JP3737580B2 - Roll forming method and roll forming apparatus - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a roll forming method and roll forming apparatus for roll forming a plate material.
[0002]
[Prior art]
One example of a product manufactured by roll forming a plate material is a car door sash. 14 is a view showing an example of a car door sash, FIG. 15 is a view taken in the direction of arrow A in FIG. 14, and FIG. 16 is a cross-sectional view taken along the cutting line BB in FIG.
[0003]
14 and 15, 1 is a door and 2 is a door sash. In order to increase rigidity, the door sash 2 is gradually narrowed in the vehicle width direction and the vehicle length direction as it goes upward.
[0004]
The cross-sectional shape of the door sash 2 includes a hollow bag portion 2a formed by bending a plate material and a folded portion 2b formed by folding the plate material. Further, the folding portion 2b includes a first holder portion 2c for holding the door weather strip 3, a door glass run 2d, and an outer surface portion 2e exposed to the outside of the vehicle.
[0005]
On the other hand, the door sash 2 is roughly divided into a constant cross-section portion CD having a constant cross-sectional shape over the entire length and a variable cross-section portion VD having a change in cross-sectional shape from the viewpoint of manufacturing. In this case, the 1st and 2nd holders 2c and 2d are constant cross-sectional parts, and the bag part 2a and the outer surface part 2e are variable cross-sectional parts.
[0006]
Such a door sash 2 is obtained by forming a plate material by a roll forming method, then cutting the plate material to a predetermined length, and bending the plate material.
[0007]
[Problems to be solved by the invention]
However, when the door sash having the above structure is manufactured by a roll forming method, there are the following problems.
[0008]
(1) Since the cross-sectional shape is complicated, the number of roll processing steps increases. When the bag part 2a is first molded and then the folded part 2b is molded, the roll may come into contact with the bag part 2a during the molding of the folded part 2b. There is a problem that the shape of the bag portion 2a cannot be maintained accurately until the last processing.
[0009]
(2) As shown in FIG. 17 (a), the outer surface 2e of the folded portion 2b of the door sash 2 has a substantially constant width range C1, a width D in which the width increases at a substantially constant rate, and a substantially constant width. When these are continuously formed, the unfolded shape is as shown in FIG. 17 (b).
[0010]
However, even if an attempt is made to fold the hatched portion of FIG. 17 (b) along the broken line, the ranges C1 and C2 are bent substantially directly downward, whereas the range D is bent obliquely downward. The so-called `` thickness deficit '' phenomenon occurs where the bent part becomes insufficient at the boundary part between C1 and range D, and the folded part remains at the boundary part between range C2 and range D. The phenomenon occurs.
[0011]
That is, there is a problem that bending cannot be performed at a portion (inflection point) where the degree of change in width changes.
(3) When cutting (shearing) to a certain length after molding, the hollow bag portion with low rigidity is deformed before cutting, and the cut surface and the vicinity of the cut surface are crushed. is there.
[0012]
The present invention has been made in view of the above problems, and a first object thereof is to provide a roll forming method and a roll forming apparatus capable of forming the shape of the hollow bag portion with high accuracy.
[0013]
A second object is to provide a roll forming method and a roll forming apparatus that can be bent even if there is a portion where the degree of change in width changes.
[0014]
[Means for Solving the Problems]
The invention according to claim 1, which solves the above problem, manufactures a long material having a cross section comprising a hollow bag portion formed by bending a plate material and a folded portion formed by folding the plate material. In the roll forming method, the bag portion is formed before forming the folded portion, and the folded portion is formed after fixing the root of the bag portion.
[0015]
By forming the bag portion and fixing the base of the bag portion before forming the folded portion, the rigidity of the bag portion is increased. Therefore, even if it forms a folding part after that, the shape of a bag part is accurately maintained until the last.
[0016]
Invention of Claim 2 has the cross section containing the folding part formed by folding a board | plate material, The roll forming method which manufactures the elongate material from which the cross-sectional shape of the said folding part changes in a longitudinal direction WHEREIN: The said folding This is a roll forming method characterized in that a substantially V-shaped cut is provided in a portion where a part is unfolded when a part is developed and folded, and a slit is provided in a portion where the meat is insufficient when folded.
[0017]
Even if there is a place where the degree of change in the width of the folded part changes, folding is performed by providing a substantially V-shaped cut at the part that will be left over when folded, and by providing a slit at the part that will become insufficient when folded. Is possible.
[0019]
The end face of the bag portion is not deformed by forming a cut portion at a location to be cut in advance and cutting at the cut portion.
Claim 3 The described invention has a cross section composed of a hollow bag portion formed by bending a plate material and a folded portion formed by folding the plate material, and the cross-sectional shapes of the bag portion and the folded portion are long. In a roll forming apparatus that manufactures a long material that changes in direction and cuts into a certain length, in the bag portion, the variable cutter portion that cuts the plate material along the developed shape of the folding portion, and the folding portion, The part that will be left over when folded will have a substantially V-shaped cut, the part that will be cut out when folded will form a slit, and the part that will be cut will be cut so that the bag will not be formed. An incision forming part, a bag roll forming part for forming the bag part, a bag temporary fixing part for temporarily fixing the base of the bag part, a folding roll forming part for forming the folding part, and the notch Cut at provided with cut portions by forming portions, a roll forming apparatus characterized by comprising a cutting unit for a certain length.
[0020]
First, the plate material is cut along the developed shape of the bag portion and the folding portion by the variable cutter portion.
Next, in the deletion part, when it is folded, a portion that becomes a surplus is formed with a substantially V-shaped cut, and when it is folded, a slit is formed in a place where the meat is insufficient, The cut portion is provided so that the bag portion is not formed.
[0021]
And a bag part is formed in a bag roll formation part, the root of a bag part is temporarily fixed in a bag temporary fixing part, and a folding part is formed in a folding roll formation part.
Finally, in the cutting part, the notch part provided by the notch forming part is cut into a certain length.
[0022]
According to the above configuration, the width of the bent portion is changed by first forming a substantially V-shaped cut at a portion that becomes excess when folded in the deletion portion, and a slit at a portion that becomes insufficient when folded. Even if there is a place where the degree of change varies, bending can be performed.
[0023]
Next, in the notch forming part, the notch part is formed in advance at the portion to be cut, and the end surface of the bag part is not deformed by cutting at the notch part.
Finally, by temporarily fixing the base of the bag portion with the bag temporary fixing portion, the rigidity of the bag portion is increased. After that, even if the roll comes into contact with the folding variable roll portion, the bag portion does not deform. The shape of the bag portion can be accurately maintained until the end.
[0024]
DETAILED DESCRIPTION OF THE INVENTION
Next, embodiments of the present invention will be described with reference to the drawings.
First, the overall configuration of the roll forming apparatus according to the present embodiment will be described with reference to FIGS. 1 to 3. 1 to 3 are overall configuration diagrams of a roll forming apparatus for realizing the roll forming method of the present invention. 1 to 3, individual devices constituting the roll forming apparatus are shown in the upper stage, and changes in the cross-sectional shape of the plate material processed by these apparatuses are shown in the lower stage. Furthermore, in this embodiment, the door sash 2 having a cross-sectional shape as shown in FIG. 16 is formed.
[0025]
In FIG. 1, reference numeral 11 denotes a roll stand on which a roll of the plate material 12 is set, and 13 denotes a punching machine that punches the reference holes 12 a in the plate material 12 at a predetermined pitch in the flow direction of the plate material 12. In the present embodiment, three reference holes 12 a are provided in the width direction of the plate 12.
[0026]
Reference numeral 14 denotes a sensor that detects the reference hole 12a, and reference numeral 15 denotes an encoder that measures the conveyance speed of the plate 12.
Behind the encoder 15 is provided a general roll forming device 16 for forming the constant cross section CD (in the present embodiment, the first holder portion 2d) with respect to the plate material 12. In this embodiment, 15 stages of general roll forming devices 16 are provided.
[0027]
Next to the general roll forming device 16, a sensor 14 and an encoder 15 are provided.
Next to the encoder 15, a variable cutter 17 is provided as a variable cutter portion that cuts one side portion of the plate member 12 along the flow direction so as to have a developed shape on the bag portion 2 a side of the door sash 2. Yes.
[0028]
Next to the variable cutter 17, a sensor 14 is provided. Next to the sensor 14, the other side portion of the plate member 12 is arranged along the flow direction so as to have a developed shape on the folding portion 2 b side of the door sash 2. A variable cutter 18 is provided as a variable cutter section for cutting.
[0029]
Next to the variable cutter 18, through the sensor 14, a substantially V-shaped cut is formed at a portion that is left over when folded, and a slit is formed at a portion that becomes insufficient when folded, and a cutting machine described later is used. A punch 19 serving as a deletion portion and a cut formation portion for providing a notch in a bag portion at a location to be cut is provided.
[0030]
In FIG. 2, reference numeral 20 denotes a variable roll molding device that is provided next to the punch 19 and serves as a bag roll forming unit that performs variable molding on the bag part 2 a side of the door sash 2. The shaft to which the top of the variable roll forming apparatus 20 is attached is movable in three directions of the width direction, the up-down direction, and the rotation direction, and is provided in a total of 10 stages. Further, a sensor 14 for detecting the hole 2a of the plate member 2 is provided immediately before the variable roll forming apparatus 20 at each stage.
[0031]
Next to the variable roll forming device 20, a variable roll forming device 21 is provided as a folding roll forming portion that performs variable forming on the folding portion 2 b side of the door sash 2. The shaft to which the top of the variable roll forming apparatus 21 is attached can be moved in two directions of width and rotation, or can be moved in the rotation direction and the up and down direction, and is provided in a total of 20 stages. Further, a sensor 14 (not shown) is provided immediately before the variable roll forming device 21 at each stage.
[0032]
A seam spot welder 22 is provided between the first stage and the second stage variable roll forming apparatus 21 as a bag temporary fixing part for welding the base of the formed bag part 2a.
[0033]
Behind the variable roll forming device 21, a general roll forming device 23 is provided as a folding roll forming portion that raises the folding portion 2b. The general roll forming apparatus 23 is provided in a total of four stages.
[0034]
In FIG. 3, behind the general roll forming device 23, a variable roll forming device 24 is provided as a folding roll forming portion that performs variable forming on the side of the folding portion 2 b of the door sash 2. The variable roll forming device 24 is provided in a total of five stages, and the shaft to which the top of the variable roll forming apparatus 24 is attached is movable in three directions, ie, the width direction, rotation, and up and down, and is provided in a total of five stages. Further, a sensor 14 (not shown) is provided immediately before the variable roll forming device 24 at each stage.
[0035]
Behind the variable roll forming device 24, a general roll forming device 25 is provided as a folding roll forming unit that raises the folding unit 2b. The general roll forming apparatus 25 is provided in a total of five stages.
[0036]
Behind the general roll forming device 25, there is provided a variable roll forming device 26 for performing final variable forming of the bag portion 2a. The variable roll forming device 26 is provided in two stages in total, and a sensor 14 (not shown) is provided immediately before the variable roll forming apparatus 26 at each stage.
[0037]
A seam spot welder 27 for welding the base of the bag portion 2a and the folded portion 2b is provided behind the general roll forming device 26, and a sensor 14 and an encoder 15 are provided behind the seam spot welder 27. ing.
[0038]
Behind the encoder 15 is provided a cutting machine 30 as a cutting part for cutting the plate 12 that has been roll-formed into a certain length.
Next, the main part of the roll forming apparatus will be described in detail.
[0039]
First, the general roll forming apparatus 16 will be described. 4A and 4B are diagrams for explaining the configuration of the general roll forming apparatus 16, wherein FIG. 4A is a plan view, and FIG. 4B is a left side view in FIG.
[0040]
In the drawing, stands 40 and 41 are arranged on the floor F so as to face each other. Two shafts 42 and 43 are rotatably supported between the stands 40 and 41. Further, the shaft 42 is provided with an upper piece 44, and the shaft 45 is provided with a lower piece 45 that sandwiches the plate 12 in cooperation with the upper piece 44 and forms a basic cross section with respect to the plate 12.
[0041]
The shaft 42 on the stand 40 side is provided with a gear 46, and the shaft 43 is provided with a gear 47 that meshes with the gear 46. Further, a pulley 48 is attached to the shaft 43.
[0042]
On the other hand, a motor 49 is provided on the floor, and a pulley 50 is provided on an output shaft 49 a of the motor 49. A belt 51 is wound around the pulley 48 and the pulley 50.
[0043]
Therefore, when the motor 49 is driven, the rotation of the output shaft 49a of the motor 49 is transmitted to the shaft 43 via the pulley 50, the belt 51, and the pulley 48, and the lower piece 45 rotates, and further, via the gears 45 and 46. Also transmitted to the shaft 42, the upper piece 44 also rotates.
[0044]
By rotating the upper piece 44 and the lower piece 45, the plate material 12 is formed by inserting the plate material 12 between these pieces 44 and 45.
Next, the variable cutters 17 and 18 will be described. 5A and 5B are diagrams for explaining the configuration of the variable cutters 17 and 18. FIG. 5A is a plan view, and FIG. 5B is a left side view of the variable cutter 17 in FIG. Note that the variable cutter 17 and the variable cutter 18 have the same structure and are only reversed in their own right, so the description will be made using the variable cutter 17 here.
[0045]
In the figure, a stand 60 is disposed on the floor F. Two shafts 61 and 62 are rotatably provided on the stand 60. Reference numerals 63 and 64 denote motors that are attached to the stand 60 and rotationally drive the shafts 61 and 62. Further, conveyance rollers 65 and 66 for holding and conveying one side portion of the plate material 12 are attached to the shafts 61 and 62.
[0046]
67 is a guide provided on the floor and extending in the width direction of the plate 12. A slider 68 is movably engaged with the guide 67. A motor 69 is provided on the floor F, and a screw rod 70 extending in the same direction as the guide 67 and screwed to the slider 68 is attached to the output shaft of the motor 69. Therefore, when the motor 69 is driven to rotate, the slider 68 is guided by the guide 67 and moves in the width direction of the plate 12.
[0047]
A pin 72 is erected on the slider 68, and a worm wheel 73 is rotatably supported on the pin 72. A motor 74 is provided on the slider 68, and a worm gear 75 that is screwed into the worm wheel 73 is attached to the output shaft of the motor 74. Therefore, when the motor 74 is driven to rotate, the worm wheel 73 rotates around the pin 72.
[0048]
The worm wheel 73 is provided with a stand 77. Two shafts 78 and 79 are rotatably supported on the stand 77. Reference numerals 80 and 81 denote motors which are attached to the stand 77 and drive the shafts 78 and 79 to rotate. Further, the shafts 78 and 79 are cut at the other side of the plate 12 (in the case of the variable cutter 17, the bag 2 a side of the door sash 2, and in the case of the variable cutter 18, the folded portion 2 b side of the door sash 2). An upper blade 82 and a lower blade 83 are provided.
[0049]
In the present embodiment, the contact points of the upper blade 82 and the lower blade 83 with the plate 12 and the pins 12 are set so as to be substantially on the same straight line.
Next, the punch 19 will be described with reference to FIG. 6A and 6B are diagrams for explaining the punch 19, wherein FIG. 6A is a plan view, and FIG. 6B is a right side view of a main part in FIG.
[0050]
In the figure, on the floor F, two guides 91 and 91 'parallel to two guides 90 and 90' parallel to the flow direction of the plate 12 are provided. Sliders 92 and 92 'are engaged with the guides 90 and 90', and sliders 93 and 93 'are engaged with the guides 91 and 91', respectively. A base 94 is provided on the sliders 92 and 92 ′, a base 95 is provided on the sliders 93 and 93 ′, and stands 96 and 97 are provided on the bases 94 and 95.
[0051]
Between the guides 90 and 90 'and between the guides 91 and 91', screw rods 98 and 99 supported rotatably on the floor F are disposed. Further, on the floor F, motors 100 and 101 are provided. Pulleys 102 and 103 are attached to the main shafts 100 a and 101 a of the motors 100 and 101, and pulleys 104 and 105 are also attached to the screw rods 99 and 100. A belt 106 is wound between the pulley 102 and the pulley 104, and a belt 107 is wound between the pulley 103 and the pulley 105.
[0052]
A nut member 108 that is screwed to the screw rod 98 is attached to the base 94, and a nut member 109 that is screwed to the screw rod 99 is attached to the base 95.
As shown in FIG. 12 (a), the stand 96 has a substantially V-shaped cut V at a portion where it becomes excessive when folded, with respect to the folded portion 2b side of the plate 12 (door sash 2). A punch 110 that forms a slit S is provided at a shortage. On the other hand, in the stand 97, a punch 111 is provided in advance with a notch D in the bag portion 2a of the portion to be cut by the cutting machine 30, as shown in FIG. 13, with respect to the bag portion 2a of the plate 12 (door sash 2). Is provided.
[0053]
When the motor 100 is driven to rotate, the screw rod 98 rotates, and the stand 96 provided on the base 94 is guided by the guides 90 and 90 'so as to be movable in the flow direction of the plate material 12. Similarly, when the motor 101 is driven to rotate, the screw rod 99 rotates, and the stand 97 provided on the base 95 is guided by the guides 91 and 91 ′ so as to be movable in the flow direction of the plate material 12.
[0054]
In the present embodiment, the stand 96 and the stand 97 can be moved along the flow direction of the plate 12 because the stands 96 and 97 are moved in synchronization with the conveying speed of the plate 12. This is because punching is performed without stopping the conveyance of 12.
[0055]
Next, the variable roll forming apparatus 20 will be described. 7A and 7B are diagrams for explaining the variable roll forming apparatus 20. FIG. 7A is a plan view, and FIG. 7B is a left side view of FIG. In the figure,
In the figure, a stand 120 is disposed on the floor F. Two shafts 121 and 122 are rotatably provided on the stand 120. Reference numerals 123 and 124 denote motors that are attached to the stand 120 and rotationally drive the shafts 121 and 122. Further, an upper piece 125 and a lower piece 126 that sandwich and convey one side portion of the plate member 12 are attached to the shafts 121 and 122.
[0056]
127 is a guide provided on the floor F and extending in the width direction of the plate 12. A slider 128 is movably engaged with the guide 127. A motor 129 is provided on the floor F, and a screw rod 130 that extends in the same direction as the guide 127 and is screwed to the slider 128 is attached to the output shaft of the motor 129. Therefore, when the motor 129 is driven to rotate, the slider 128 is guided by the guide 127 and moves in the width direction of the plate 12.
[0057]
A pin 132 is erected on the slider 128, and a worm wheel 133 is rotatably supported by the pin 132. A motor 134 is provided on the slider 128, and a worm gear 135 that is screwed to the worm wheel 133 is attached to the output shaft of the motor 134. Therefore, when the motor 134 is driven to rotate, the worm wheel 133 rotates about the pin 132.
[0058]
The worm wheel 133 is provided with a stand 137. The stand 137 is provided with sliders 138 and 139 that are movable in the vertical direction. Motors 140 and 141 are provided on the upper portion of the stand 137, and the output shafts of the motors 140 and 141 have sliders 138 and 139 through a mechanism that converts a rotational motion including a screw rod and a nut member into a linear motion. It is connected to the. Therefore, when the motors 140 and 141 are driven, the sliders 138 and 139 move in the vertical direction.
[0059]
Shafts 142 and 143 are rotatably provided on the sliders 138 and 139, respectively. An upper piece 144 and a lower piece 145 are formed on the shafts 142 and 143, respectively. The upper piece 144 and the lower piece 145 are formed by variably forming the plate material 12 and forming the bag portion 2a side of the door sash 2.
[0060]
In the present embodiment, the contact points of the upper piece 144 and the lower piece 143 with the plate 12 and the pins 132 are set to be substantially on the same straight line.
Next, the variable roll forming apparatus 21 will be described. The variable roll forming apparatus 21 has 20 stages, and there are three types of variable roll forming apparatuses 21, 21 'and 21 ". FIG. 8 is a diagram for explaining the variable roll forming apparatuses 21 and 21'. The top view, (b) and (c) are left side views of (a).
[0061]
The variable roll forming apparatus 20 provided in the first two stages will be described. In FIGS. (A) and (b), a stand 150 is disposed on the floor F. FIG. The stand 150 is provided with two shafts 151 and 152 so as to be rotatable. Reference numerals 153 and 154 denote motors that are attached to the stand 150 and rotationally drive the shafts 151 and 152. Further, an upper piece 155 and a lower piece 156 that sandwich and convey one side portion of the plate member 12 are attached to the shafts 151 and 152.
[0062]
Reference numeral 157 denotes a guide provided on the floor F and extending in the width direction of the plate 12. A slider 158 is movably engaged with the guide 157. A motor 159 is provided on the floor F, and a screw rod 160 that extends in the same direction as the guide 157 and is screwed to the slider 158 is attached to the output shaft of the motor 159. Therefore, when the motor 159 is driven to rotate, the slider 158 is guided by the guide 157 and moves in the width direction of the plate 12.
[0063]
A pin 162 is erected on the slider 158, and a worm wheel 163 is rotatably supported by the pin 162. A motor 164 is provided on the slider 158, and a worm gear 165 that is screwed into the worm wheel 163 is attached to the output shaft of the motor 164. Therefore, when the motor 164 is driven to rotate, the worm wheel 163 rotates around the pin 162.
[0064]
The worm wheel 163 is provided with a stand 167. The stand 167 is rotatably provided with shafts 168 and 169. An upper piece 170 and a lower piece 171 are formed on the shafts 168 and 169 to variably form the plate material 12 to form the folding portion 2b side of the door sash 2.
[0065]
The variable roll forming apparatus 21 'provided in the third to fifteenth stages is provided with a back roller-shaped abacus ball type upper piece 170' as shown in FIG.
[0066]
In the present embodiment, the contact points of the upper piece 170 (170 ') and the lower piece 171 with the plate material 12 and the pins 162 are set to be substantially on the same straight line.
10A and 10B are diagrams for explaining the configuration of the variable roll forming device 24. FIG. 10A is a plan view, and FIG. 10B is a left side view of FIG.
[0067]
Further, the variable roll forming apparatus 21 ″ provided in the 16th to 20th stages will be described. FIG. 9 is a diagram illustrating the configuration of the variable roll forming apparatus 21 ″, (a) is a plan view, (b) ) Is a left side view of FIG.
[0068]
In the figure, on the floor F, base plates 200 and 201 are disposed. On the base plate 200, pins 202 and 203 are erected, and worm wheels 204 and 205 are rotatably supported by these pins 202 and 203, respectively.
[0069]
Further, motors 206 and 207 are provided on the bases 200 and 201, and worm gears 208 and 209 that are screwed into the worm wheels 204 and 205 are attached to output shafts of the motors 206 and 207, respectively.
[0070]
Stands 210 and 211 are provided on the worm wheels 204 and 205. The stand 210 is provided with sliders 212 and 213 that are movable in the vertical direction. Motors 214 and 215 are provided on the upper portion of the stand 210, and output shafts of the motors 214 and 215 are provided with sliders 212 and 213 through a mechanism that converts a rotational motion including a screw rod and a nut member into a linear movement motion. It is connected to the. Therefore, when the motor 206 is driven, the stand 210 rotates about the pin 202, when the motor 207 is driven, the stand 211 rotates about the pin 203, and when the motors 214 and 215 are driven, the sliders 212 and 213 are moved up and down. Will move in the direction.
[0071]
The sliders 212 and 213 are provided with shafts 215 and 216 that are rotationally driven by motors 217 and 218, respectively. The shaft 215 is provided with an upper piece 219 of an abacus ball type having a backup roller shape, and the shaft 216 is provided with a lower piece 220.
[0072]
The stand 211 is provided with shafts 223 and 224 that are rotationally driven by motors 221 and 222. An upper piece 225 is attached to the shaft 223, and a lower piece 226 is attached to the shaft 224.
[0073]
Moreover, since the structure of the variable roll forming apparatus 26 is the same as that of the variable roll forming apparatus 20, description thereof is omitted.
Next, the general roll forming apparatus 23 will be described. 10A and 10B are diagrams for explaining the configuration of the general roll forming apparatus 23. FIG. 10A is a plan view, and FIG. 10B is a left side view of FIG.
[0074]
In the figure, stands 190 and 191 are arranged on the floor F so as to face each other. Two shafts 192 and 193 are rotatably supported between the stands 190 and 191. Further, the shaft 192 is provided with an upper piece 194, and the shaft 193 is provided with a lower piece 195 that sandwiches the plate 12 in cooperation with the upper piece 194 and raises the folding portion 2 b side of the door sash 2.
[0075]
Motors 196 and 197 for rotating the shafts 192 and 193 are attached to the stand 190.
In addition, since the structure of the general roll forming apparatus 25 is the same as the structure of the general roll forming apparatus 23, description is abbreviate | omitted.
[0076]
Next, the variable roll forming apparatus 24 having four stages will be described. 11A and 11B are diagrams for explaining the configuration of the variable roll forming device 24. FIG. 11A is a plan view, and FIG. 11B is a left side view of FIG. In addition, the same code | symbol is attached | subjected to the same part as variable roll shaping | molding apparatus 21 ", and those description is abbreviate | omitted.
[0077]
In the figure, a guide 230 extending in the width direction of the plate member 120 is provided on the floor F. A slider 231 is movably engaged with the guide 230. On the other hand, a motor 232 is provided on the floor F. A screw rod 233 that extends in the same direction as the guide 230 and is screwed to the slider 231 is attached to the output shaft of the motor 232. Accordingly, when the motor 232 is driven to rotate, the slider 231 is guided by the guide 230 and moves in the width direction of the plate 12.
[0078]
A stand 235 is provided on the slider 231. A shaft 236 is rotatably provided on the stand 235, and an upper piece 237 is attached to the shaft 236.
[0079]
Next, the operation of the roll forming apparatus having the above configuration will be described.
The punching machine 13 opens the reference holes 12 a at a predetermined pitch in the plate material 12 fed out from the roll stand 11.
[0080]
When the reference hole 12a is opened, the sensor 14 detects the reference hole 12a, the encoder 15 measures the conveyance speed of the plate material 12, and a control unit (not shown) calculates the timing at which the plate material 12 is variably formed.
[0081]
Then, the general roll forming device 16 forms the constant cross section CD (first holder portion 2c) of the sash 2 to be formed. When the constant section CD is formed, the sensor 14 detects the reference hole 12a, the encoder 15 detects the conveying speed of the plate 12, and a control unit (not shown) detects the elongation of the plate 12 generated by the general roll forming device 16. Calculate and feed back the elongation rate to the subsequent device.
[0082]
Based on the detection signal of the sensor 14, the variable cutter 17 drives the upper blade 82 and the lower blade 83 in the width direction of the plate material 12, cuts one side portion of the plate material 12 along the flow direction, and forms the sash 2 to be molded. An unfolded shape on the bag portion 2a side which is the variable cross-section portion VD is formed.
[0083]
Next, the variable cutter 18 also cuts the other side portion of the plate member 12 along the flow direction and forms a developed shape on the folding portion 2b side including the variable cross-sectional portion VD (outer surface portion 2e) of the door sash 2 to be formed. Mold.
[0084]
When forming the folding part 2b, the punch 19 is formed in advance with a substantially V-shaped cut V in a portion that becomes excessive when folded, and a slit S is formed in a portion that becomes insufficient when folded, and finally the cutting machine 30. A notch D is also provided in advance in the bag portion 2a at the location to be cut in step (b).
[0085]
The 10-stage variable roll forming apparatus 20 drives the upper piece 144 and the lower piece 143 in the up-down direction, the width direction of the plate member 2, and the rotation direction based on the detection signal of the sensor 14 provided in each variable roll forming apparatus 20. And the variable shaping | molding of the bag part 2a which is the variable cross-section part VD is performed.
[0086]
When the bag 2a having the variable cross section VD is formed, the sensor 14 detects the reference hole 12a, the encoder 15 detects the conveying speed of the plate 12, and a control unit (not shown) is generated in the variable roll forming apparatus 20. The elongation of the plate 12 is calculated, and the elongation rate is fed back to the subsequent apparatus.
[0087]
The 20-stage variable roll 21 drives the upper piece 170 and the lower piece 171 in the width direction and the rotation direction in accordance with the detection signal of the sensor 14 provided in each variable roll forming apparatus 21, and the variable cross section VD. The foldable portion 2b including the (outer surface portion 2e) is variably formed.
[0088]
A seam spot welder 22 provided between the first-stage and second-stage variable roll forming apparatuses 21 welds the base of the formed bag portion 2a (a location indicated by an arrow W in FIG. 2).
[0089]
The general roll forming apparatus 23 provided in four stages raises the folding part 2b side of the sash 2.
The variable roll forming devices 24 provided in five stages rotate the upper piece 219 'and the lower piece 220' in the width direction by the detection signal of the sensor 14 provided in each variable roll forming device 21. It drives in three directions of the up-and-down direction, and shape | molds the outer surface part 2e which is the variable cross section VD of the folding part 2b side of the door sash 2.
[0090]
The five-stage general roll forming device 25 raises the folding portion 2b side of the sash 2, and the two-stage variable roll forming device 26 performs final variable forming of the bag portion 2a.
[0091]
Next, the seam spot welder 27 welds the base of the bag portion 2a and the folded portion 2b (location indicated by an arrow W ′ in FIG. 3).
When the base of the bag portion 2a and the folded portion 2b are welded, the sensor 14 detects the reference hole 12a, the encoder 15 detects the conveying speed of the plate material 12, and a control unit (not shown) reaches the general roll forming device 25. The generated elongation of the plate material 12 is calculated, and the elongation rate is fed back to the subsequent cutting machine 30.
[0092]
The cutting machine 30 cuts the plate material 12 into a certain length by the detection signal of the sensor 14.
According to such a roll forming method and roll forming apparatus, the bag portion 2a is formed before the folding portion 2b is formed, and the base of the bag portion 2a is fixed by the seam spot welder 22, thereby Increases rigidity. Therefore, after that, even if the folding part 2b is formed, the shape of the bag part 2a is accurately maintained until the end.
In addition, after forming the unfolded shape of the folding part 2b with the variable cutter 18, the punch 19 is cut into a substantially V-shaped cut V in a portion that becomes excessive when folded, and a slit in a portion that becomes short when folded. By providing S, bending can be performed.
[0093]
Furthermore, by providing a notch D with the punch 19 in advance at a location to be cut by the cutting unit 30 and cutting the notch D, it is possible to prevent the cut surface and the shape in the vicinity of the cut surface from being deformed.
[0094]
【The invention's effect】
As described above, according to the first aspect of the invention, the bag portion is formed before the folding portion is formed, and the base of the bag portion is fixed, thereby increasing the rigidity of the bag portion. Therefore, even if it forms a folding part after that, the shape of a bag part is accurately maintained until the last.
[0095]
According to the second aspect of the present invention, even if there is a portion where the degree of change in the width of the bent portion changes, the portion that becomes excessive when folded is provided with a substantially V-shaped cut, and the portion that becomes insufficient when folded By providing a slit, bending can be performed.
[0096]
According to invention of Claim 3, , Ahead First, in the deleted part, there is a part where the degree of change in the width of the bent part changes by forming a substantially V-shaped cut at the part that becomes excessive when folded, and forming a slit at the part that becomes insufficient when folded. Even if it exists, it can be bent.
[0097]
Next, in the notch forming part, the notch part is formed in advance at the portion to be cut, and the end surface of the bag part is not deformed by cutting at the notch part.
Finally, by temporarily fixing the base of the bag portion with the bag temporary fixing portion, the rigidity of the bag portion is increased. After that, even if the roll comes into contact with the folding variable roll portion, the bag portion does not deform. The shape of the bag portion can be accurately maintained until the end.
[Brief description of the drawings]
FIG. 1 is an overall configuration diagram of a roll forming apparatus that realizes a roll forming method of the present invention.
FIG. 2 is an overall configuration diagram of a roll forming apparatus that realizes the roll forming method of the present invention.
FIG. 3 is an overall configuration diagram of a roll forming apparatus that realizes the roll forming method of the present invention.
4 is a diagram for explaining the configuration of a general roll forming apparatus 16 in FIG. 1. FIG.
FIG. 5 is a diagram illustrating the configuration of variable cutters 17 and 18 in FIG. 1;
6 is a view for explaining a punch 19 in FIG. 1. FIG.
7 is a diagram illustrating a variable roll forming apparatus 20 in FIG.
FIG. 8 is a diagram illustrating a variable roll forming apparatus 21 in FIG.
FIG. 9 is a diagram for explaining the variable roll forming apparatus 21 in FIG. 2;
10 is a diagram for explaining the configuration of a general roll forming apparatus 23 in FIG. 2. FIG.
11 is a diagram illustrating the configuration of the variable roll forming device 24 in FIG. 3. FIG.
12 is an explanatory diagram of a cut V and a slit S formed by the punch 19 in FIG. 1. FIG.
13 is an explanatory diagram of a notch D formed by the punch 19 in FIG. 1. FIG.
FIG. 14 is a diagram showing an example of a car door sash.
15 is a view in the direction of arrow A in FIG.
16 is a cross-sectional view taken along a cutting line BB in FIG.
FIG. 17 is a diagram illustrating a problem.
[Explanation of symbols]
16, 23, 25 General roll forming device
19 Punch
20, 21, 24, 26 Variable roll forming apparatus
22 Seam spot welder

Claims (3)

In a roll forming method for producing a long material having a cross section composed of a hollow bag portion formed by bending a plate material and a folded portion formed by folding the plate material,
Prior to the formation of the folded portion, the bag portion is formed,
After fixing the base of the bag part,
A roll forming method comprising forming the folding portion. In a roll forming method for producing a long material having a cross section including a folded portion formed by folding a plate material, and the cross-sectional shape of the folded portion changes in the longitudinal direction,
Forming an unfolded shape of the folded portion;
For the part that will be left over when folded, a roughly V-shaped cut,
A roll forming method, wherein a slit is provided at a location where the meat becomes insufficient when folded. A length having a cross section composed of a hollow bag portion formed by bending a plate material and a folded portion formed by folding the plate material, and the cross-sectional shapes of the bag portion and the folded portion change in the longitudinal direction. In roll forming equipment that manufactures the scale material and cuts it to a certain length,
A variable cutter part for cutting the plate material along the developed shape of the bag part and the folding part;
In the folding part, when it is folded, it becomes a surplus portion, a substantially V- shaped cut, and when it is folded, a deletion part that forms a slit at a place where the meat becomes insufficient,
In the part to be cut, a notch forming part that provides a notch part so that the bag part is not formed, and
A bag roll forming portion that forms the bag portion; a bag temporary fixing portion that temporarily fixes the base of the bag portion;
A folding roll forming portion that forms the folding portion, a cutting portion that is cut at a notch provided by the notch forming portion, and has a constant length;
Roll forming apparatus characterized by comprising a.

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