Method and equipment for manufacturing three-dimensional curved corrugated steel plate

Abstract

A method for manufacturing three-dimensional curved corrugated steel plates, comprising the following steps: S1, pre-leveling: leveling a flat steel plate; S2, punching: feeding the pre-leveled steel plate into a punching machine for punching; S3, cold pressing: feeding the punched steel plate into a cold pressing machine for cold pressing to obtain a curved steel plate; S4, waving: feeding the curved steel plate into the waving machine via a CNC feeder, punching the curved steel plate to form multiple corrugations; S5, correction: adjusting the shape of the three-dimensional curved corrugated steel plate. A device for manufacturing three-dimensional curved corrugated steel plates, used to implement the above method, comprises a pre-leveling device, a punching machine, a cold pressing machine, a CNC feeder, a waving machine and a correction machine. The present invention solves the warping problem of the steel plate by pre-leveling, solves the width expansion problem of the steel plate during waving by correction, improves the dimensional consistency of the finished three-dimensional curved steel plate, and reduces the scrap rate, belonging to the field of steel plate processing.

Description

Technical Field

[0001] The present invention relates to the field of steel plate processing, and in particular to a method and equipment for manufacturing three-dimensional curved corrugated steel plates. Background Art

[0002] The three-dimensional curved corrugated steel plate structure has the advantages of high strength and good stability, and is widely used in industry. When manufacturing three-dimensional curved corrugated steel plates, the steel plates are generally punched first, then pressed into a curved shape, and then a wave punching machine is used to press multiple waves on the curved steel plates according to a certain wave pitch and depth. By controlling parameters such as wave pitch and wave depth, the curved corrugated steel plates can form different curvatures. At present, the manufacturing process of three-dimensional curved corrugated steel plates still has the following defects: (1) Punching is affected by the warping of the steel plates, and the hole position deviation will occur when punching a single hole, resulting in an increase in the scrap rate; (2) Punching a single hole requires frequent movement of the steel plates, and a large amount of lubricating oil needs to be applied, which not only causes pollution but also affects the subsequent anti-corrosion processing of the steel plates; (3) The steel plates will expand during the wave punching process, resulting in large dimensional deviations of the produced three-dimensional curved corrugated steel plates, which need to be adjusted during installation on site, reducing installation efficiency. Summary of the Invention

[0003] In view of the technical problems existing in the prior art, the purpose of the present invention is to provide a method and equipment for manufacturing three-dimensional curved corrugated steel plates with high efficiency and low scrap rate.

[0004] In order to achieve the above object, the present invention adopts the following technical solution: a method for manufacturing a three-dimensional curved corrugated steel plate, comprising the following steps:

[0005] S1, pre-leveling: leveling the flat steel plate;

[0006] S2, punching: the pre-leveled steel plate is fed into the punching machine for punching;

[0007] S3, cold press forming: feeding the punched steel plate into a cold press forming machine, cold press forming the steel plate to obtain a curved steel plate;

[0008] S4, corrugation: The curved steel plate is fed into the corrugation machine through a CNC feeder, and the corrugation machine is started to punch the curved steel plate, so that multiple corrugations are formed on the curved steel plate to obtain a three-dimensional curved corrugated steel plate;

[0009] S5, correction: adjust the shape of the three-dimensional curved corrugated steel plate.

[0010] After adopting this method, the steel plate is leveled before punching, which can solve the warping problem of the steel plate and avoid affecting the punching. After punching, it enters the cold press forming machine for forming. There is no need for rounding. The steel plate is directly punched into a curved surface. At this time, the curved steel plate is only bent in the transverse direction. When punching, multiple transverse corrugations are punched along the longitudinal direction of the curved steel plate, so that the steel plate is bent in the longitudinal direction to form a three-dimensional curved steel plate. During the punching process, the steel plate will expand to a certain extent, resulting in its width increasing or distortion. After punching, it is corrected to make the shape of the three-dimensional curved corrugated steel plate meet the design requirements.

[0011] As a preferred embodiment, in step S2, punching is performed by using multiple punching needles to punch holes in rows.

[0012] As a preferred embodiment, in step S4, the CNC feeder drives the curved steel plate to advance according to the required step distance. Each time the curved steel plate advances, the corrugator punches out a corrugation on the curved steel plate; by controlling the wave depth of each corrugation and the wave distance between two adjacent corrugations, the curvature of the three-dimensional curved corrugated steel plate is adjusted.

[0013] As a preferred embodiment, in step S5, the shape of the three-dimensional curved steel plate is adjusted by extrusion, and a ruler is used to measure the width during the correction process.

[0014] A device for manufacturing three-dimensional curved corrugated steel plates, used to implement the above-mentioned method for manufacturing three-dimensional curved corrugated steel plates, includes a pre-leveling device, a punching machine, a cold pressing machine, a CNC feeder, a wave punching machine and a correction machine. The steel plates are processed in sequence by the pre-leveling device, the punching machine, the cold pressing machine, the CNC feeder, the wave punching machine and the correction machine to obtain three-dimensional curved corrugated steel plates; the pre-leveling device includes a pressing roller for leveling the steel plates.

[0015] As a preferred embodiment, the pressing roller includes an upper pressing roller and a lower pressing roller, and the pre-leveling device also includes a leveling motor. The leveling motor drives the upper pressing roller and the lower pressing roller to rotate. When the steel plate passes through the pre-leveling device, the upper pressing roller and the lower pressing roller are respectively located above and below the steel plate and squeeze the steel plate. The lengths of the upper pressing roller and the lower pressing roller are both greater than the width of the steel plate.

[0016] As a preferred embodiment, it also includes a post-leveling device, the structure of the post-leveling device is the same as that of the pre-leveling device, and the punching machine is located between the pre-leveling device and the post-leveling device, so that the steel plate passes through the pre-leveling device, the punching machine and the post-leveling device in sequence, and then enters the cold press forming machine.

[0017] As a preferred embodiment, the punching machine includes a punching machine, which is provided with a punching die, the punching die includes an upper die base, an upper die assembly, a stripping plate, a lower die, and a lower die base, the upper die assembly includes a stamping plate, multiple cylinders and multiple punching needles, the upper die base, the stamping plate, the stripping plate, the lower die and the lower die base are arranged in sequence from top to bottom, the stamping plate is fixedly connected to the upper die base, the stripping plate is fixedly connected to the lower die, and the lower die is fixedly connected to the lower die base; the stamping plate is provided with multiple mounting holes, the mounting holes pass through the stamping plate up and down, the punching needles are connected to the stamping plate through the mounting holes, and the stripping plate is provided with stripping holes corresponding to the punching needles; the punching needles are clearance-matched with the stamping plate, and the upper surface of the stamping plate is slidably connected to multiple blocks, the cylinders are connected to the blocks and drive the blocks to move, and the moving area of the blocks includes above the mounting holes. When the blocks are located above the mounting holes, the upper end of the punching needles is supported by the blocks.

[0018] As a preferred embodiment, the correction machine includes a cylinder and an extrusion groove, and the output end of the cylinder is connected to the extrusion groove, so that the cylinder drives the extrusion groove to extrude from both sides of the three-dimensional curved corrugated steel plate to the middle.

[0019] As a preferred embodiment, the extrusion groove is a strip-shaped groove, and the cross section of the extrusion groove is a horizontal V-shape.

[0020] The cold press forming machine uses eight hydraulic cylinders with a nominal pressure of 1000kN to provide driving force to cold press the steel plates.

[0021] There are three CNC feeders, three wave punchers, and three levelers, and one each of pre-leveling, punching, and cold press forming. After the cold press forming machine, the steel sheets are divided into two sections for wave punching. Because the cold press forming step takes less time than the wave punching step, this setup maximizes machine utilization and improves production efficiency.

[0022] In general, the present invention has the following advantages:

[0023] 1. Improved production efficiency: The present invention uses an improved cold press forming machine to directly cold press flat steel plates, eliminating the need for rounding and reducing the number of steps. Furthermore, the invention employs a multi-punch punching method, which significantly reduces the time required for punching compared to existing punching methods. Consequently, a single production line can utilize one punching machine in conjunction with three wave punching machines, exponentially increasing the efficiency of the entire production system.

[0024] 2. Improved manufacturing precision and increased yield rate. The present invention utilizes row punching technology to improve punching precision. It utilizes an eight-column, eight-cylinder cold press machine, which provides high pressure and enables single-shot forming, preventing deformation of the steel plate. It also incorporates a pre- and post-punching leveling process to ensure the flatness of the steel plate. A post-punching correction process is added to reduce distortion. Therefore, by improving the multiple steps involved in manufacturing three-dimensional curved corrugated steel plate, the present invention improves manufacturing precision at each step and significantly reduces scrap rates. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 The present invention is a flow chart of a method for manufacturing three-dimensional curved corrugated steel plates.

[0026] Figure 2 It is a schematic diagram of the structure of the pre-leveling device, punching machine and post-leveling device.

[0027] Figure 3 This is a schematic diagram of the floor plan layout of the punching machine, cold press forming machine, wave punching machine and correction machine.

[0028] Among them, 1 is a pre-leveling device, 2 is a punching machine, 3 is a post-leveling device, 4 is a cold press forming machine, 5 is a wave punching machine, and 6 is a correction machine. DETAILED DESCRIPTION

[0029] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0030] Example 1

[0031] like Figure 1 As shown, a method for manufacturing a three-dimensional curved corrugated steel plate comprises the following steps:

[0032] S1, pre-leveling: leveling the flat steel plate;

[0033] S2, punching: the pre-leveled steel plate is fed into the punching machine for punching;

[0034] S3, cold press forming: feeding the punched steel plate into a cold press forming machine, cold press forming the steel plate to obtain a curved steel plate;

[0035] S4, corrugation: The curved steel plate is fed into the corrugation machine through a CNC feeder, and the corrugation machine is started to punch the curved steel plate, so that multiple corrugations are formed on the curved steel plate to obtain a three-dimensional curved corrugated steel plate;

[0036] S5, correction: adjust the shape of the three-dimensional curved corrugated steel plate.

[0037] After adopting this method, the steel plate is leveled before punching to solve the warping problem of the steel plate and avoid affecting the accuracy of punching. After punching, it enters the cold press forming machine directly for forming without the need for rounding. The steel plate is directly punched into a curved surface. The curved steel plate is only bent in the transverse direction, and the steel plate is not bent in the longitudinal direction. When punching, multiple transverse corrugations are punched along the longitudinal direction of the curved steel plate, so that the steel plate is bent in the longitudinal direction to form a three-dimensional curved steel plate. During the punching process, the steel plate will expand to a certain extent, resulting in its width increasing or distortion. After punching, its shape is adjusted to meet the design requirements.

[0038] In step S2, punching is performed by using multiple punching needles to punch holes in rows.

[0039] In step S4, the CNC feeder drives the curved steel plate to advance according to the required step distance. Each time the curved steel plate advances, the corrugator punches a corrugation on the curved steel plate. By controlling the depth of each corrugation and the distance between two adjacent corrugations, the curvature of the three-dimensional curved corrugated steel plate is adjusted.

[0040] In step S5, the shape of the three-dimensional curved steel plate is adjusted by extrusion, and the width is measured using a ruler during the calibration process.

[0041] like Figure 2 and Figure 3 As shown, a device for manufacturing three-dimensional curved corrugated steel plates is used to implement the above-mentioned method for manufacturing three-dimensional curved corrugated steel plates, including a pre-leveling device, a punching machine, a cold pressing machine, a CNC feeder, a wave punching machine and a correction machine. The steel plates are processed in sequence by the pre-leveling device, the punching machine, the cold pressing machine, the CNC feeder, the wave punching machine and the correction machine to obtain three-dimensional curved corrugated steel plates; the pre-leveling device includes a pressing roller for leveling the steel plates.

[0042] The CNC feeder is a commercially available product, the wave forming machine is an existing press machine combined with a specific wave forming die. The cold forming machine uses eight hydraulic cylinders with a nominal pressure of 1000kN to provide driving force for cold forming the steel plates.

[0043] There are three CNC feeders, three wave punchers, and three levelers, and one pre-leveler, one puncher, and one cold press. After the cold press, the steel sheets are divided into three sections for wave punching.

[0044] The pressure rollers include an upper pressure roller and a lower pressure roller, and the pre-leveling device also includes a leveling motor. The leveling motor drives the upper pressure roller and the lower pressure roller to rotate. When the steel plate passes through the pre-leveling device, the upper pressure roller and the lower pressure roller are respectively located above and below the steel plate and squeeze the steel plate. The lengths of the upper pressure roller and the lower pressure roller are both greater than the width of the steel plate.

[0045] It also includes a post-leveling device, the structure of which is the same as that of the pre-leveling device. The punching machine is located between the pre-leveling device and the post-leveling device, so that the steel plate passes through the pre-leveling device, the punching machine and the post-leveling device in sequence, and then enters the cold press forming machine.

[0046] The punching machine includes a punching machine, which is provided with a punching die. The punching die includes an upper die base, an upper die assembly, a stripper plate, a lower die, and a lower die base. The upper die assembly includes a punching plate, multiple cylinders, and multiple punching needles. The upper die base, the punching plate, the stripper plate, the lower die, and the lower die base are arranged in order from top to bottom. The punching plate is fixedly connected to the upper die base, the stripper plate is fixedly connected to the lower die, and the lower die is fixedly connected to the lower die base. The punching plate is provided with multiple mounting holes, which pass through the punching plate from top to bottom. The punching needles are connected to the punching plate through the mounting holes. The stripper plate is provided with stripping holes corresponding to the punching needles. The punching needles are fitted with a clearance between the punching plate and the upper surface of the punching plate. The cylinders are connected to the blocks and drive the blocks to move. The moving area of the blocks includes the area above the mounting holes. When the blocks are located above the mounting holes, the upper end of the punching needle is supported by the blocks. When the blocks deviate from the area above the mounting holes, the punching needle can slide up and down along the mounting holes, so that when the punching machine is started, the punching needle is in an empty punching state. The mounting holes, punching needles, stops and cylinders correspond to each other one by one, so that the position of each stopper can be adjusted by the cylinder, thereby adjusting the state of each punching needle to adapt to different punching requirements.

[0047] The correction machine consists of a cylinder and an extrusion trough. The cylinder's output end is connected to the extrusion trough, which drives the cylinder to squeeze the trough from both sides of the three-dimensional corrugated steel plate toward the center. During operation, the extrusion trough is located on both sides of the steel plate. The cylinder is activated to drive the extrusion trough toward the center of the steel plate, and the pressure is maintained for a period of time before being released to prevent additional distortion of the three-dimensional corrugated steel plate after the wave is impacted.

[0048] The extrusion groove is a strip groove, and the cross section of the extrusion groove is a horizontal V shape.

[0049] The cold press forming machine includes a hydraulic module and a forming module; the forming module includes a top plate, a base, a die, a punch and a slider, a guide column is connected between the top plate and the base, the slider is slidably connected to the guide column, the die is fixedly connected to the slider, the punch is connected to the base, and the top plate, slider, die, punch and base are arranged in sequence from top to bottom; the hydraulic module includes eight hydraulic cylinders for driving the slider to rise and fall, and the hydraulic cylinders are installed between the slider and the top plate, and the eight hydraulic cylinders are evenly distributed; a limiting mechanism for limiting and guiding the steel plate is provided between the top plate and the base, and the limiting mechanism is provided on both sides of the punch, and the limiting mechanisms on both sides are arranged linearly.

[0050] The limiting mechanism includes a slide rod, which is fixedly connected to the base. A pulley is mounted on the slide rod, and the pulley is fitted with a clearance between the slide rod and the slide rod. The pulley is a concave wheel. A spring is also mounted on the slide rod, and the spring is located below the pulley and is in a compressed state.

[0051] The above embodiments are preferred implementations of the invention, but the implementation of the present invention is not limited to the above embodiments. Any other changes, modifications, substitutions, combinations, and simplifications that do not deviate from the spirit and principles of the present invention should be considered equivalent replacement methods and are included in the scope of protection of the present invention.

Claims

1. An apparatus for manufacturing three-dimensional curved corrugated steel sheets, used to implement a method for manufacturing three-dimensional curved corrugated steel sheets, characterized in that: It includes a pre-leveling device, a punching machine, a cold press forming machine, a CNC feeder, a wave punching machine and a straightening machine. The steel plate is processed in sequence by the pre-leveling device, the punching machine, the cold press forming machine, the CNC feeder, the wave punching machine and the straightening machine to obtain a three-dimensional curved corrugated steel plate; the pre-leveling device includes a pressing roller for leveling the steel plate; It also includes a post-leveling device, the structure of the post-leveling device is the same as the pre-leveling device, and the punching machine is located between the pre-leveling device and the post-leveling device, so that the steel plate passes through the pre-leveling device, the punching machine and the post-leveling device in sequence, and then enters the cold press forming machine; The punching machine includes a punching machine, which is provided with a punching die, which includes an upper die base, an upper die assembly, a stripper plate, a lower die, and a lower die base. The upper die assembly includes a stamping plate, multiple cylinders and multiple punching needles. The upper die base, the stamping plate, the stripper plate, the lower die and the lower die base are arranged in sequence from top to bottom. The stamping plate is fixedly connected to the upper die base, the stripper plate is fixedly connected to the lower die, and the lower die is fixedly connected to the lower die base; the stamping plate is provided with multiple mounting holes, which pass through the stamping plate up and down, the punching needle is connected to the stamping plate through the mounting hole, and the stripper plate is provided with a stripping hole corresponding to the punching needle; the punching needle is clearance-matched with the stamping plate, and the upper surface of the stamping plate is slidably connected to multiple blocks, the cylinder is connected to the block and drives the block to move, and the moving area of the block includes the top of the mounting hole. When the block is located above the mounting hole, the upper end of the punching needle is supported by the block; The method comprises the following steps: S1, pre-leveling: leveling the flat steel plate; S2, punching: the pre-leveled steel plate is fed into the punching machine for punching; S3, cold press forming: the punched steel plate is fed into a cold press forming machine. The cold press forming machine uses eight hydraulic cylinders with a nominal pressure of 1000kN to provide driving force to cold press the steel plate to obtain a curved steel plate; S4, corrugation: The curved steel plate is fed into the corrugation machine through a CNC feeder, and the corrugation machine is started to punch the curved steel plate, so that multiple corrugations are formed on the curved steel plate to obtain a three-dimensional curved corrugated steel plate; S5, correction: adjust the shape of the three-dimensional curved corrugated steel plate.

2. The apparatus for manufacturing three-dimensional curved corrugated steel plates according to claim 1, characterized in that: In step S2, punching is performed by using multiple punching needles to punch holes in rows.

3. The apparatus for manufacturing three-dimensional curved corrugated steel plates according to claim 1, characterized in that: In step S4, the CNC feeder drives the curved steel plate to advance according to the required step distance. Each time the curved steel plate advances, the corrugator punches a corrugation on the curved steel plate. By controlling the depth of each corrugation and the distance between two adjacent corrugations, the curvature of the three-dimensional curved corrugated steel plate is adjusted.

4. The apparatus for manufacturing three-dimensional curved corrugated steel plates according to claim 1, characterized in that: In step S5, the shape of the three-dimensional curved steel plate is adjusted by extrusion, and the width is measured using a ruler during the calibration process.

5. The apparatus for manufacturing three-dimensional curved corrugated steel plates according to claim 1, characterized in that: The pressure rollers include an upper pressure roller and a lower pressure roller, and the pre-leveling device also includes a leveling motor. The leveling motor drives the upper pressure roller and the lower pressure roller to rotate. When the steel plate passes through the pre-leveling device, the upper pressure roller and the lower pressure roller are respectively located above and below the steel plate and squeeze the steel plate. The lengths of the upper pressure roller and the lower pressure roller are both greater than the width of the steel plate.

6. The apparatus for manufacturing three-dimensional curved corrugated steel plates according to claim 1, characterized in that: The correction machine includes a cylinder and an extrusion groove. The output end of the cylinder is connected to the extrusion groove, so that the cylinder drives the extrusion groove to extrude from both sides of the three-dimensional curved corrugated steel plate to the middle.

7. The apparatus for manufacturing three-dimensional curved corrugated steel plates according to claim 6, characterized in that: The extrusion groove is a strip groove, and the cross section of the extrusion groove is a horizontal V shape.

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