser scanner is provided in the welding step S5 in such a roll forming system and its stepwise process to irradiate the laser beam outputted from the laser oscillator 51 And the welding position on the forming beam 30 is irradiated.

On the other hand, in the case where the forming beam 30 has a closed end shape, the laser welding apparatus 5 for welding both ends of the forming beam 30 has a constant The front and rear guide roller units 53 and 55 are provided at intervals to guide the movement of the forming beam 30.

The conventional guide roller units 53 and 55 are configured such that the upper and lower guide rollers R1 and R2 rotatably installed on the frame F are disposed on the upper surface of the joining portion W of the forming beam 30, So as to support the lower surface thereof.

In recent years, a beam of a bumper beam or the like is applied to a vehicle body by using an aluminum plate material in order to reduce the weight of the vehicle body.

As described above, the aluminum plate material has a disadvantage in that, when the joining portion is welded through the focus welding of the laser beam using a conventional laser welding apparatus, welding failure occurs due to generation of pores therein. Therefore, depending on the material of the material, the welding method to be applied should be different according to the examination of the weldability and the quality control of the weld.

An embodiment of the present invention is to provide a roll forming apparatus and a roll forming method capable of ensuring bonding quality and productivity by laser welding while supplying filler wires to a joining portion of a roll formed forming aluminum formed beam.

Further, by preheating the joining portion of the aluminum formed beam through the heating unit before the welding step, the joining strength can be ensured by increasing the initial heat input amount of the joining portion to induce sufficient penetration of the filler wire, Roll forming method.

A further object of the present invention is to provide a roll forming apparatus and a roll forming method capable of ensuring the quality of welding by shielding the joining portion with air by supplying a shield gas to the joining portion of the aluminum formed beam.

According to one or more embodiments of the present invention, there is provided an uncoiler which is formed at a widthwise center of the front of a process line and uncoils and supplies a coil, a straightener for uncoiling the coil unwound from the uncoiler at the rear of the uncoiler, A brake press for forming holes for various purposes for assembling the beam to be formed in the flat coil supplied from the straightener and a flat coil supplied from the rear of the brake press through the straightener and the brake press are successively bent A method of manufacturing a roll forming apparatus comprising a roll forming unit that rolls a forming beam having a predetermined shape, the method comprising the steps of: heating a forming beam using a high frequency output from a high frequency generator at a rear side of the roll forming unit, A heater; And a laser welder for irradiating and welding the laser beam while supplying the filler wire to the preheated joint portion of the forming beam at the rear of the high frequency heater.

Further, the high frequency heater may be a high frequency induction heater.

The laser welder may further include: a frame installed on the base; An optical head provided on a bottom surface of the upper plate of the frame to irradiate a laser beam output from the laser oscillator to a junction of the formed beam; And a wire feed pipe that is fixed to the front of the optical head and feeds the filler wire supplied from the wire feeder to a focal point of the laser beam irradiated to the junction of the forming beam.

Further, the laser welder is fixed to one side of the frame rearward in the process direction in a state where it is disposed in correspondence with the joining portion of the forming beam, and is connected to the shield gas supplier through a gas supply pipe, And may further include an injection nozzle.

Further, the coil may be an aluminum coil.

In one or more embodiments of the present invention, an uncoil step for uncoiling a coil to be supplied for forming by using an uncoiler is provided in front of a process line. (S1) (S2) a flattening step of stretching the coil unwound from the uncoiled step to a flat coil; (S2) a step of winding the flat coil from the straightening step using a brake press at the rear of the straightener, (S3) a step of bending the planar coils supplied from the piercing step sequentially by using a roll forming unit comprising a multi-stage roll former at the rear of the brake press, A roll forming step of roll forming into a beam shape; (S4) A preheating step of heating the forming beam by using a high frequency output from the high frequency generator at a rear side of the roll forming unit to preheat the joining part; (S5) And a welding step (S6) of irradiating and welding a laser beam while supplying the filler wire to the preformed joint of the forming beam with the filler material.

Further, in the welding step (S6), a shield gas supplied from a shield gas supplier through a gas supply pipe through a gas injection nozzle arranged corresponding to a junction part of the forming beam may be injected to the joint part.

Further, in the welding step (S6), the filler wire may be supplied to the focal point of the laser beam irradiated on the junction of the forming beam.

The coil may be an aluminum coil.

The embodiment of the present invention can ensure the quality and productivity of the bonding by laser welding while supplying the filler wire to the joining portion of the aluminum formed beam that has been roll-formed.

In addition, by preheating the joining portion of the aluminum formed beam through the heating unit before the welding step, the initial heat input amount of the joining portion can be increased to induce sufficient penetration of the filler wire to secure the joining strength.

Further, a shield gas is supplied to the joining portion of the aluminum formed beam to shield the joining portion from the air, thereby ensuring the welding quality.

1 is a general roll forming system and its step-by-step process diagram.
2 is a process diagram of a welding step to which a laser welding apparatus according to the prior art is applied.
3 is a block diagram of a roll forming system according to an embodiment of the present invention.
4 is a process diagram of a preheating step to which a heating unit applied in an embodiment of the present invention is applied and a welding step to which a laser welding apparatus is applied.

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

It is to be understood, however, that the present invention is not limited to the illustrated embodiments, and that various changes and modifications may be made without departing from the spirit and scope of the invention. .

In order to clearly explain the embodiments of the present invention, parts that are not related to the description are omitted, and the same or similar components are denoted by the same reference numerals throughout the specification.

FIG. 3 is a process diagram of a roll forming system according to an embodiment of the present invention, and FIG. 4 is a pre-heating step to which a heating unit applied in an embodiment of the present invention is applied and a welding step to which a laser welding apparatus is applied.

Referring to FIG. 3, in the roll forming apparatus according to the embodiment of the present invention, the uncoiler 1 is formed at the center front of the process line.

A straightener 2 is arranged behind the uncoiler 1 to spread the coil 10 unwound from the uncoiler 1 to the flat plate 20. [

Here, the coil 10 is an aluminum coil material.

A brake press 3 is provided behind the straightener 2 to form holes for various purposes for assembling the beam to be formed on the flat plate 20 supplied from the straightener 2. [

A roll forming unit 4 is formed at the rear of the brake press 3 so as to sequentially form a flat plate 20 supplied via the straightener 2 and the brake press 3 to form molding beams (30).

The roll forming unit 4 is constituted by arranging roll formers R1, R2, ..., R9 and R10 (not shown) of at least 10 stages in a row.

4, the molding beam 30 is rapidly heated to a predetermined temperature by using a high frequency output from the high frequency generator 61, and a high frequency (preheating) temperature of the bonding portion W is applied to the rear of the roll forming unit 4 A heater 6 is provided.

At this time, the high frequency heater 6 may be a high frequency induction heater.

A laser welder 5 for supplying a filler wire 57b to the preheated welding portion W of the forming beam 30 while irradiating the welding beam with a laser beam is provided at the rear of the high frequency heater 6.

Here, the laser welder 5 is provided with a frame 5a on a base 9, and an optical head 5c is provided on a lower surface of the upper plate 5b of the frame 5a.

The optical head 5c irradiates the laser beam outputted from the laser oscillator 51 to the junction W of the forming beam 30. [

A wire feed pipe 57a is fixed to the front of the optic head 5c so that the filler wire 57b supplied from the wire feeder 57 is inserted into the bonding portion W of the forming beam 30, To the focus portion.

The laser welder 5 further includes a gas injection nozzle 59a which is disposed in correspondence with the junction W of the forming beam 30, 5a in the process direction.

The gas injection nozzle 59a is connected to the shield gas supply unit 59 through the gas supply pipe 59b and continuously injects and shields the shield gas to the joint W to cut off the joint W from the air .

Therefore, in the roll forming method using the roll forming apparatus having the above-described configuration, as shown in FIG. 3, first, the coil 10 to be supplied for forming by using the uncoiler 1, (Step S1).

The uncoil step S1 is followed by a straightening step of straightening the coil 10 uncoiled from the uncoil step S1 to the flat plate 20 by using a straightener 2 at the rear of the uncoiler 1, (S2). ≪ / RTI >

The flat plate 30 supplied from the straightening step S3 uses a brake press 3 at the rear of the straightener 2 to form holes for various purposes for assembling the beam to be formed. The process proceeds to step S3.

And a flat plate (not shown) supplied from the piercing step S3 by using a roll forming unit 4 comprising a multi-stage roll formers R1, R2, R9 and R10 (not shown) at the rear of the brake press 3 30 are sequentially bent and formed into an incomplete shape of the forming beam 30 to be obtained.

4, the high frequency heater 6 heats the forming beam 30 to a predetermined temperature by using a high frequency output from the high frequency generator 61, W) is preheated in advance.

The molding beam 30 preheated at the junction W is heated at the rear of the high frequency heater 6 by the laser welder 5 to the preheated junction W of the molding beam 30, The welding step S6 is performed in which the laser beam is irradiated and welded while the wire 57b is supplied as a sparse material.

In this welding step S6, the shield gas supplied from the shield gas supplier 59 through the gas supply pipe 59b through the gas injection nozzle 59a arranged corresponding to the junction W of the forming beam 30 The shield gas is welded to the welding portion W, which shields the welding portion W from the air, thereby improving the welding quality.

At this time, in the welding step S6, the filler wire 57b is supplied to the focal portion of the laser beam irradiated on the joining portion W of the forming beam 30.

In other words, the roll forming apparatus and the roll forming method according to the present invention as described above can secure the quality of the joining of the joining portion by laser welding while sufficiently supplying the filler material composed of the filler wire to the joining portion of the roll forming forming aluminum forming beam, The productivity can be improved.

In addition, by preheating the joining portion of the aluminum forming beam through the heating unit before the welding step, the initial heat input amount of the joining portion can be increased to secure sufficient joining strength by inducing sufficient penetration of the filler such as the filler wire.

In addition, shield gas is supplied to the joining portion of the aluminum forming beam to shield the joining portion from air, so that generation of pores inside the joining portion can be suppressed and welding quality can be improved.

While the present invention has been described with reference to exemplary embodiments, it is to be understood that the invention is not limited to the disclosed exemplary embodiments, but, on the contrary, And all changes to the scope that are deemed to be valid.

1: Uncoiler
2: Straightener
3: Brake press
4: Roll forming unit
5: Laser welding machine
5a: frame
5b: top plate
5c: Optic head
51: laser oscillator
57: Wire feeder
57a: wire feed pipe
57b: Filler wire
59: shield gas supply
59a: Gas injection nozzle
6: High frequency heater
61: High frequency generator

Claims (9)

An uncoiler which is disposed at the center in the width direction in front of the processing line and releases the coils and supplies the uncoiler; a straightener for flattening the coil unwound from the uncoiler at the rear of the uncoiler; And a plate coil supplied from the rear of the brake press through the straightener and a brake press are successively bent and formed into a shaped beam having a constant shape by roll molding A roll forming apparatus including a roll forming unit,
A high frequency heater for heating the formed beam by using a high frequency output from the high frequency generator at a rear portion of the roll forming unit to preheat the joined portion;
A laser welder for irradiating and welding a laser beam while feeding filler wires to the preheated joint portion of the formed beam at the rear of the high frequency heater;
The roll forming apparatus comprising: The method according to claim 1,
The high-
Wherein the high-frequency induction heater is a high-frequency induction heater. The method according to claim 1,
The laser welder
A frame installed on the base;
An optical head provided on a bottom surface of the upper plate of the frame to irradiate a laser beam output from the laser oscillator to a junction of the formed beam;
A wire feed pipe fixed to the front of the optical head to supply a filler wire supplied from a wire feeder to a focal point of a laser beam irradiated to a junction of the forming beam;
. The method according to claim 1,
The laser welder
And a gas injection nozzle fixed to one side of the frame in the process direction in a state corresponding to the junction of the forming beams and connected to the shield gas supplier through a gas supply pipe to inject shield gas to the junction and supply the shield gas, Roll forming device. The method according to claim 1,
Wherein the coil is an aluminum coil. An uncoil step for uncoiling a coil to be supplied for forming by using an uncoiler at the front of the process line; (S1) a step of uncoiling the coil unwound from the uncoiled step using a straightener at the back of the uncoiler, (S2) a piercing step for forming holes for various purposes for assembling the beam to be formed on the flat coil supplied from the straightening step, using a brake press, in the rear of the straightener; S3 A roll forming step of performing roll forming in the shape of a forming beam to be obtained by successively bending the flat plate coils supplied from the piercing step by using a roll forming unit comprising a multi-stage roll former at the rear of the brake press; (S4), comprising:
A preheating step of heating the shaped beam by using a high frequency output from the high frequency generator at the rear of the roll forming unit to preheat the joined part;
A welding step (S6) of irradiating and welding a laser beam while supplying a filler wire to the preheated joint portion of the formed beam using a laser welder from behind the high frequency heater;
/ RTI > The method of claim 6,
Wherein in the welding step (S6), a shield gas supplied from a shield gas supplier through a gas supply pipe through a gas injection nozzle arranged corresponding to a junction part of the forming beam is injected to the joining part. The method according to claim 6,
Wherein in the welding step (S6), the filler wire is supplied to a focal portion of the laser beam irradiated on the junction of the forming beam. The method according to claim 6,
Wherein the coil is an aluminum coil.

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