RU2184634C2 - Automated line for making thin-wall bent shapes - Google Patents

Abstract

FIELD: equipment for making thin-wall bent shapes. SUBSTANCE: automated line includes uncoiler, feeding unit, guiding unit, shape bending aggregate, apparatus for cutting off shape; measuring device and electric drive unit with control board; receiving table with knocking out member. In order to realize continuous operation mode of shape bending aggregate and to cut off predetermined length shape, line includes metering device with electronic control circuit. Electric heating furnace is used for shaping low-ductile materials. Shape bending aggregate includes bending-sizing unit for shaping flat blank and sizing shape by tension with use of roller pair and bending shape according to predetermined curvature. All apparatuses are in the form of separate units. In order to shape low- ductile materials, shape bending aggregate has electric furnace for heating rollers of shaping stands. EFFECT: enhanced quality of bent thin-wall shapes due to equalized remaining stresses, enlarged manufacturing possibilities due to heating hard-to-form materials, lowered metal consumption due to decreased number of transition stages. 2 cl, 2 dwg

Description

 The invention relates to the processing of metals by pressure, in particular to the manufacture of profiles from sheet blanks by roll profiling, and can be used in mechanical engineering, primarily in the aerospace industry, in the manufacture of thin-walled profiles from a wide range of materials.

 The claimed invention is aimed at solving the national economic problem: expanding technological capabilities in the manufacture of profiles from sheet blanks and improving their quality.

 It is known A.S. 278614 USSR, IPC В 21 D 5/06, "A mill for obtaining profiles from sheet blanks", published on 04/30/75, bull. 16, according to which profiles are obtained from sheet blanks of hardly deformable materials by rolling using a bending unit in the form of two inductors located one above the other. The mill contains a pre-bending device, also consisting of heating and forming inductors, calibrating a roller pair. Inductors act as concentrators of magnetic fields excited in them by currents from generators of strong current pulses. Inductors are made of high strength ceramics. The workpiece, moving in the rolling direction, gradually takes the form of a profile. The workpiece is profiled continuously, the gap in the inductors is regulated depending on the initial thickness of the workpiece.

The disadvantages of this analogue are:
- the production of profiles from a wide range of materials is not ensured, since inductors cannot change process parameters;
- there is no regulation of the profiling process by technological parameters;
- it is not clear how the workpiece is fed into the mill;
- the parameters of the profiling process and the finished profile are not controlled;
- bending of profiles with longitudinal curvature is not provided.

 There is also known a device for manufacturing profiles of a wide range of "Automatic Line" (PIEMME, VIA MONTEGRAPPA, 109, 30030, SALZANO-VE-ITALIA), including a feed roll, straightening rollers, a punch punch, a roller conveyor guide, a profiling machine (20 stands), a table guide, roller conveyor guide, die-cut stamp, table with ejector. The moment is transferred from the electric drive to the stand by a cross on both shafts (upper and lower). Bursting forces are compensated by an adjustable earring. Behind the last stand there are sensors measuring the deviation of the profile from the given parameters. There is the possibility of replacing shafts for profiling of any width (from 100 to 1500 mm).

The disadvantages of this analog can be considered:
- complication of the design due to the increased number of stands, transmission of torsion moment from the electric drive to two shafts at once;
- a significant increase in metal consumption due to the increased number of stands, the availability of auxiliary devices (two roller conveyors of guides, two tables: a guide and with a ejector);
- the impossibility of profiling blanks of difficultly deformed materials, since there are no heating devices.

 The closest in technical essence to the claimed invention is the device selected as a prototype "Automated line for the manufacture of thin-walled profiles", (A. p. 1796311, 21 D 5/06, publ. 02.23.1993 B.I. 7) . The known line contains a supply roll installed in the technological sequence in the form of an unwinder and a feeding device, a guiding device, a roll forming unit, installation of profile sections, a measuring device and an electric drive with a control panel, a receiving table with an actuator.

The prototype and the claimed invention have the following similar essential features:
- the line includes a feeding roll in the form of an unwinder and a feeding device, a guiding device, a roll forming unit, installation of profile sections, a measuring device and an electric drive with a control panel, a receiving table with an actuator;
- the main units of the line are mounted in the same technological sequence;
- profiling is carried out with the same workpiece thickness of 0.5-2.0 mm, that is, thin-walled profiles.

The disadvantages of the prototype are:
- profiling of the workpieces is carried out with small degrees of deformation, which increases the number of working stands, therefore, the intensity of the equipment;
- it is impossible to profile blanks of difficult to deform materials (aluminum-lithium, titanium, aluminum-beryllium, etc.);
- lubrication of profiled workpieces is not provided, which reduces the technological capabilities of the process and line;
- the impossibility of manufacturing a profile with longitudinal curvature;
- there is no control device that provides control of the parameters of the process of forming the profile and quantitative accounting.

 The technical result is the expansion of technological capabilities by installing heating devices, a combination of rolling drawing processes and improving the quality of profiles. These similar essential features are necessary to achieve a technical result.

 In relation to the prototype of the claimed invention has the following distinctive features.

 An electric heating furnace allows profiling of hardly deformed titanium, aluminum-lithium, aluminum-beryllium and similar alloys.

 A lubricating and feeding device with an individual drive allows lubrication of the workpiece and ensures its supply to the profiling unit.

 Guide device - adjustable, provides directional feed of the workpiece into the forming roller pairs.

 The five-stand drawing and rolling installation (roll forming unit) / Patent 2148455 / provides for the deformation of the workpiece with the creation of axial support and tension in the forming stands, the bending of the profile along the radius simultaneously with its calibration.

 The block of the counting device with the electronic control unit ensures the continuity of the profiling process, punching of fixing holes, and a section of the profile of a given length.

 The mounted furnace for heating the forming rollers provides the profiling of billets heated in the electric furnace.

 The invention is illustrated graphic materials. Figure 1 shows the layout of an automated line; figure 2 is a structural diagram of a counting device.

 The inventive device according to the first claim, "Automated line for the manufacture of thin-walled bent profiles" contains a supply roll 1 (Fig. 1), an electric heating furnace 2, a roll forming unit (PHA) 3, which includes a bending-calibration unit, installed in the technological sequence 4 with the possibility of its deviation in the direction of profiling, lubricating-feeding device 5, the block of the counting device 6 mounted on the frame of the roll forming unit, the guiding device adjustable 7, a device for cutting off a profile in the form of a stamp of volatile 8, a reception table with a trigger 9 and a control panel 10.

 The counting device (Fig. 2) consists of a frame 11, a housing 12, on which a sensor 13 is mounted. Inside the housing 12, a roller 15 is attached using the shaft 14, which is pressed against the workpiece by means of a spring 16.

 The control panel 10 and the counting device 6 are interconnected by an electronic control system.

 All units of the automated line are made by independent blocks on their base, are installed in the line along the floor rails and can be removed from the profiling line of plastic or low plastic materials.

 According to the second claim, the automated line comprises a mounted electric furnace for heating the rollers of the forming stands, which is fixed to the body of the roll forming unit.

 In the process, the workpiece from the supply roll 1, having an individual electric drive and feeding device, is sent to the lubricating and feeding device 5, and in the case of applying hot deformation, to the heating electric furnace 2, then through the counting device 6 and the guiding device adjustable 7 in the first pair rollers drawing and rolling installation 3 (figure 1). In the device 6, the photodiode converts the energy of the infrared ray of the LED into an electrical signal and sends a command to the sensor input of the reading device. The roll forming unit deforms the workpiece in roller pairs manufactured according to the accepted pattern of formation under conditions of tight bending with the creation of axial support at the inlet and axial tension at the output at the main forming transitions (2 and 4 stands). Accordingly, the signal given in the stamp of volatile 8 is a segment of the profile of a given length, which is fed to the receiving table with a reset device 9.

When deforming blanks of low-plastic materials heated in furnace 2 according to automatic control of installed thermocouples, a mounted electric furnace is installed on the roll forming unit to maintain the temperature of the roll forming tool within 200-250 ^o С. The furnace has a transparent screen, thermocouples at the input and output for automatic control of maintaining the set temperature.

 Refueling the workpiece in the units of an automated line - manually, profiling - automatic.

 The experimental testing of individual units of the line was carried out on the existing production base using the VPU-120 / 7.5 installation, bending and rolling machines like GPS-200, GPS-300, GPS-500. The main part of the automated line was developed on the basis of design calculations.

The claimed invention "Automated line for the manufacture of thin-walled bent profiles" is of interest to the national economy as it will allow:
- to produce cold formed sections from a wide range of sheet materials with a thickness of 0.6-2.5 mm with a molding depth of 50 mm;
- to produce bent profiles from hardly deformable materials under conditions of hot deformation at heating temperatures up to 400 ^o C;
- to reduce the metal consumption of the structure in comparison with the prototype by 2-2.5 times, since in conditions of tight bending it is enough to obtain profiles of complex section shape for 3-5 transitions;
- increase the accuracy of the process and the quality of the profiles due to the combination in the PHA of the processes of drawing and rolling, creating axial tension, which makes it possible to equalize the residual stresses over the cross section.

 The claimed technical solution does not adversely affect the state of the environment.

Claims (2)

 1. An automated line for the production of thin-walled bent profiles, containing a roll of a roll installed in the technological sequence in the form of an uncoiler and a feeding device, a guiding device, a roll forming unit, installation of profile sections, a measuring and electric drive with a control panel, a receiving table with a resetter, characterized in that it is equipped with an electric heating furnace installed behind the roll, a lubricating and feeding device with an individual drive, updated behind the heating furnace, a counting device with an electronic control unit to ensure continuous operation of the roll forming unit and profile sections of a given length installed behind the lubricating-feeding device, the roll forming unit has a bending-calibration unit for profiling a flat workpiece and calibrating the profile by stretching with a roller pair and bending profile of a given curvature, while all units are made in the form of independent blocks.  2. The automated line according to claim 1, characterized in that the roll forming unit has a mounted electric furnace for heating the rollers of the forming stands.

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