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WO2013003880A1 - Procédé et appareil pour former des panneaux ondulés - Google Patents

Procédé et appareil pour former des panneaux ondulés Download PDF

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Publication number
WO2013003880A1
WO2013003880A1 PCT/AU2011/001652 AU2011001652W WO2013003880A1 WO 2013003880 A1 WO2013003880 A1 WO 2013003880A1 AU 2011001652 W AU2011001652 W AU 2011001652W WO 2013003880 A1 WO2013003880 A1 WO 2013003880A1
Authority
WO
WIPO (PCT)
Prior art keywords
ribs
interim
rib
profile
segments
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/AU2011/001652
Other languages
English (en)
Inventor
John Alastair EASLING
Brian Douglas Watson
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
REVROOF Pty Ltd
Original Assignee
REVROOF Pty Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from AU2011902692A external-priority patent/AU2011902692A0/en
Application filed by REVROOF Pty Ltd filed Critical REVROOF Pty Ltd
Priority to NZ620655A priority Critical patent/NZ620655A/en
Priority to AU2011372482A priority patent/AU2011372482B2/en
Publication of WO2013003880A1 publication Critical patent/WO2013003880A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D13/00—Corrugating sheet metal, rods or profiles; Bending sheet metal, rods or profiles into wave form
    • B21D13/04—Corrugating sheet metal, rods or profiles; Bending sheet metal, rods or profiles into wave form by rolling
    • B21D13/045—Corrugating sheet metal, rods or profiles; Bending sheet metal, rods or profiles into wave form by rolling the corrugations being parallel to the feeding movement

Definitions

  • the present invention relates to corrugated panels of the type typically used as a building material.
  • Such panels are normally formed from sheets of iron or steel strengthened by being formed into a series of smoothly curved, alternating, concave and convex ribs (presenting a generally sinusoidal profile), often galvanized, powdercoated or anodized for weather resistance and/or appearance.
  • Corrugated panels are building materials that have been used successfully for many years. There have of course been developments to corrugated panels, which have mainly related to the adoption of profiles other than the traditional, generally sinusoidal profile (such as profiles having square, trapezoidal, rectangular or triangular ribs rather than smoothly curved ribs, or complex arrangements of combinations of these other types of profiles). In the normal course, it will also be appreciated that the usual geometric variables of a corrugated panel are also often adjusted, such as the height (or depth) of the ribs, the radius of the rib arcs, the thickness of the sheet metal, the pitch of the ribs (being the crest-to-crest distance of the ribs), and the size of the flat section between alternating ribs.
  • corrugated panels have typically been by way of cold roll forming where ribs are rolled into a flat sheet of metal in progressive steps, the flat sheet being passed between different stages (or stations) of cooperating rollers that have surfaces configured with a desired profile able to impart a shape to a sheet of material passed therebetween, with intermediate stages providing an intermediate form to the sheet metal, and the last stage finalising the exact form of the desired profile.
  • the number and type of the intermediate stages, and the configuration of the surface profiles of the rollers for those intermediate stages, will depend upon the thickness and tensile strength of the metal and of course the nature of the final desired profile. Indeed, profiles that are reasonably complex might require intermediate stages to only contact the sheet at some locations across its width, or might require overbending or underbending of certain sections of the profile, in order to eventually result in the desired profile after passing through subsequent stages having rollers of different profiles. Indeed, the setting up of a roll forming machine to produce a desired profile is typically a time consuming process of trial and error where rollers of different profiles are trialled with the desired sheet metal and a variety of rollers with different surface profiles with the aim of producing a roll formed sheet of a certain final profile.
  • a common design difficulty brought about by the tensile strength and thickness of some metals is that a desired bend in a metal may not be achievable due to the phenomenon of "springback", even when a reasonably significant overbend is allowed for in one of the intermediate passes.
  • corrugated panels formed from sheet metal it has thus been virtually impossible to achieve (at an acceptable cost) ribs with a reasonably large radius, particularly with thinner materials and/or materials of higher tensile strength.
  • efforts to use traditional roll forming processes to achieve corrugated panels having a rib radius above about 25mm, and particularly above 40mm to 50mm (or more), particularly with material thicknesses as low as 0.3 to 0.4 mm (or lower) have typically failed to produce an acceptable product at an acceptable price.
  • the present invention provides a method of forming a corrugated panel from sheet metal, the corrugated panel having a plurality of alternating, concave and convex ribs, the method including the steps of: forming an interim profile in the sheet metal, the interim profile including alternating, concave and convex interim ribs, each of the interim ribs having alternating, concave and convex rib segments; and
  • the interim profile is formed, and the rib segments are then flattened, using traditional cold roll forming techniques and rollers whose surface profiles have been adapted to form the required interim and final profiles.
  • traditional cold roll forming techniques and rollers whose surface profiles have been adapted to form the required interim and final profiles.
  • other forming techniques could also be used, such as press forming (press breaking) or roll forming using barrel rollers.
  • interim profile need not actually be brought into existence during the manufacturing process in the form of a sheet where interim ribs (each having rib segments) are present across the full lateral extent of the sheet. This of course is contrary to the profile of the final product, where the smoothly curved, alternating, concave and convex ribs will physically exist in the final product and will indeed extend across the full lateral extent of the corrugated panel.
  • the ribs of a corrugated panel (and the interim ribs in the present invention) will be formed in stages along the length of a roll forming machine, with the innermost ribs of a sheet generally formed first.
  • ribs will be evident at some locations and not others, and interim ribs (being ribs defined by rib segments of the type mentioned above) will also be evident at some locations and not others.
  • the rib segments formed in accordance with the method of the present invention will also be evident in some locations and not others.
  • the rib segments that will be because, in some sections, the rib segments will not have been formed and because, in other sections, they will have been formed but already flattened.
  • the flattening of a rib segment will ideally occur soon after a rib segment is formed, such as in the next forming stage.
  • interim ribs may not yet have rib segments formed across the entire lateral extent thereof (but only partly thereacross). Indeed, some interim ribs may not require rib segments to be formed continuously across the entire lateral extent thereof. Indeed, the innermost ribs of a corrugated panel tend to be easier to form and thus tend to be impacted less by the forming difficulties mentioned above. It is thus possible that these innermost ribs will be formed satisfactorily with fewer rib segments being formed and flattened than might be required for the outermost ribs at the edges of the sheet.
  • the reference above to the corrugated panel having a plurality of smoothly curved, alternating, concave and convex ribs is intended to be a reference to the generally sinusoidal profile that is traditional in corrugated panels.
  • the reference to "smoothly curved" is important and is intended to distinguish from the interim profile where the interim ribs will not be smoothly curved as they will each be defined by the presence of the alternating concave and convex rib segments.
  • a smoothly curved rib is thus one which generally comprises only a single arc, being a single arc from which a single radius is able to be determined, not the plurality of arcs as present in the interim ribs (provided by the rib segments) of the invention.
  • an acceptable final profile for a corrugated panel produced by the present invention would be a profile where the rib segments have been flattened to an extent that the smoothly curved ribs do not have rib segments that can be seen by the naked eye when viewed at a distance of from about 2 to about 5 metres.
  • rib segments to be flattened to an extent that the smoothly curved ribs of the final profile will not have rib segments that can be felt by a person rubbing their finger over the rib, nor seen by that person when standing within touching distance of the corrugated panel.
  • corrugated panels formed in accordance with the method will have a rib radius above about 25mm with sheet metal having a thickness of from about 0.45mm or smaller.
  • corrugated panels formed in accordance with the method will have a rib radius above about 40mm with sheet metal having a thickness of from about 0.45mm or smaller.
  • the present invention also provides apparatus for forming a corrugated panel from sheet metal, the corrugated panel having a plurality of alternating, concave and convex ribs, the apparatus including: a primary forming means configured to form an interim profile in the sheet metal, the interim profile including alternating, concave and convex interim ribs, each of the interim ribs having alternating, concave and convex rib segments, and
  • a secondary forming means configured to flatten each rib segment of each interim rib so that the interim ribs become smoothly curved to form ribs of the corrugated panel.
  • the primary and secondary forming means are roll formers that are a part of a cold roll forming machine.
  • the rib segments can be formed in the interim profile by use of a roller having a surface that has been adapted to provide the required segments.
  • the rib segments are themselves a series of alternating, concave and convex segments that are formed by correspondingly shaped segments on the surface of a roller.
  • the surface profile of the roller may thus include a series of scalloped grooves extending about the periphery thereof, adjacent grooves being separated by a ridge therebetween, the ridge also extending about the periphery thereof.
  • the pitch, depth and radius (the curvature) of the scalloped grooves may be altered in accordance with the dimensions and profile required for the rib segments.
  • a similarly profiled roller may then be adapted for use in a next stage, but with oppositely configured scalloped grooves and ridges in order to flatten the rib segments in the manner mentioned above to form smoothly curved ribs.
  • the ridges of such an oppositely configured roller would align with the grooves of the rib segments, and the grooves of such an oppositely configured roller would align with the ridges of the rib segments, as the sheet with the interim profile is passed therethrough.
  • rollers for use in roll forming are generally provided as a set of rollers, with each set comprising a male and a female roller that together form a cooperating roller set.
  • the roll forming process then utilizes a number of adjacent roller sets in stages, there being multiple stages along the length of a roll forming machine, through which the sheet metal is passed for the corrugated panel to be formed.
  • the sheet metal ordinarily passes though many such stages, having rollers with varying surface profiles, before the final desired profile is formed.
  • Figure 1 is a cross-section of a corrugated panel (showing the final profile) formed by the method and apparatus of an embodiment of the present invention
  • Figure 2a is a cross-section of the interim profile formed during the production of the corrugated panel of Figure 1 , showing the interim ribs;
  • Figure 2b is an exploded view of a portion of the interim profile of Figure 2a, showing the rib segments of an interim rib of the interim profile;
  • Figure 3 is a cross-section of part of a stage of rollers able to be used to form the corrugated panel of Figure 1 , showing a formed metal sheet therewithin;
  • Figure 4a is a cross-section of a roller set from the stage of rollers of Figure 3, again showing a formed metal sheet therewithin;
  • Figure 4b is an exploded cross-section of a portion of the male roller of Figure 4a, showing the scalloped grooves and ridges used to form the rib segments of the interim profile of Figure 2a. Description of a Preferred Embodiment
  • FIG. 1 Illustrated in Figure 1 is the final profile of a corrugated panel 10 that is generally of the traditional generally sinusoidal profile, the panel 10 having a plurality of alternating, concave ribs 10a and convex ribs 10b across the entire lateral extent thereof.
  • the panel 10 is said to have 61 ⁇ 2 "ribs” due to the counting of "ribs” normally regarding a concave/convex rib pair (10a, 10b) as a single "rib” for industry purposes, although for the purposes of this patent specification reference is being made to both the concave “ribs” 10a and the convex "ribs” 10b as being ribs that together make up the profile of the corrugated panel.
  • the "pitch" of the panel 10 is the crest- to-crest distance P as shown in Figure 1
  • the height of the ribs 10a, 10b is the distance H.
  • P the pitch
  • H the height of the ribs 10a, 10b
  • the ribs 10a, 10b of the panel 10 are shown in Figure 1 as being smoothly curved in that a single radius R is defined by the continuous arc 12a, 12b of each rib 10a, 10b, the arc being defined by a radial angle ⁇ .
  • a single radius R is defined by the continuous arc 12a, 12b of each rib 10a, 10b, the arc being defined by a radial angle ⁇ .
  • ⁇ radial angle
  • the corrugated panel 10 will have an overall width of about 835mm (formed from a metal sheet having an initial width of about 990mm) and a pitch P of about 76mm (or 3 inches), which results in 101 ⁇ 2 "ribs" being present as referred to above.
  • the height H of the ribs will be about 21 mm
  • the radius R will be about 21 mm (with a radial angle of about 48°)
  • the material thickness T and material tensile strength will be about 0.42mm and 550MPa respectively.
  • the panel 10 having different metal thicknesses such as 0.35mm, 0.48mm, and 0.60mm, and different metal sheet sizes such as 762mm.
  • the minimum roof pitch for the panel 10 is 3° and, in addition to roofing, the panel 10 can be used for walling and fencing applications.
  • the corrugated panel 10 will have an overall width of about 831 mm (again formed from a metal sheet having an initial width of about 990mm) and a pitch P of about 121 mm (or 41 ⁇ 2 inches), which results in 7 "ribs" being present.
  • the height H of the ribs will be about 35mm
  • the radius R will be about 32mm (with a radial angle of about 47°)
  • the material thickness T and tensile strength will be about 0.42mm and 550MPa respectively.
  • the panel 10 can have different metal thicknesses such as 0.35mm, 0.48mm, and 0.60mm, and different metal sheet sizes such as 735mm.
  • the minimum roof pitch for the panel 10 is 2° and, in addition to roofing, the panel 10 can be used for walling applications.
  • the corrugated panel 10 will have an overall width of about 800mm (again formed from a metal sheet having an initial width of about 990mm) and a shallower pitch P of about 38.1 mm.
  • the height H of the ribs will be about 10mm.
  • the panel 10 has a metal thickness of 0.48mm and, in use, can be used for walling, ceiling, verandah and canopy applications.
  • the method of the present invention is able to produce corrugated panels of the dimensions of both of these preferred forms, using relatively thin sheet metal, resulting in significant cost savings per unit area of panel. Also, these corrugated panel profiles have other advantages over existing panels such as having deeper corrugations and being stronger.
  • Figures 2a and 2b are provided to illustrate one type of interim profile 20 that could be formed in accordance with the method of the present invention.
  • the interim profile 20 illustrated in Figure 2a includes interim ribs 20a, 20b that each have alternating, concave rib segments 22a and convex rib segments 22b, although given the scale of the drawing the rib segments 22a, 22b are only barely visible (upon very close inspection by the naked eye) in Figure 2a and indeed are not identified in Figure 2a by reference numerals.
  • the rib segments 22a, 22b are visible in the exploded view of an interim rib 20b provided in Figure 2b and are illustrated in the form of scalloped grooves (22a) separated by ridges (22b).
  • the grooves 22a are defined by an arc with a radial angle ⁇ and a radius Ri , whereas the ridges are defined by a smaller arc with a smaller radial angle ⁇ 2 and a smaller radius F1 ⁇ 2.
  • rib segments 22a,22b having grooves 22a of radius Ri of 15.5mm and a radial angle ⁇ 1 of 14° (or a radius Ri of 15.0mm and a radial angle ⁇ 1 of 17°) could be used in conjunction with ridges 22b with a radius R2 of 3.4mm and a radial angle ⁇ 2 of 23°.
  • the interim profile 20 is formed, and the rib segments 22a, 22b are then flattened, using traditional cold roll forming techniques and rollers whose surface profiles have been adapted to form the required interim profile 20 and final profile of the panel 10.
  • interim profile 20 With reference to the formation of the interim profile 20, although an interim profile 20 is illustrated in Figures 2a and 2b, it must be appreciated that the interim profile 20 need not actually be brought into existence during the manufacturing process in the form of a sheet where interim ribs 20a,20b, each having a full series of rib segments 22a, 22b, are present across the full lateral extent (width) of the sheet. As mentioned above, in roll forming it is likely that the ribs 10a, 10b of a corrugated panel 10 (and the interim ribs 20a, 20b of the interim profile 20) will be formed in stages along the length of a roll forming machine, with the innermost ribs of a sheet generally being formed first.
  • ribs 10a, 10b will be evident at some locations and not others, and interim ribs 20a, 20b (being ribs defined by rib segments 22a, 22b) will also be evident at some locations and not others.
  • the rib segments 22a, 22b will also be evident in some locations and not others because, in some sections, the rib segments 22a, 22b will not have been formed and because, in other sections, they will have been formed but already flattened. Additionally, some interim ribs 20a,20b may not yet have rib segments 22a, 22b formed across the entire width thereof (but only partly thereacross.
  • rollers for use in roll forming are generally provided in stages 30, with each stage 30 including the desired number of roller sets 32 (shown as 32a, 32b and 32c in Figure 3), with each set 32 comprising a male roller 34 and a female roller 36 that together form a cooperating roller set (32b).
  • the roll forming process then utilizes a number of adjacent roller sets 32 in stages 30, there being multiple stages 30 along the length of a roll forming machine, through which the sheet metal (identified in Figure 3 by the letter A) is passed for the corrugated panel 10 to be formed.
  • the sheet metal ordinarily passes though many such stages, having rollers (34,36) with varying surface profiles, before the final desired profile of the panel 10 is formed.
  • the rib segments 22a, 22b as shown in Figure 2b can be formed in the interim profile 20 by use of a roller 34 having a surface 34a that has been adapted to provide the required segments.
  • the rib segments 22a, 22b are themselves a series of alternating, concave and convex segments and they are formed in this form by correspondingly shaped segments on the surface of the roller 34.
  • the profile of the surface 34a of the roller 34 includes a series of scalloped grooves 37 extending about the periphery thereof, with adjacent grooves 37 being separated by ridges 38 therebetween, the ridges 38 also extending about the periphery thereof.
  • the pitch, depth and radius (the curvature) of the scalloped grooves 37 and of the ridges 38 may be altered in accordance with the dimensions and profile required for the rib segments 22a,22b of the interim profile 20.
  • the female roller 36 is of course similarly profiled.
  • a similarly profiled roller set is then adapted for use in a next stage, but with oppositely configured scalloped grooves and ridges in order to flatten the rib segments 22a,22b in the manner mentioned above to form the smoothly curved ribs 10a, 10b of the final profile of the panel 10.
  • the ridges of such an oppositely configured roller would align with the grooves 22a of the interim ribs 20a, 20b, and the grooves of such an oppositely configured roller would align with the ridges 22b of the interim ribs 20a, 20b, as the sheet with the interim profile 20 is passed therethrough.
  • an acceptable final profile for a corrugated panel 10 produced by the present invention would be a profile where the rib segments 22a, 22b have been flattened to an extent that the smoothly curved ribs 10a, 10b do not have rib segments that can be seen by the naked eye when viewed at a distance of from about 2 to about 5 metres.
  • a more preferred outcome (which is envisaged to be possible from, for example, the adoption of more accurate roller profiles or a more accurate flattening process) would be for the rib segments 22a, 22b to be flattened to an extent that the smoothly curved ribs 10a, 10b of the final profile of the panel 10 will not have rib segments that can be felt by a person rubbing their finger over the ribs 10a, 10b, nor seen by that person when standing within touching distance of the corrugated panel 10.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Bending Of Plates, Rods, And Pipes (AREA)
  • Laminated Bodies (AREA)

Abstract

L'invention porte sur un procédé de formation d'un panneau ondulé en tôle, le panneau ondulé comportant une pluralité de nervures alternées, concaves et convexes, le procédé comprenant les étapes consistant à former un profil provisoire dans la tôle, le profil provisoire comprenant des nervures provisoires alternées, concaves et convexes, chacune des nervures provisoires ayant des segments de nervure alternés, concaves et convexes, et à aplatir chaque segment de nervure de chaque nervure provisoire de manière que les nervures provisoires deviennent doucement incurvées pour former les nervures de la tôle ondulée.
PCT/AU2011/001652 2011-07-06 2011-12-21 Procédé et appareil pour former des panneaux ondulés Ceased WO2013003880A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
NZ620655A NZ620655A (en) 2011-07-06 2011-12-21 Method and apparatus for forming corrugated panels
AU2011372482A AU2011372482B2 (en) 2011-07-06 2011-12-21 Method and apparatus for forming corrugated panels

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
AU2011902692A AU2011902692A0 (en) 2011-07-06 Method and Apparatus for Forming Corrugated Panels
AU2011902692 2011-07-06

Publications (1)

Publication Number Publication Date
WO2013003880A1 true WO2013003880A1 (fr) 2013-01-10

Family

ID=47436361

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/AU2011/001652 Ceased WO2013003880A1 (fr) 2011-07-06 2011-12-21 Procédé et appareil pour former des panneaux ondulés

Country Status (3)

Country Link
AU (1) AU2011372482B2 (fr)
NZ (1) NZ620655A (fr)
WO (1) WO2013003880A1 (fr)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2565410A (en) * 2017-06-16 2019-02-13 Gram Engineering Pty Ltd Corrugated sheet and method of manufacturing same
CN114638828A (zh) * 2022-05-18 2022-06-17 数聚(山东)医疗科技有限公司 一种基于计算机视觉的放射影像智能分割方法

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB366617A (en) * 1930-11-14 1932-02-11 Richard Felix Summers Improvements in or relating to the corrugation of metal sheets
US4233833A (en) * 1978-06-05 1980-11-18 United States Gypsum Company Method for stretching sheet metal and structural members formed therefrom
WO1987004375A1 (fr) * 1986-01-17 1987-07-30 Trond Nilsen Machine pour conferer aux materiaux en feuilles des ondulations longitudinales variables
WO1988001208A1 (fr) * 1986-08-15 1988-02-25 Hoeglund Nils Goeran Machine a onduler de la tole ou autre
AU2001285613B2 (en) * 2000-09-15 2007-08-09 Bluescope Steel Limited Method and apparatus for the continuous press-forming of wide panels

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB366617A (en) * 1930-11-14 1932-02-11 Richard Felix Summers Improvements in or relating to the corrugation of metal sheets
US4233833A (en) * 1978-06-05 1980-11-18 United States Gypsum Company Method for stretching sheet metal and structural members formed therefrom
WO1987004375A1 (fr) * 1986-01-17 1987-07-30 Trond Nilsen Machine pour conferer aux materiaux en feuilles des ondulations longitudinales variables
WO1988001208A1 (fr) * 1986-08-15 1988-02-25 Hoeglund Nils Goeran Machine a onduler de la tole ou autre
AU2001285613B2 (en) * 2000-09-15 2007-08-09 Bluescope Steel Limited Method and apparatus for the continuous press-forming of wide panels

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2565410A (en) * 2017-06-16 2019-02-13 Gram Engineering Pty Ltd Corrugated sheet and method of manufacturing same
GB2565410B (en) * 2017-06-16 2020-08-26 Gram Engineering Pty Ltd Corrugated sheet and method of manufacturing same
CN114638828A (zh) * 2022-05-18 2022-06-17 数聚(山东)医疗科技有限公司 一种基于计算机视觉的放射影像智能分割方法

Also Published As

Publication number Publication date
NZ620655A (en) 2014-10-31
AU2011372482B2 (en) 2017-03-02
AU2011372482A1 (en) 2014-02-27

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