Roller welding forming method for convex guide rail and secondary shaping roller assembly used in the method

Abstract

The present invention discloses a roller-welding forming method for a convex guide rail, comprising the following steps: (1) forming, passing a steel strip blank through a convex guide rail pressure forming roller assembly, curling the steel strip to form a convex guide rail blank, wherein the perimeter of the convex guide rail blank is equal to the width of the steel strip; (2) high-frequency welding; (3) planing; (4) galvanizing; (5) cooling; (6) flaw detection; (7) cutting to a certain length; and (8) packaging. The present invention also discloses a secondary shaping roller assembly used in the roller-welding forming method for the convex guide rail.

Description

Technical Field

[0001] The invention relates to the technical field of welded pipe forming, and in particular to a roller-pressing welding forming method for a convex guide rail and a secondary shaping roller assembly used in the method. Background Art

[0002] Straight seam high-frequency welded steel pipe is made of curled and welded steel strip. The width of the steel strip is equal to the circumference of the steel pipe. The steel strip is first unwound on a decoiler, then cold-rolled and shaped, and then the pipe seam is welded by high-frequency induction heating to obtain a welded steel pipe. After being shaped and sized by a sizing roller, it is rolled into steel pipes of various specifications. The welded steel pipe can be cut into the required length as needed.

[0003] With the widespread application of convex guide rails in the elevator field, the demand for convex guide rails is increasing. At the same time, as an effective means to improve production efficiency in the process of convex guide rail forming, convex guide rail automatic forming equipment has gradually entered the market. However, the convex guide rail forming process is complicated, the accuracy is difficult to ensure, and the high difficulty of the forming process has not been effectively solved.

[0004] For example, the "production device of welded pipe unit" disclosed in Chinese patent CN110252825A includes a rounding mechanism, a guiding mechanism, a rolling mechanism, a welding mechanism and a planing mechanism. The rounding mechanism includes multiple groups of flat roller mechanisms and vertical roller mechanisms arranged alternately. The flat roller mechanism includes upper and lower rollers. The middle of the upper and lower rollers is equipped with upper and lower molds that match each other. The left and right ends of the upper and lower rollers are supported in the upper and lower roller bearing seats respectively, and the lower roller bearing seat is fixed at the bottom of the roller gantry. The welded steel pipe disclosed therein is rolled into round pipes of various specifications after being shaped and sized by sizing rollers, and does not involve other forming processes such as convex welded pipes and other special-shaped pipes.

[0005] In addition, due to the complexity of the convex guide rail forming process, there is a certain deformation error in the guide rail during the extrusion forming process, which makes the guide rail forming process unable to meet the accuracy requirements at one time. Therefore, it is necessary to add a secondary shaping process to make it meet the preset accuracy requirements. Summary of the invention

[0006] The technical problem to be solved by the present invention is to provide a roller welding forming method for a convex guide rail.

[0007] In order to solve the above technical problems, the technical solution adopted by the present invention is: a roll-welding forming method of a convex guide rail, comprising the following steps:

[0008] (1) Forming: the steel strip blank is passed through a convex guide rail pressure forming roller assembly to curl the steel strip to form a convex guide rail blank. The circumference of the convex guide rail blank is equal to the width of the steel strip, as follows:

[0009] (a) Flanging: The two sides of the plate are bent and flanged by flanging rollers with N1 forming passes. After the forming pass is completed, a flanging roller is used to correct the springback of the workpiece; the final flanging length is half the width of the guide rail installation surface, and the final flanging angle is 90°;

[0010] Let F1 be the total side length of the bending part of the flanging process, n1 be the number of all bending angles of the flanging process, t be the thickness of the plate, and use the shape factor function: θ1 = F1n1t to calculate the value of θ1. Compare it with the "Shape Factor and Forming Passes of Symmetrical Sections" curve in the "Cold Roll Forming Technology Manual" to obtain the number of forming passes N1;

[0011] The bending angle θ of the workpiece during flanging opt for: H is the length of the single side of the bent part of the flanging process, and t is the thickness of the workpiece;

[0012] The distribution of the bending angle of the flanging rollers in each pass is as follows:

[0013] The bending angle θ of the i-th roll forming 1i The total number of flanging passes is 1+N1, and the final bending angle of the force edge is θ 10 The relationship is: The bending angle θ of each forming pass is calculated by the above relationship. 1i Calculated;

[0014] (b) Upper cavity forming, using multiple forming rollers to roll out a trapezoidal portion that gradually bulges toward the edge of the flanging from the middle of the workpiece after flanging; after forming passes N2 times, the upper cavity of the convex guide rail is formed;

[0015] Use the shape factor function: θ2 = F2n2t, where F2 is the total side length of the upper cavity forming bending part, n2 is the number of all bending angles in the upper cavity forming process, and t is the thickness of the sheet. Calculate the value of θ2 and compare it with the "Shape Factor and Forming Passes of Symmetrical Sections" curve in the "Cold Roll Forming Technology Manual" to obtain the number of forming passes N2;

[0016] The distribution of the bending angle of the cavity forming roller in each pass is as follows:

[0017] The bending angle θ of the mth roll forming 2m The total number of upper cavity forming passes is N2, and the final bending angle of the force edge is θ 20 The relationship is: The bending angle θ of each forming pass is calculated by the above relationship. 2m Calculated;

[0018] (c) Lower cavity forming: using a forming roller with a forming pass number of N3 to complete the pressing of the supporting top plate of the workpiece corresponding to the guide rail guide part and folding the two side guide plates of the workpiece corresponding to the guide rail guide part toward each other by 90° to form the lower cavity of the convex guide rail.

[0019] Use the shape factor function: θ3 = F3n3t, where F3 is the total side length of the bending part of the lower cavity forming process, n3 is the number of all bending angles in the lower cavity forming process, and t is the thickness of the plate. Calculate the value of θ3 and compare it with the "Shape Factor and Forming Passes of Symmetrical Sections" curve in the "Cold Roll Forming Technology Manual" to obtain the number of forming passes N3;

[0020] The distribution of the bending angle of the cavity forming roller in each pass is as follows:

[0021] The p-th pass roll forming bending angle θ 3p The total number of lower cavity forming passes is N3, and the final bending angle of the force side is θ 30 The relationship is: The bending angle θ of each forming pass is calculated by the above relationship. 3p Calculated;

[0022] (d) Mold closing: the workpiece passes through the mold roller extrusion die and is molded under the extrusion of the left roller and the right roller, so that the two flange edges of the workpiece initially processed are butted together, so that the shape of the workpiece after mold closing is consistent with that of the finished product;

[0023] (2) High-frequency welding: the convex guide rail blank passes through the roller welding mechanism through the guide device. After the convex guide rail blank and the joint seam are further shaped, the high-frequency welding gun enters the joint seam from above for welding;

[0024] (3) Planing: The convex guide rail blank is scraped flat by the planing mechanism to improve the smoothness of the outer surface of the welded pipe;

[0025] (4) Galvanizing;

[0026] (5) Cooling;

[0027] (6) Flaw detection: ultrasonic or radiographic flaw detection is used to detect internal defects in welds, and magnetic powder, penetrant or eddy current flaw detection is used to detect surface and near-surface defects to check whether the workpiece is qualified after welding;

[0028] (7) Cutting to length;

[0029] (8) Packaging.

[0030] Preferably, after the cut-to-length sawing process is completed, a secondary shaping roller assembly is used for the qualified workpiece to eliminate the springback of the workpiece during the upper cavity forming process and the lower cavity forming process.

[0031] Preferably, during the upper cavity forming process, the inclination angles of the bevels of the raised trapezoidal portion on the formed workpiece on each pass roller are equal, and the sum of the lengths of the bevels on both sides of each pass roller plus the length of the connecting portion between the bevels is equal.

[0032] Preferably, in the cut-to-length sawing process, a sawing clamping device clamps and cuts the qualified welded workpiece.

[0033] Another technical problem to be solved by the present invention is to provide a shaping roller assembly for secondary shaping of the convex guide rail as described in the above forming method.

[0034] In order to solve the above technical problems, the technical solution adopted by the present invention is: a convex guide rail secondary shaping roller assembly, comprising a base, and a first roller assembly, a second roller assembly, and a third roller assembly arranged on the base;

[0035] The first roller assembly includes a first mounting seat arranged on a base, and a horizontally arranged lower roller and an upper roller are arranged in parallel on the first mounting seat for assisting positioning and guiding the convex guide rail.

[0036] The second roller assembly includes a second mounting seat arranged on the base and adjustable in position along the feeding direction, two first side rollers are arranged in parallel on the second mounting seat for respectively extruding the upper side surfaces of both sides of the convex guide rail, the bottom of the roller shaft of the first side roller is connected to the adjusting screw arranged on the second mounting seat through a nut seat, the two sections of the thread on the adjusting screw have opposite rotation directions, and the thread rotation directions of the two first side rollers corresponding to the nut seats are set to be opposite;

[0037] The third roller assembly includes a third mounting seat arranged on the base, and two second side rollers are arranged in parallel on the third mounting seat for respectively squeezing the lower side surfaces of both sides of the convex guide rail, and a locking assembly is mounted on the two second side rollers for preventing the two second side rollers from being stretched outward due to squeezing.

[0038] The locking assembly includes a locking plate fixedly arranged on the top of one of the second side rollers, a waist-shaped hole arranged along the line connecting the two second side rollers is provided on the locking plate, the upper end of the roller shaft of the other second side roller penetrates into the waist-shaped hole, an adjustment through hole arranged along the line connecting the two second side rollers is provided on the locking plate, an adjustment screw penetrates into the adjustment through hole and the end thereof pushes against the upper end of the roller shaft of the second side roller penetrated into the waist-shaped hole;

[0039] The bottom of the roller shaft of the second side roller is connected to the adjusting screw arranged on the third mounting seat through a nut seat, the two sections of thread on the adjusting screw have opposite rotation directions, and the thread rotation directions of the corresponding nut seats of the two second side rollers are set to be opposite.

[0040] Preferably, a fourth roller assembly is provided on the base at the feed side of the first roller assembly, the fourth roller assembly includes a fourth mounting seat arranged on the base, two third side rollers are arranged in parallel on the fourth mounting seat, which are respectively used to extrude the upper side surfaces on both sides of the convex guide rail, and the bottom of the roller shaft of the third side roller is connected to the adjusting screw arranged on the fourth mounting seat through a nut seat, the two sections of the thread on the adjusting screw have opposite rotation directions, and the thread rotation directions of the corresponding nut seats of the two third side rollers are set to be opposite.

[0041] Preferably, the first roller assembly, the second roller assembly and the third roller assembly are detachably arranged on the base in sequence along the feeding direction.

[0042] Preferably, the first roller assembly, the third roller assembly and the second roller assembly are detachably arranged on the base in sequence along the feeding direction.

[0043] Preferably, the positions of the first roller assembly, the third roller assembly and the second roller assembly are adjustable along the feeding direction on the base.

[0044] The beneficial effects of the present invention are:

[0045] The present invention proposes a production method different from the traditional welded pipe forming method, which meets the production demand of convex elevator guide rails in the production of elevator guide rails, greatly improves the production efficiency of the elevator guide rails through roll forming and welding processing, and greatly improves the production and processing accuracy of the elevator guide rails.

[0046] During flanging, the two sides of the plate are bent and flanging by using a flanging roller with a forming pass number N1. After the forming pass is completed, a flanging roller is used to correct the springback of the workpiece. By calculating the bending angle θ of the workpiece opt , and reasonably allocate the bending angle θ of each flanging roller 1i ; The final folding length is half of the width of the guide rail finished product installation surface, and the final folding angle is 90°, ensuring the product processing accuracy; In the upper cavity forming and the lower cavity forming, the forming bending angle θ is reasonably allocated in each forming pass 2m ,θ 3p , ensuring processing accuracy and improving the yield rate.

[0047] After the cut-to-size sawing process is completed, a secondary shaping roller assembly is used for qualified workpieces to eliminate the springback of the workpieces during the upper cavity forming and lower cavity forming processes, thereby further improving the precision and yield of the finished products. BRIEF DESCRIPTION OF THE DRAWINGS

[0048] Figure 1 Schematic diagram of flanging process for steel strip blank.

[0049] Figure 2 Schematic diagram of the flanging roller extrusion die.

[0050] Figure 3 This is a schematic diagram of the upper cavity processing of the steel strip blank.

[0051] Figure 4 Schematic diagram of the upper cavity forming roller extrusion die.

[0052] Figure 5 Schematic diagram of the lower cavity molding process.

[0053] Figure 6 Schematic diagram of the lower cavity forming roller extrusion die.

[0054] Figure 7 Schematic diagram of the clamping roller extrusion die.

[0055] Figure 8 It is a schematic diagram of the overall structure of the first layout of the convex guide rail secondary shaping roller assembly.

[0056] Fig. 9 It is another overall structural schematic diagram of the first layout of the convex guide rail secondary shaping roller assembly.

[0057] Fig.10 It is the front view of the first layout of the convex guide rail secondary shaping roller assembly.

[0058] Fig.11 It is the rear view of the first layout of the convex guide rail secondary shaping roller assembly.

[0059] Fig.12 It is a schematic diagram of the overall structure of the second layout of the convex guide rail secondary shaping roller assembly.

[0060] Fig.13 It is a schematic diagram of the convex guide rail structure.

[0061] Fig.14 This is a schematic diagram of the shaping effect of the second layout method of the convex guide rail secondary shaping roller assembly. DETAILED DESCRIPTION

[0062] The specific embodiments of the present invention are described in detail below in conjunction with the accompanying drawings.

[0063] like Figure 1-14 As shown, the roll-welding forming method of the convex guide rail comprises the following steps:

[0064] (1) Forming: the steel strip blank is passed through a convex guide rail pressure forming roller assembly to curl the steel strip to form a convex guide rail blank. The circumference of the convex guide rail blank is equal to the width of the steel strip, as follows:

[0065] (a) Flanging: The two sides of the plate are bent and flanged by a flanging roller with a forming pass number N1. After the forming pass is completed, a flanging roller is used to correct the springback of the workpiece; the final flanging length is half the width of the guide rail finished installation surface, and the final flanging angle is 90°.

[0066] Let F1 be the total side length of the bending part of the flanging process, n1 be the number of all bending angles of the flanging process, t be the thickness of the plate, and use the shape factor function: θ1 = F1n1t to calculate the value of θ1. Compare it with the "Shape Factor and Forming Passes of Symmetrical Sections" curve in the "Cold Roll Forming Technology Manual" to obtain the number of forming passes N1;

[0067] The bending angle of the workpiece θ opt for: H is the length of the single side of the bending part of the flanging process, t is the thickness of the workpiece, and the bending angle θ is obtained opt ;

[0068] The distribution of the bending angle of the flanging rollers in each pass is as follows:

[0069] The bending angle θ of the i-th roll forming 1i The total number of flanging passes is 1+N1, and the final bending angle of the force edge is θ 10 The relationship is: The bending angle θ of each forming pass is calculated by the above relationship. 1i Calculated;

[0070] (b) Upper cavity forming, using multiple forming rollers to roll out a trapezoidal portion that gradually bulges toward the edge of the flanging from the middle of the workpiece after flanging; after forming passes N2 times, the upper cavity of the convex guide rail is formed;

[0071] Use the shape factor function: θ2 = F2n2t, where F2 is the total side length of the upper cavity forming bending part, n2 is the number of all bending angles in the upper cavity forming process, and t is the thickness of the sheet. Calculate the value of θ2 and compare it with the "Shape Factor and Forming Passes of Symmetrical Sections" curve in the "Cold Roll Forming Technology Manual" to obtain the number of forming passes N2;

[0072] The distribution of the bending angle of the cavity forming roller in each pass is as follows:

[0073] The bending angle θ of the mth roll forming 2m The total number of upper cavity forming passes is N2, and the final bending angle of the force edge is θ 20 The relationship is: The bending angle θ of each forming pass is calculated by the above relationship. 2m Calculated;

[0074] During the upper cavity forming process, the inclination angles of the bevels of the raised trapezoidal portion on the formed workpiece on each pass roller are equal, and the sum of the lengths of the bevels on both sides of each pass roller plus the length of the connecting portion between the bevels is equal.

[0075] (c) Lower cavity forming: using a forming roller with a forming pass number of N3 to complete the pressing of the supporting top plate of the workpiece corresponding to the guide rail guide part and folding the two side guide plates of the workpiece corresponding to the guide rail guide part toward each other by 90° to form the lower cavity of the convex guide rail.

[0076] Use the shape factor function: θ3 = F3n3t, where F3 is the total side length of the bending part of the lower cavity forming process, n3 is the number of all bending angles in the lower cavity forming process, and t is the thickness of the plate. Calculate the value of θ3 and compare it with the "Shape Factor and Forming Passes of Symmetrical Sections" curve in the "Cold Roll Forming Technology Manual" to obtain the number of forming passes N3;

[0077] The distribution of the bending angle of the cavity forming roller in each pass is as follows:

[0078] The p-th roll forming bending angle θ 3p The total number of lower cavity forming passes is N3, and the final bending angle of the force side is θ 30 The relationship is: The bending angle θ of each forming pass is calculated by the above relationship. 3p Calculated;

[0079] (d) Mold closing: the workpiece passes through the mold roller extrusion die and is molded under the extrusion of the left roller and the right roller, so that the two flange edges of the workpiece initially processed are butted together, so that the shape of the workpiece after mold closing is consistent with that of the finished product;

[0080] (2) High-frequency welding: the convex guide rail blank passes through the roller welding mechanism through the guide device. After the convex guide rail blank and the joint seam are further shaped, the high-frequency welding gun enters the joint seam from above for welding;

[0081] (3) Planing: The convex guide rail blank is scraped flat by the planing mechanism to improve the smoothness of the outer surface of the welded pipe;

[0082] (4) Galvanizing;

[0083] (5) Cooling;

[0084] (6) Flaw detection: ultrasonic or radiographic flaw detection is used to detect internal defects in welds, and magnetic powder, penetrant or eddy current flaw detection is used to detect surface and near-surface defects to check whether the workpiece is qualified after welding;

[0085] (7) Cutting to size: During the cutting process, the sawing clamping device will clamp and cut the qualified welded workpiece.

[0086] After the cut-to-length sawing process is completed, the qualified workpiece is subjected to a secondary shaping roller assembly to eliminate the springback of the workpiece during the upper cavity forming and lower cavity forming processes.

[0087] (8) Packaging.

[0088] like Figure 8-Figure 11 As shown, a structure of a convex guide rail secondary shaping roller assembly mainly for adjusting the lower side of the convex guide rail includes a base, and a first roller assembly 1, a second roller assembly 2, and a third roller assembly 3 detachably arranged on the base in sequence along the feed direction.

[0089] The first roller assembly 1 includes a first mounting seat arranged on a base, on which a horizontally arranged lower roller 11 and an upper roller 12 are arranged in parallel for assisting the positioning and guiding of the convex guide rail 10; the lower roller 11 and the upper roller 12 are auxiliary extrusion rollers, which are used for assisting the extrusion and guiding of the convex guide rail 10, and can also play a shock-absorbing role in the fixed-length follow-up sawing process.

[0090] The second roller assembly 2 includes a second mounting seat arranged on the base and adjustable in position along the feed direction, and two first side rollers 21 are arranged in parallel on the second mounting seat, respectively used for extruding the upper side surfaces on both sides of the convex guide rail, and the bottom of the roller shaft of the first side roller 21 is connected to the adjusting screw arranged on the second mounting seat through a nut seat, and the two sections of the thread rotation directions on the adjusting screw are opposite, and the thread rotation directions of the two first side rollers 21 corresponding to the nut seats are set to be opposite; the screw adjustment method is adopted, which not only makes the adjustment fast, but also can meet the precision requirements of the upper side surface of the convex guide rail 10, and the forming accuracy is high.

[0091] The third roller assembly 3 includes a third mounting seat arranged on the base, on which two second side rollers 31 are arranged in parallel for respectively squeezing the lower side surfaces of both sides of the convex guide rail, and a locking assembly 32 is mounted on the two second side rollers 31 for preventing the two second side rollers 31 from being stretched outward due to squeezing.

[0092] The locking assembly 32 includes a locking plate fixedly arranged on the top of one of the second side rollers 31, and the locking plate is provided with a waist-shaped hole arranged along the line connecting the two second side rollers 31, and the upper end of the roller shaft of the other second side roller 31 is inserted into the waist-shaped hole, and the locking plate is provided with an adjustment through hole arranged along the line connecting the two second side rollers 31, and the adjusting screw is inserted into the adjustment through hole and the end thereof pushes against the upper end of the roller shaft of the second side roller 31 inserted into the waist-shaped hole; the screw adjustment method is adopted, which is not only fast to adjust, but also can meet the precision requirements of the upper side surface of the convex guide rail 10, and has high forming accuracy; the adjusting screw is inserted into the adjustment through hole and the end thereof pushes against the upper end of the roller shaft of the second side roller 31 inserted into the waist-shaped hole, which can effectively prevent the two second side rollers 31 from expanding outward due to extrusion, thereby further ensuring the processing accuracy.

[0093] The bottom of the roller shaft of the second side roller 31 is connected to the adjusting screw arranged on the third mounting seat through a nut seat, and the two sections of the thread on the adjusting screw have opposite rotation directions, and the thread rotation directions of the corresponding nut seats of the two second side rollers 31 are set to be opposite.

[0094] Specific adjustment method of the convex guide rail secondary shaping roller assembly:

[0095] (1) First, adjust the spacing between the second side rollers 31, fit the apex of the second side roller 31 to the intersection of the convex guide rail fillet, and further correct the spacing between the two second side rollers 31 until the width of the lower side of the convex guide rail meets the tolerance requirement;

[0096] (2) Then, a first side roller 21 is added, and the spacing of the first side rollers 21 is adjusted so that the upper side surface of the convex guide rail is shaped to meet the tolerance requirements;

[0097] (3) Finally, the spacing between the second side rollers 31 is further adjusted so that the lower side of the upper side of the convex guide rail after extrusion and shaping still meets the tolerance requirements.

[0098] like Figure 12-14 As shown, another structure of the secondary shaping roller assembly of the convex guide rail mainly for adjusting the upper side of the convex guide rail includes a base, and a first roller assembly 1, a third roller assembly 3, and a second roller assembly 2 which are detachably arranged on the base in sequence along the feed direction; the first roller assembly 1, the third roller assembly 3, and the second roller assembly 2 are adjustable in position along the feed direction on the base.

[0099] The first roller assembly 1 comprises a first mounting seat arranged on a base, on which a horizontally arranged lower roller 11 and an upper roller 12 are arranged in parallel for assisting positioning and guiding the convex guide rail 10.

[0100] The second roller assembly 2 includes a second mounting seat arranged on the base and adjustable in position along the feeding direction, two first side rollers 21 are arranged in parallel on the second mounting seat, which are respectively used to squeeze the upper side surfaces of both sides of the convex guide rail, and the bottom of the roller shaft of the first side roller 21 is connected to the adjusting screw arranged on the second mounting seat through a nut seat, and the two sections of the thread on the adjusting screw have opposite rotation directions, and the thread rotation directions of the two first side rollers 21 corresponding to the nut seats are set to be opposite;

[0101] The third roller assembly 3 includes a third mounting seat arranged on the base, on which two second side rollers 31 are arranged in parallel for respectively squeezing the lower side surfaces of both sides of the convex guide rail, and a locking assembly 32 is mounted on the two second side rollers 31 for preventing the two second side rollers 31 from being stretched outward due to squeezing.

[0102] The locking assembly 32 includes a locking plate fixedly arranged on the top of one of the second side rollers 31, a waist-shaped hole arranged along the line connecting the two second side rollers 31 is provided on the locking plate, the upper end of the roller shaft of the other second side roller 31 penetrates into the waist-shaped hole, and an adjustment through hole arranged along the line connecting the two second side rollers 31 is provided on the locking plate, the adjustment screw penetrates into the adjustment through hole and the end thereof pushes against the upper end of the roller shaft of the second side roller 31 penetrated into the waist-shaped hole;

[0103] The bottom of the roller shaft of the second side roller 31 is connected to the adjusting screw arranged on the third mounting seat through a nut seat, and the two sections of the thread on the adjusting screw have opposite rotation directions, and the thread rotation directions of the corresponding nut seats of the two second side rollers 31 are set to be opposite.

[0104] A fourth roller assembly 4 is provided on the base at the feeding side of the first roller assembly 1. The fourth roller assembly 4 includes a fourth mounting seat provided on the base. Two third side rollers are arranged in parallel on the fourth mounting seat, which are used to extrude the upper side surfaces of the two sides of the convex guide rail. The bottom of the roller shaft of the third side roller is connected to the adjusting screw provided on the fourth mounting seat through a nut seat. The two sections of the thread on the adjusting screw have opposite rotation directions. The thread rotation directions of the two third side rollers corresponding to the nut seats are set to be opposite. The fourth roller assembly 4 can prevent the guide rail from shaking left and right. The lower side of the convex guide rail is extruded and shaped first, and then the upper side is extruded and shaped. The secondary shaping effect is better. The shaping result is as shown in FIG. Fig.14 shown.

[0105] The above-mentioned embodiments are only illustrative of the principles and effects of the invention, as well as some embodiments of its application, and are not intended to limit the invention. It should be pointed out that a person skilled in the art can make several modifications and improvements without departing from the inventive concept of the invention, and all of these belong to the protection scope of the invention.

Claims

1. A roll-welding forming method for a convex guide rail, comprising the following steps: (1) Forming: the steel strip blank is passed through a convex guide rail pressure forming roller assembly to curl the steel strip to form a convex guide rail blank. The circumference of the convex guide rail blank is equal to the width of the steel strip, as follows: (a) Flanging: The two sides of the plate are bent and flanged by a flanging roller with a forming pass number N1. After the forming pass is completed, a flanging roller is used to correct the springback of the workpiece; the final flanging length is half the width of the guide rail finished installation surface, and the final flanging angle is 90°. Let F1 be the total side length of the bending part of the flanging process, n1 be the number of all bending angles of the flanging process, t be the thickness of the plate, and use the shape factor function: θ1 = F1n1t to calculate the value of θ1. Compare it with the "Shape Factor and Forming Passes of Symmetrical Sections" curve in the "Cold Roll Forming Technology Manual" to obtain the number of forming passes N1; The bending angle θ of the workpiece during flanging opt for: H is the length of the single side of the bent part of the flanging process, and t is the thickness of the workpiece; The distribution of the bending angle of the flanging rollers in each pass is as follows: The bending angle θ of the i-th roll forming 1i The total number of flanging passes is 1+N1, and the final bending angle of the force edge is θ 10 The relationship is: The bending angle θ of each forming pass is calculated by the above relationship. 1i Calculated; (b) Upper cavity forming, using multiple forming rollers to roll out a trapezoidal portion that gradually bulges toward the edge of the flanging from the middle of the workpiece after flanging; after forming passes N2 times, the upper cavity of the convex guide rail is formed; Using the shape factor function: θ2 = F2n2t, where F2 is the total side length of the bending part of the upper cavity forming process, n2 is the number of all bending angles in the upper cavity forming process, t is the thickness of the plate, and the value of θ2 is calculated and compared with the "Shape Factor and Forming Passes of Symmetrical Sections" curve in the "Cold Roll Forming Technology Manual" to obtain the number of forming passes N2; The distribution of the bending angle of the cavity forming roller in each pass is as follows: The bending angle θ of the mth roll forming 2m The total number of upper cavity forming passes is N2, and the final bending angle of the force edge is θ 20 The relationship is: The bending angle θ of each forming pass is calculated by the above relationship. 2m Calculated; (c) Lower cavity forming: using a forming roller with a forming pass number of N3 to complete the pressing of the supporting top plate of the workpiece corresponding to the guide rail guide part and folding the two side guide plates of the workpiece corresponding to the guide rail guide part toward each other by 90° to form the lower cavity of the convex guide rail. Use the shape factor function: θ3 = F3n3t, where F3 is the total side length of the bending part of the lower cavity forming process, n3 is the number of all bending angles in the lower cavity forming process, and t is the thickness of the plate. Calculate the value of θ3 and compare it with the "Shape Factor and Forming Passes of Symmetrical Sections" curve in the "Cold Roll Forming Technology Manual" to obtain the number of forming passes N3; The distribution of the bending angle of the cavity forming roller in each pass is as follows: The p-th roll forming bending angle θ 3p The total number of lower cavity forming passes is N3, and the final bending angle of the force side is θ 30 The relationship is: The bending angle θ of each forming pass is calculated by the above relationship. 3p Calculated; (d) Mold closing: the workpiece passes through the mold roller extrusion die and is molded under the extrusion of the left roller and the right roller, so that the two flange edges of the workpiece initially processed are butted together, so that the shape of the workpiece after mold closing is consistent with that of the finished product; (2) High-frequency welding: the convex guide rail blank passes through the roller welding mechanism through the guide device. After the convex guide rail blank and the joint seam are further shaped, the high-frequency welding gun enters the joint seam from above for welding; (3) Planing: The convex guide rail blank is scraped flat by the planing mechanism to improve the smoothness of the outer surface of the welded pipe; (4) Galvanizing; (5) Cooling; (6) Flaw detection: ultrasonic or radiographic flaw detection is used to detect internal defects in welds, and magnetic powder, penetrant or eddy current flaw detection is used to detect surface and near-surface defects to check whether the workpiece is qualified after welding; (7) Cutting to length; (8) Packaging.

2. The roll-welding forming method of a convex guide rail according to claim 1, characterized in that: After the cut-to-length sawing process is completed, a secondary shaping roller assembly is used for the qualified workpiece to eliminate the springback of the workpiece during the upper cavity forming process and the lower cavity forming process.

3. A roll-welding forming method for a convex guide rail as claimed in claim 2, characterized in that: During the upper cavity forming process, the inclination angles of the bevels of the raised trapezoidal portion on the formed workpiece on each pass roller are equal, and the sum of the lengths of the bevels on both sides of each pass roller plus the length of the connecting portion between the bevels is equal.

4. A roll-welding forming method for a convex guide rail as claimed in claim 3, characterized in that: In the process of cutting to length, the sawing clamping device clamps and cuts the qualified welded workpiece.

5. A secondary shaping roller assembly for use in a roll-welding forming method for a convex guide rail as claimed in any one of claims 2 to 4, characterized in that: It comprises a base, and a first roller assembly, a second roller assembly, and a third roller assembly arranged on the base; The first roller assembly includes a first mounting seat arranged on a base, and a horizontally arranged lower roller and an upper roller are arranged in parallel on the first mounting seat for assisting positioning and guiding the convex guide rail. The second roller assembly includes a second mounting seat arranged on the base and adjustable in position along the feeding direction, two first side rollers are arranged in parallel on the second mounting seat for respectively extruding the upper side surfaces of both sides of the convex guide rail, the bottom of the roller shaft of the first side roller is connected to the adjusting screw arranged on the second mounting seat through a nut seat, the two sections of the thread on the adjusting screw have opposite rotation directions, and the thread rotation directions of the two first side rollers corresponding to the nut seats are set to be opposite; The third roller assembly includes a third mounting seat arranged on the base, and two second side rollers are arranged in parallel on the third mounting seat for respectively squeezing the lower side surfaces of both sides of the convex guide rail, and a locking assembly is mounted on the two second side rollers for preventing the two second side rollers from being stretched outward due to squeezing. The locking assembly includes a locking plate fixedly arranged on the top of one of the second side rollers, a waist-shaped hole arranged along the line connecting the two second side rollers is provided on the locking plate, the upper end of the roller shaft of the other second side roller penetrates into the waist-shaped hole, an adjustment through hole arranged along the line connecting the two second side rollers is provided on the locking plate, an adjustment screw penetrates into the adjustment through hole and the end thereof pushes against the upper end of the roller shaft of the second side roller penetrated into the waist-shaped hole; The bottom of the roller shaft of the second side roller is connected to the adjusting screw arranged on the third mounting seat through a nut seat, the two sections of thread on the adjusting screw have opposite rotation directions, and the thread rotation directions of the corresponding nut seats of the two second side rollers are set to be opposite.

6. A secondary shaping roller assembly for use in the roll-welding forming method of a convex guide rail as claimed in claim 5, characterized in that: A fourth roller assembly is provided on the base at the feed side of the first roller assembly, the fourth roller assembly includes a fourth mounting seat arranged on the base, two third side rollers are arranged in parallel on the fourth mounting seat, which are respectively used to extrude the upper side surfaces on both sides of the convex guide rail, and the bottom of the roller shaft of the third side roller is connected to the adjusting screw arranged on the fourth mounting seat through a nut seat, the two sections of the thread on the adjusting screw have opposite rotation directions, and the thread rotation directions of the two third side rollers corresponding to the nut seats are set to be opposite.

7. A secondary shaping roller assembly for the roll-welding forming method of a convex guide rail as claimed in claim 6, characterized in that: The first roller assembly, the second roller assembly and the third roller assembly are detachably arranged on the base in sequence along the feeding direction.

8. A secondary shaping roller assembly for use in the roll-welding forming method of a convex guide rail as claimed in claim 6, characterized in that: The first roller assembly, the third roller assembly and the second roller assembly are detachably arranged on the base in sequence along the feeding direction.

9. A secondary shaping roller assembly for use in the roll-welding forming method of a convex guide rail as claimed in claim 7 or 8, characterized in that: The positions of the first roller assembly, the third roller assembly and the second roller assembly are adjustable along the feeding direction on the base.

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