JPH0475089B2 - - Google Patents

Description

Detailed Description of the Invention [Field of Industrial Application] The present invention relates to a corrugated plate forming method and a forming apparatus for forming a band-shaped flat plate into a continuous corrugated plate using a cylindrical roll mold, and particularly The present invention relates to a corrugated plate forming method and a forming apparatus suitable for manufacturing corrugated plates with good dimensional accuracy and low production costs.

[Conventional technology]

Conventionally, a cold roll forming device for forming a corrugated sheet from a flat strip using a cylindrical roll mold was developed in Japanese Patent Application Laid-Open No. 59
As described in No. 42135, a rolling down device and a roll crown adjustment mechanism were provided at the shaft end of a forming roll mold to control the pressing force and roll crown amount of the forming roll. Further, these pressing force and roll crown amount are controlled by feedback by detecting the shape after molding.

[Problem that the invention seeks to solve]

The above conventional technology adjusts and controls the forming force and the amount of roll crown of the forming roll at the shaft end of the forming roll, so when forming a wide corrugated sheet, a large forming force and sufficient amount of forming force are required. It is necessary to use forming rolls with bending stiffness. In order to achieve sufficient rigidity, it is necessary to increase the roll diameter of the forming roll, but increasing the roll diameter of the forming roll requires strict dimensional accuracy and hard surface hardness. In addition to making it difficult to process, the cost of roll processing increases.

An object of the present invention is to make it possible to apply sufficient forming force even with a small diameter forming roll, and to reduce the processing cost of the forming roll. Another object is to easily and reliably apply a uniform forming force in the width direction of the plate.

[Means for solving problems]

The above purpose is to arrange a back-up mechanism above and below a pair of forming rolls each having a row of protrusions for wave-forming on the cylindrical surface, and to control the load to apply wave-forming force to the forming roll via this back-up mechanism. This can be achieved by configuring a corrugated plate forming apparatus that can appropriately adjust and control the magnitude and distribution of the forming force applied in the axial direction of the forming roll.

The backup mechanism is made up of one roll or a roll divided into a plurality of rolls and a support mechanism thereof, and the load control device includes a plurality of hydraulic cylinder mounting parts provided on the upper base along the axial direction of the forming roll, A hydraulic cylinder is installed at a predetermined location on the mounting portion, and the load of the hydraulic cylinder is independently applied to a predetermined location in the axial direction of the forming roll via a backup mechanism.

[Effect]

The corrugated plate forming method of the present invention is a type of cold roll forming method in which a flat plate is inserted between a pair of cylindrical forming rolls and a corrugated plate is formed by applying strong pressure. In this forming method, a back-up mechanism for the forming roll is provided in order to appropriately control the magnitude and distribution of the forming force, and the corrugated sheet forming force is applied via this back-up mechanism. Therefore, with the forming method of the present invention, even when forming a wide corrugated sheet, it is possible to apply a uniform and sufficient forming force in the axial direction of the forming roll, resulting in a good formed shape and a wave with good dimensional accuracy. A plate can be formed.

Since the forming force of the corrugated sheet is transmitted to the forming roll and the flat plate via the backup mechanism, it is not necessary to use forming rolls with high bending rigidity as in the conventional method.

〔Example〕

Embodiments of the present invention will be described below with reference to the drawings.

FIG. 1 illustrates the structure of a forming apparatus in an embodiment of corrugated sheet forming according to the present invention. As shown in FIG. 1, the corrugated plate forming apparatus of the present invention sandwiches a flat band-shaped plate between forming rolls having a row of protrusions on the cylindrical surface, and applies forming force to the forming rolls via a back-up mechanism. This process forms a flat plate into a corrugated plate. The pair of corrugated plate forming rolls 1a and 1b are rotatably supported by bearings 5 held in a bearing support frame 4, parallel to the axis thereof, with their protrusion rows meshing with each other. The corrugated plate forming force is applied to the forming rolls by applying the pressing force of a hydraulic cylinder 9 attached to the upper base 7 to the forming rolls through backup mechanisms installed above and below the forming rolls 1a and 1b. Further, the rotational driving force of the forming rolls 1a and 1b is obtained by converting the rotational force of the motor 11 into a two-axis output that rotates in opposite directions at the same speed using a synchronizing gear 12, and then passing it through universal joints 10a and 10b to the forming rolls 1a and 1b. transmitted to the role. The magnitude and distribution of the forming force applied to the forming rolls 1a, 1b can be appropriately set by controlling the arrangement of the upper and lower backup mechanisms and the pressing force of the hydraulic cylinder 9. The spring 6 interposed in the gap between the bearings 5 of the forming rolls is used to widen the gap between the forming rolls 1a and 1b with spring force in order to facilitate insertion of the flat plate at the start of forming. FIG. 2 shows the shapes of forming rolls 1a and 1b for forming corrugated sheets. An annular projection 14 is provided on the surface of the forming roll 1a in parallel with the roll axis.
In addition to providing a row of grooves 15, protrusions 1b and grooves 17 are similarly provided on the surface of the forming roll 1b, and the protrusion rows and groove rows of these two forming rolls mesh with each other and are held parallel to the roll axis. do. Insert a flat plate into the gap between the forming rolls 1a and 1b,
The corrugated sheet 18 can be formed by rotationally driving the roll shaft while clamping the flat sheet with forming rolls. FIG. 3 is an explanatory diagram for explaining the principle of the corrugated plate forming method of the present invention, and shows the forming apparatus viewed from the side. The corrugated sheet forming apparatus 19 of the present invention is composed of a pair of forming rolls 1a, 1b and backup mechanisms 22, 23 disposed above and below the forming rolls.
The strip-shaped flat plate 20 can be continuously formed into a flat plate 21. In addition, the backup mechanisms 22 and 23 arranged above and below are composed of one oar or a roll divided into a plurality of rolls and its support mechanism, and the back-up mechanisms 22 and 23 are composed of a single oar or a roll divided into a plurality of rolls and a support mechanism for the roll. Transfer to forming rolls.
Furthermore, the forming force transmitted to the forming rolls 1a, 1b via the back-up mechanisms 22, 23 can be set to an appropriate magnitude and distribution depending on the shape, thickness, and width of the corrugated sheet to be formed. can.

4 and 5 are explanatory diagrams for explaining the relationship between the distribution state of forming force and the load point, and for the sake of simplicity, the case of a smooth roll is shown. When an equal pressing force W is applied to both shaft ends of a forming roll, which has been commonly done in the past, due to the difference in the amount of deflection deformation of the roll shaft, the center is small and the ends are small, as shown in Figure 4. It shows a large concave molding pressure distribution. When a corrugated sheet is molded under such load conditions, defects such as pocket waves and wrinkles are likely to occur because the molded shape and pressure conditions at the center and both ends are different. Therefore, as shown in FIG. 5, if the pressing force is applied to the center of the forming roll in divided parts as shown in the figure, the forming pressure distribution of the flat plate becomes almost uniform in the width direction of the plate.
If a corrugated sheet is formed under such load conditions, the formed shape and stress state in the width direction of the sheet will be approximately equal, so the above-mentioned defects can be eliminated and a good corrugated sheet can be formed. Further, it is desirable that the magnitude of the pressing force and the load position can be appropriately set according to the conditions of the corrugated sheet to be formed.
Further, the size of the pressing force, the load position, and its distribution state are controlled by a means for detecting the shape of the corrugated plate after forming, a means for processing the detection signal, and a control signal obtained by the processing means. Adding a pressing force control means further improves the molded shape and dimensional accuracy.

FIG. 6 and FIG. 7 are explanatory diagrams for explaining another embodiment of the present invention. The corrugated plate forming device 19 is
The belt-shaped flat plate 20 is passed through a pair of forming rolls 26a, 26.
The corrugated sheet 21 is formed by being fed into the gap in b, and is uniformly distributed in the sheet width direction and sufficiently large so that it can be formed from a flat sheet into the final corrugated shape with one roll stand. It is configured such that molding pressure can be applied to the molding rolls 26a, 26b. The forming rolls 26a and 26b are
As shown in FIG. 7, the cylindrical surface has protrusions 27a, 27b parallel to the roll axis and grooves 28a, 28b. The projection rows of the pair of forming rolls 26a, 26b are held so as to mesh with each other, and the belt-shaped flat plate 20 is supplied into the gap between the rolls, and the projection rows 27a,
This band-shaped flat plate is clamped by 27b to form the corrugated plate 21.
to form. As shown in FIG. 6, in this embodiment as well, the corrugated plate forming force is applied to the forming rolls 26a, 26b via the upper and lower back-up rolls 22, 23.
It can be added at an appropriate position and in an appropriate size.

FIG. 8 shows an example of a system diagram showing the configuration of a waveform shaping system when carrying out the corrugated sheet forming method of the present invention. The corrugated plate forming system shown in Figure 8 is mainly
It is composed of a coil stand 30, a leveler 31, a corrugated plate forming device 34, and a control device for these devices, and their operations will be explained below. A coil 29 wound with a band-shaped flat plate is set on a coil stand 30. After straightening the curl of the coil 29 with the leveler 31 to form a flat strip 35, the flat strip 35 is fed into the gap between the forming rolls 37 of the forming device 34 by the roll stand 32 and the positioning device 33 in the width direction of the plate. . The forming device 34 is composed of a forming roll 37, a backup roll 38, and a hydraulic cylinder 39, and forms the corrugated sheet 36 by a row of protrusions on the surface of the forming roll 37. The thickness of the material to be formed is detected by a detection element 41 that detects the amount of reduction of the roll stand 32. Further, the width of the material to be formed is detected by the width detection element 42, and the calculating element 43 calculates the amount of positional deviation in the width direction, and the width of the material is determined based on the signal from the width position control element 44. A match is made. hydraulic cylinder 39
The pressing force and the distribution state of the pressing force are determined by processing the signals of the control signal generating element 45, pressing force detecting element 48, and rolling reduction amount detecting element 49 according to the plate thickness and plate width by the calculation processing elements 46 and 47. Control to meet the molding conditions. Further, the molded shape after molding is measured with a shape measuring device (not shown), and the pressing force of the hydraulic cylinder 39 and the molding force distribution are corrected so as to obtain the set shape. Coil 29 mentioned above
The entire process of forming the corrugated plate 36 from the blank can be carried out continuously, so the production speed is high and the production cost is low. Moreover, during forming, the plate thickness, plate width, reduction amount, and forming force are detected while forming, and the forming conditions are corrected, so the dimensional accuracy of the formed shape is good and the reproducibility is also good. Furthermore, by measuring the shape of the molded product, it is possible to correct the molding conditions so as to eliminate errors with the set shape. In addition, the molding condition data such as the molding shape of the corrugated sheet obtained by molding in the past, sheet thickness, sheet width, material, etc. is stored in the molding condition memory element, and when necessary, this data can be retrieved to It is possible to reproduce the molding conditions of In addition, in the corrugated plate forming system of the present invention, it is possible to automatically control the entire forming process, and by automating the corrugated plate forming system, labor saving, energy saving, and the lowest defect rate can be achieved.

Although the above-described corrugated plate forming apparatus is exemplified in which the forming rolls are simultaneously driven to rotate, the corrugated plate forming apparatus of the present invention is also capable of rotational driving other than this. That is, it is also possible to drive only one shaft of the forming roll to rotate while the other shafts of the forming rolls follow, or it is also possible to drive one or both axes of the backup roll to rotate. Furthermore, although the corrugated sheet forming roll is shown as an integral type, the forming apparatus of the present invention can also be used with a split roll mold that is appropriately divided or a roll mold that is appropriately divided and arranged separately.

〔Effect of the invention〕

According to the present invention, it is possible to easily achieve the optimum forming pressure distribution according to the corrugated shape to be formed, plate thickness, plate width, and material, so a corrugated plate with a good forming shape and high dimensional accuracy can be formed. can do. In addition, even if the sheet width is wide, the forming roll can be pressed at an appropriate position in the center via the back-up mechanism, so even small diameter forming rolls can be loaded with sufficient forming force and have a uniform forming pressure distribution. This makes it possible to form corrugated sheets with fewer defects.

In addition, the corrugated plate forming method of the present invention can form the final shape of the corrugated plate from a flat plate by passing it through one roll stand, so the structure of the forming device is very simple and the equipment cost is low. . Furthermore, since corrugated plate forming is performed continuously, mass production, low cost, and improved dimensional accuracy can be realized.

Furthermore, in the corrugated plate forming method of the present invention, it is only necessary to prepare a pair of forming rolls in order to change the forming shape, so the processing cost of the forming rolls is low, and the work of replacing the forming rolls is easy. be.

Further, since the corrugated plate forming apparatus of the present invention can perform all forming operations continuously and automatically, it is possible to save labor, save energy, and reduce the defect rate. Furthermore, since it is possible to perform molding while detecting the molding conditions and molding shape during molding, it is possible to control the molding conditions so as to mold a good corrugated sheet, and also to memorize and store data on these molding conditions. By regenerating, the previous molding conditions can be quickly reproduced. Furthermore, it is possible to analyze the cause of defects and remove defects during corrugated sheet molding, and the reproducibility of the molded shape is improved, which also improves the quality of the molded product.

[Brief explanation of the drawing]

FIG. 1 is a front sectional view of a corrugated sheet forming apparatus of the present invention, FIG. 2 is a forming roll, and FIG. 3 is a diagram showing the principle of the corrugated sheet forming method of the present invention. FIGS. 4 and 5 are explanatory diagrams of the forming pressure distribution when a flat plate is clamped with smooth rolls. 6 and 7 are explanatory diagrams of another embodiment of the corrugated plate forming method of the present invention. Figure 8 shows
FIG. 1 is a system diagram showing a corrugated plate forming system of the present invention. DESCRIPTION OF SYMBOLS 1... Forming roll, 2, 3... Backup roll, 9... Hydraulic cylinder, 19... Forming device, 20... Band-shaped flat plate, 21... Corrugated plate, 22, 2
3... Roll for backup, 24... Smooth roll, 25... Flat plate, 26... Roll for forming.

Claims (1)

[Scope of Claims] 1. A pair of forming rolls having a row of protrusions for corrugation on the cylindrical surface, a back-up mechanism for the forming roll, and a mechanism for applying forming force to the forming roll via the back-up mechanism. A wave forming device comprising a load control device and an upper base that holds the load control device, wherein the backup mechanism is composed of one roll or a roll divided into a plurality of rolls and a support mechanism thereof, and the load control device The upper base has a plurality of hydraulic cylinder mounting parts along the axial direction of the forming roll, and one hydraulic cylinder mounting part that can be installed at any location on the hydraulic cylinder mounting part and is attached to the forming roll via the back-up mechanism in the axial direction of the forming roll. A waveform shaping device comprising a hydraulic cylinder that can independently apply a load to one or more locations.