HK1060709B - A roll forming machine - Google Patents

Description

Roll forming machine

Field of the invention

The invention relates to a plant comprising forming/shaping rolls and, in a production line, a device for unwinding a thin metal sheet strip from a coil, strip shears and a sheet strip forming station equipped with rolls.

Description of the background Art

One method of covering a roof with a thin metal roof panel involves the use of standing seams, i.e. seams having a height that always extends above any water that may be present on the roof. It is known that such seams are not snapped together by squeezing, for example seams according to U.S.5,519,974 and U.S.5,535,567, wherein the sheets are interlocked together, with or without tape, at the respective seams after having been placed together, as described in U.S.6,115,899. The panels are secured to the roof at the seams, thereby avoiding the use of studs or bolts. Known apparatus for roll forming seam-formed edges typically only edge-form a uniform width sheet of material. Transverse seams are undesirable and in this way very long sheets can be produced. Long roof panels are sometimes produced with equipment that is lifted onto the roof. This allows the direct production of roofing panels that can cover very wide roofs, said panels being obtained from a strip-fed reel. As production is carried out on roofs, it may be necessary to handle strips of several tens of metres length.

JP9052125 describes an apparatus which can roll form the edge of a sheet material which tapers towards one end. Such panels are used, for example, to cover the roof of a round building. However, this apparatus is only capable of handling segmented sheets that have been cut and edged in other apparatuses.

Object of the Invention

The object of the present invention is to provide an apparatus which enables roll forming and/or roll forming of long sheets which do not necessarily have a constant uniform width, said sheets being cut directly from a strip. In principle, this object is achieved with an apparatus of the type mentioned in the introduction, wherein the roll-forming section comprises a forming table line comprising forming rolls supported with shafts on one side on each side of the sheet movement path, wherein the forming tables are motor-driven in each column or row for lateral movement relative to the forming section, wherein each column of forming tables is provided with a trimmer, and wherein the trimmers are connected to the first forming table so as to be movable therewith. The invention is defined in the appended claims.

Brief description of the drawings

Fig. 1 is a top view of one example of a sheet forming apparatus equipped with rollers according to the present invention.

FIG. 2 is a side view of the same apparatus.

FIG. 3 is a diagram showing an example of the sheet profile that can be obtained with the apparatus shown in FIGS. 1 and 2.

FIGS. 4, 5 and 6 are partial cross-sectional views of the components of the apparatus shown in FIGS. 1 and 2, respectively, the views being taken along lines 4-4, 5-5 and 6-6, respectively, in FIG. 1. Fig. 5 is also a cross-sectional view taken along line 5-5 of fig. 11.

FIG. 7 corresponds to the portion shown in FIG. 1, but some features are shown in different locations.

Fig. 8-10 correspond to fig. 7 and show different stages in the sheet roll forming operation.

Fig. 11 is a top view of a roll formed section according to the invention replacing the roll formed section shown in fig. 1 and 2.

Fig. 12 is a side view of the roll forming section shown in fig. 8.

FIG. 13 is a cross-sectional view taken along line 13-13 of FIG. 11

FIG. 14 is a cross-sectional view taken along line 14-14 of FIG. 13.

Fig. 15 and 16 show examples of roofing panels that can be produced with a plant comprising the roll-forming section shown in fig. 11-14.

Description of two exemplary preferred embodiments

Shown in fig. 1 and 2 is a roll forming machine comprising a device 11 for unwinding a strip 10, for example steel, copper, zinc or aluminium, from a coil 12 of metal strip. Also included is a strip centering device 14 which also has the function of advancing the strip, a sensor or detector 16 which measures the length of the advancing strip, two short roll forming sections 17, 19 and a shear 18. As shown in fig. 3, the roll formed sections 17 and 19 function to form two parallel grooves 21 and 22, 23, respectively, in the sheet 10. By separating the rollers from each other in the stations, one or both of the stations 17, 19 can be deactivated. Figure 3 shows the profile of the finished panel, which comprises upright sides 25, 26, said sides 25, 26 ending in semi-circular dome-shaped structures 27, 28, the dimensions of which are such that smaller structures can be fitted into larger structures. These smaller dome-shaped structures, i.e. structures 28, have a seal receiving groove 29 and are sealingly interlocked by means of a sealer to cover the roof. The panels are secured to the roof with clips that extend up into the seams and interlock. These clamps are screw-fitted to the roof, which means that the panels are completely free of threaded holes.

The side edges 25, 26 for shaping the sheet material and the front end of the shaping segment 30 for shaping the dome-shaped structures 27-29 are connected directly to the shears 18. The station 30 comprises two longitudinally extending forming table carriers 31, 32 for forming the web portions between the forming tables supported by the carriers. In fig. 2, carrier 32 is shown. It can be seen that the carrier body 32 is supported on four transverse guides 33a-d on the intermediate part 34 so that it can move at right angles to its longitudinal axis and to the longitudinal axis of the intermediate part. The intermediate part 34 is in turn pivotally mounted to a fixed chassis 35 on a pivot device 36 and is arranged on three slide belts 37 a-c. Thus, intermediate part 34 and carrier 32 can swing as a unit about pivot device 36, and carrier 32 can move on the intermediate part at right angles to its longitudinal axis. These movements are assisted by motors and controlled by a computer. In order not to complicate the problem, the strip is not shown in fig. 1 in the forming section 30, but in fig. 2.

The table carrier 31 is supported in the same manner as the table carrier 32 and its pivoting device 38 is shown in fig. 1.

Each of the table carriers 31, 32 carries four groups 40-43 and 44-47 with three pairs of tables, each having a forming roller on a free shaft, i.e. a shaft supported on one side. Each group has one motor for driving all three forming stations in the group. Such a drive is already present and is therefore not shown. The diagram shows all the roll shafts 71 without forming rolls; all of which are shown on each roll shaft are end plates that function to securely lock the form rolls to their respective shafts.

Fig. 4 and 5 are partial views of such pairs of forming tables facing each other. Fig. 1 and 2 show all the roll shafts 71 without forming rolls. The forming rollers 67-70 and 72-75 are shown separately in fig. 4 and 5 inserted into respective shafts 71. Fig. 4 shows a first pair of forming stations 50, 51 in the first set 40, 44, and fig. 5 shows a last pair of forming stations 52, 53 in the last set 41, 45. Fig. 5 is a partial view and shows only the forming rollers and the motors 76, 77 and the belt drive driving the rollers. Fig. 4 shows the respective drive motors 78, 79 and the belt drive.

The function of the first set of forming stations 40, 44 on each side is to form a channel extending parallel to the edges of the sheet. This set can be used instead of the units 17, 19 or together with the units 17, 19, said units 17, 18 being used to shape the grooves extending parallel to the line of symmetry of the sheet. The remaining sets 41-43 and 45-47 are used to form the upright side edges 25, 26. Not all pairs of forming tables are completely opposite each other but are offset from each other in a zigzag manner so as not to interfere with each other when producing narrow-shaped sheets. The fact that the forming table has free rollers, i.e. rollers supported on only one side, allows the rollers to be tilted. The inclination of the roll shafts thus in turn enables the forming rolls to have a relatively small diameter and a simple form, whereupon the roll pairs can be brought closer together and in a mutually offset form, so that the entire roll-forming section can be shortened.

Mounted on the carriers 31, 32 upstream of the pair of first forming stations 50, 51 are a pair of edge trimmers 58, 59, which pair of edge trimmers 58, 59 moves with a parallel movement of the pair of first forming stations 50, 51 simultaneously with respect to the angular arrangement and towards and away from each other, i.e. towards and away from the centre line of the forming section and thus also of the sheet path. The edge trimmer may be constituted by a disc cutter. Fig. 2 shows a cut edge 65.

Downstream of the last pair of forming stations is a pair of forming knives 63, 64 mounted on carriers 31, 32 for movement with the angular disposition and parallel movement of the last pair of forming stations to accompany the movement of the first pair of forming stations 50, 51 in a manner similar to edge trimmers 58, 59. As shown in fig. 6, the upstanding sides 25, 26 of the finished shape may be cut in forming tools 63, 64.

The shear 18 is a parallel shear having convex shear blades so that the blade overlap increases from the center. Thus, by appropriately adjusting the length of the shearing stroke, the shearing length can be varied and a cut can be made in the strip or plate that does not reach the edge. Alternatively, it may be completely cut off.

Fig. 1 shows a forming section 30 provided for forming a metal sheet having a constant width. It is then advantageously possible to shape a continuous strip and to cut the strip into the shape of a plate after the shaping of the strip. This allows a higher measurement accuracy to be obtained for the ends of the sheet. At this point the shears 18 shear to form a cut that does not reach the edge of the strip and then cut the edge into the finished shape using the forming tools 63, 64 as shown in figure 6. The start and end of the cutting operation is controlled by a computer to which a length measuring sensor 16 is connected. The edge trimmers 58, 59 need not be employed when the strip 10 has the correct width and fine edges. However, it is possible to use a slightly wider strip and cut off a narrow strip from the edges of the strip, thereby ensuring that a fine edge is obtained. A cut edge 65 is shown in fig. 2.

Fig. 7 shows a forming section suitable for forming a so-called conical plate, i.e. a plate narrowing towards one end. By the intermediate portion 34 swinging in the respective pivoting device and the portions being locked in their angularly set positions, the rear ends of the carrier bodies 31, 32 swing out symmetrically to each other.

Roll forming of the sheet material begins with oscillation of each intermediate section 34 in its transfer device 36, 38 and sliding on their respective slide belts 37a-c so that the forming table will be adapted to first form the widest end of a particular sheet material. This angular setting is locked. As shown in fig. 8, the sheet 10 is completely cut in the shears 18 to obtain individual sheets 66, the sheets 66 being fed into the forming section. When the sheet 66 is fed into the forming section 30 by the strip centering device 14, the carriers 31, 32 are moved parallel-symmetrically towards the centre line of the forming table with the aid of a ball screw (not shown), so that the edge cutters 58, 59 will continuously cut off the increasing edge strip and the width of the sheet is continuously reduced. Fig. 9 shows the sheet 66 halfway through the forming section, while fig. 10 shows the sheet 66 as it exits the section. The speed of advance of the sheet 66 and the speed of parallel movement of the carriers 32, 33 must be adapted so that the individual forming rollers of the different forming stations work in the correct grooves on the narrowed strip. This process is controlled by a computer connected to sensor 16 and sensors (not shown) that detect the width position of carriers 31, 32.

When the sensor 16 delivers a signal indicating that the strip should be cut, the computer stops the advancement of the strip and cuts the strip in the shears 18. The feeding and forming of the cut strip is then resumed until the forming of the sheet is complete, after which the formed/formed sheet is ejected from the forming unit 30.

When the forming of the plate material that has been cut out from the strip is finished, the measurement accuracy of the plate material end portion is worse than when the plate material is cut out from the strip to be formed. When it is desired to improve the accuracy of the measurement of said end, it is possible to make a cut with the shears 18, which does not reach the edge, and subsequently advance the strip through a distance of, for example, 1-2dm, after which the strip is completely severed. The strip then advances through 1-2dm and further forms a slit that does not reach the edge of the strip. Then, the forming cutters 63, 64 can completely cut the plate material along the aforementioned two cuts, and improve the end accuracy. This can improve the accuracy of the two ends at the expense of less than 0.5 meter of scrap between the two sheets and a slight drop in productivity during shut down.

In order to produce a sheet material with a pronounced taper and which is very narrow at one end, it may be necessary to separate the carrier so that the rear carrier parts with the last two sets of forming tables 42, 43, 46, 47 on each side can continue to move relative to each other when the sheet material has left the front two sets of forming tables 40, 41, 44, 45 and the front of the carrier cannot move closer together.

Fig. 7-10 show roll forming of a sheet material that narrows toward one end, with the widest portion of the sheet material being roll formed first. Of course, however, the narrowest end may be roll-formed first. This may be advantageous when the device is placed on the roof to be covered, close to the base of the roof, and when roll forming roof panels of a length of several tens of meters and sheet material facing towards the centre of the roof are roll formed, since the sheet material will thus face upwards with the correct end.

The length of the apparatus shown may be short enough to allow the apparatus to be used in a standard size shipping container, for example 12m x 2.4m, and the container is lifted with the apparatus by a crane onto the roof to be covered with roof panels. A diesel-driven power plant can be built into the vessel so that the plant can be self-contained. The invention is not limited to equipment for forming holding plates with vertical seams but can also be used for other types of roll forming.

Fig. 11 and 12 show a roll-formed section 90 modified from the roll-formed section 30 of the previous figures. The forming station 90 includes four respective sets 91-94 and 95-98 of forming stations on each side of the sheet portion, similar to the previous embodiment. In this embodiment, each group has a carrier that can move in parallel and whose angle can be adjusted individually. The carriers 100, 101 in the first group 91, 95 (corresponding to the carriers 31, 32 in fig. 1-2) carry respective edge cutters 102, 103, respectively, and in addition three forming stations 104 and 109. Since each group 91-98 can be adjusted individually, it is not only possible to work towards one end of the conical sheet, but it is also possible to produce a sheet material that contains the selected curved shape under given constraints, thereby providing a dome-shaped roof plate structure with a free design, e.g. drawn with a constant or variable radius of curvature. Fig. 15 and 16 show an example of a roof panel for a dome-shaped roof, which can be produced in the roll-formed part 90. The roofing panel comprises grooves 120, 121 extending parallel to the edges of the sheet, i.e. grooves made in the first set 91, 95 of forming tables in the forming section 90. The edge cutters 102, 103 are always moved simultaneously with the first pair of forming stations and, as in the previously described embodiment, the forming station can also be directly connected to a device for unwinding the strip.

Fig. 13 shows a first pair of forming stations 104, 107 in a first set 91, 95. Since the forming rollers are similar to those shown in fig. 4, the forming rollers are designated with the same reference numerals 67-70 as in fig. 4. Because of the symmetry, only the forming table 104 will be described. The forming rollers 69, 70 are carried by a carrier 100, said carrier 100 being mounted on a transfer device 111 (fig. 14) on the intermediate part 112. The intermediate part 112 is movably carried by slide bars 113, 114 on a fixed chassis (bracket) 115 and can be moved by means of a motor 116 and a ball screw 117. Carrier 100 is pivotally mounted to intermediate portion 112 by means of a motor 118 and a ball screw 119. Fig. 14 shows two alternative angular positions of the carrier 100 in the chain line.

The angle of the carrier body 100 can thus be adjusted relative to the longitudinal axis of the profiled section, and the carrier body can also be moved transversely in parallel relative to said longitudinal axis, so that the carried profiling table can be moved and angularly adjusted simultaneously. Each set of forming tables can be moved individually in this way, which means that in addition to producing sheets with straight edges, it is also possible to produce sheets with curved edges and varying radii of curvature on each individual sheet. Since each group contains more than one forming table and since the forming tables are each supported by one carrier, it can only be used to make one of the forming tables in each group follow the correct slot exactly, although with a reasonable radius of curvature the error will be only in the order of millimetres. Such errors will not affect the functionality. In the case of small radii of curvature, it is necessary to be able to adjust the individual shaping stations individually. However, as shown, two or more forming stations may actually be adjusted simultaneously.

Claims (10)

1. A roll forming apparatus comprising, in a production line, a device (11) for unwinding a metal strip (10) from a strip-carrying coil (12), a shear (18) for shearing the strip, and forming stations (30, 90) for forming the strip, said forming stations forming a sheet channel, characterized in that the forming section (30, 90) comprises a row of forming tables (50, 51, 52, 53, 104) 109 with forming rollers (67-75) on one single-sided supported shaft (71) on each side of the sheet section, wherein in each row the forming stations are movable across the forming stations by means of a mechanized drive, and wherein a trimmer (58, 59, 102, 103) is assigned to each row of forming stations and is connected for movement with the first forming station.

2. The apparatus as claimed in claim 1, characterized in that the edge cutters (58, 59, 102, 103) and the first forming stations (50, 51, 104, 107) in each row of forming stations are mounted on a common movable carrier (31, 32, 100, 101) for movement with one another.

3. Apparatus according to claim 1 or 2, characterized in that at each row of forming stations, several forming stations in the row are mounted on a carrier (31, 32, 100, 101), the angle of which carrier (31, 32, 100, 101) can be adjusted in relation to the longitudinal axis of the forming section, and which carrier can also be moved parallel transversely in relation to the longitudinal axis, so that a synchronized movement and angular adjustment of the forming stations is obtained.

4. A device as claimed in claim 3, characterized in that each row of forming stations comprises several carriers (31, 32, 100, 101) on the production line, which each carry two or more forming stations and are individually movable.

5. A device according to claim 3, characterised in that all the forming stations in each column are mounted on a common carrier (31, 32).

6. Apparatus according to claim 1, characterized in that at least a part of the two rows of forming stations are arranged so that the forming rollers (67-75) on either side are offset with respect to the forming rollers on the other side.

7. An apparatus according to claim 1, characterized in that at least a part of the forming stations have forming rolls (67-75) mounted on inclined axes.

8. Apparatus according to claim 1, wherein the shear (18) has a shearing edge that is convex towards the centre, and wherein the shear has a stroke of variable length, so that a variable length cut can be made towards the edge of the strip in the flat central portion of the strip, or the strip can be completely cut.

9. Apparatus according to claim 1, characterized in that the shears (63, 64) for profiled shearing of the edges are placed downstream of the last forming station.

10. The apparatus of claim 1, wherein the apparatus is provided in a shipping container.