Continuous roll forming apparatus and method for forming a profile of non-uniform wall thickness

Abstract

This invention discloses a continuous roll forming apparatus and method for profiles with unequal wall thicknesses. It continuously forms a strip of material using multiple roll forming components until a pre-designed profile is obtained. The rolling distance of each roll forming component is adjustable to ensure that the rolling distance of each component is always consistent with the thickness of the strip segment currently being rolled. This invention can roll strips of unequal thicknesses into profiles with unequal wall thicknesses.

Description

Technical Field

[0001] This invention relates to the field of profile processing technology, specifically a continuous roll forming apparatus and forming method for profiles with unequal wall thicknesses. Background Technology

[0002] Door crash barriers are the main anti-collision components in side collisions of automobiles, requiring them to have sufficient strength while also meeting the requirements for localized energy absorption. Common cross-sectional shapes of door crash barriers include round tubes, rectangular tubes, quincunx-shaped tubes, and elliptical tubes.

[0003] Due to limitations in roll forming technology, current door crash barriers are made by roll forming high-strength plates of uniform thickness, then welding them together using high-frequency welding, and finally cutting them to the required length. This type of door crash barrier is not only heavy but also fails to meet local energy absorption requirements. Summary of the Invention

[0004] This application provides a continuous roll forming apparatus and forming method for profiles with unequal wall thickness, which can roll strips of unequal thickness to form profiles with unequal wall thickness.

[0005] The forming method of the continuous roll forming apparatus for profiles with unequal wall thickness provided in this application uses a continuous roll forming apparatus, which includes:

[0006] Multiple roll forming assemblies are located downstream of the material strip in the direction of travel. These multiple roll forming assemblies are used to continuously form the material strip until a pre-designed profile is obtained. The material strip has a different thickness along its direction of travel. The multiple roll forming assemblies are arranged at equal intervals along the direction of travel of the material strip. Each roll forming assembly includes two rolling rollers and a drive component for adjusting the rolling distance between the two rolling rollers.

[0007] The displacement detection device is located upstream of the conveyor belt in the direction of its forward movement and is used to detect the forward displacement data of the conveyor belt.

[0008] The thickness sensor is located upstream in the direction of the material belt's movement and is used to detect the thickness of the material belt every certain distance it travels.

[0009] The controller, coupled to the displacement detection device, the thickness sensor and the drive components of the multiple roll forming assemblies, is used to adjust the rolling gap of each roll forming assembly according to the data of the displacement detection device and the thickness sensor, so that the rolling gap of each roll forming assembly is always adapted to the thickness of the strip during the forward movement of the strip.

[0010] The number of roll forming components is: The roll forming components are marked in order of their distance from the thickness sensor. , ... , The distance to the thickness sensor is closest; the conveyor belt moves forward at a constant speed and the forward speed is... Thickness sensor and roll forming assembly The spacing is The spacing between any two adjacent roll forming components is ;

[0011] The molding method includes the following steps:

[0012] The forward displacement data of the conveyor belt is detected by a displacement detection device and sent to the controller;

[0013] In time The thickness sensor performs the first thickness detection on the strip, and then the strip advances a certain distance each time. Then the thickness sensor performs a thickness detection on the strip and sends the detection data to the controller. The controller arranges and stores the detection data of the thickness sensor in chronological order of detection time.

[0014] For roll forming components Its time The thickness sensor's detection data is then processed sequentially from the beginning. , =1, 2, ..., n; When each roll forming component executes the detection data of the thickness sensor, the roll forming component adjusts the roll forming gap to be consistent with the detection data of the thickness sensor; The action of each roll forming component executing the detection data of the thickness sensor is synchronized with the action of the thickness sensor detecting the thickness of the material strip.

[0015] Preferably, the strip is composed of several segments connected sequentially along its length. Each segment includes a first equal-thickness segment, a first transition segment, a second equal-thickness segment, a second transition region, a third equal-thickness segment, and a third transition region, all connected sequentially along the strip's length. The thicknesses of the first, second, and third equal-thickness segments are different. The thicknesses of the first, second, and third transition segments gradually change along the strip's length. The length of the third transition segment is... ;

[0016] Thickness sensor and roll forming assembly A punching device is installed between them, and the distance between the thickness sensor and the punching device is [missing information]. ;

[0017] During the conveyor belt's forward movement, whenever the thickness sensor detects a change in the belt's thickness from the third equal-thickness section to the third transition section, that moment is recorded. The conveyor belt then advances a further distance after that moment. During the process, the punching device punches the strip to create a process notch. After the strip is rolled to form a profile, the cutting device locates the cutting position by detecting the process notch. .

[0018] One or more technical solutions provided in this application have at least the following technical effects or advantages:

[0019] This application discloses a continuous roll forming apparatus and forming method for profiles with unequal wall thicknesses. It can roll strips of unequal thicknesses to form profiles with unequal wall thicknesses, which can be used to produce door anti-collision tubes with unequal wall thicknesses. The wall thickness of the door anti-collision tube is unequal along its length. The thicker wall areas of the door anti-collision tube result in greater strength, while the thinner wall areas reduce its weight. Furthermore, the thinner wall areas of the door anti-collision tube undergo localized plastic deformation upon impact, thereby absorbing impact energy and meeting the localized energy absorption requirements of the door anti-collision tube. Attached Figure Description

[0020] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0021] Figure 1 This is a schematic diagram of the continuous roll forming apparatus for profiles with unequal wall thicknesses according to the present invention.

[0022] Figure 2 This is a schematic diagram of the roll forming component.

[0023] Figure 3 This is a schematic diagram of the material strip structure;

[0024] Figure 4 This is a schematic diagram of the structure of the profile after roll forming. Detailed Implementation

[0025] like Figure 1 As shown, the continuous roll forming apparatus for profiles with unequal wall thickness in this embodiment includes multiple roll forming components 10, a displacement detection device, a thickness sensor 30, a controller, and a punching device 40.

[0026] Multiple roll forming assemblies 10 are located downstream of the feed strip 50 in the forward direction. These multiple roll forming assemblies 10 are used to continuously form the feed strip 50 until a pre-designed profile is obtained. The feed strip 50 has a different thickness along its forward direction. The multiple roll forming assemblies 10 are arranged at equal intervals along the forward direction of the feed strip 50.

[0027] like Figure 3 As shown, the strip 50 is a steel coil that has been leveled and then released. The strip 50 is composed of several sections 51, which are connected sequentially along the length of the strip. Each section 51 includes a first equal-thickness section 511, a first transition section 512, a second equal-thickness section 513, a second transition section 514, a third equal-thickness section 515, and a third transition section 516, all connected sequentially along the length of the strip 50. The thicknesses of the first equal-thickness section 511, the second equal-thickness section 513, and the third equal-thickness section 515 are different. The thickness of the first equal-thickness section 511 is 2.3 mm, the second equal-thickness section 514 is 5.3 mm, and the thickness of the third equal-thickness section 515 is 5.3 mm. The thickness of section 513 is 3mm, the thickness of the third equal-thickness section 515 is 1.6mm, and the thickness of the first transition section 512, the second transition section 514, and the third transition section 516 all gradually change along the length of the strip 50. That is, the thickness of the first transition section 512 gradually changes from 2.3mm to 3mm from right to left; the thickness of the second transition section 514 gradually changes from 3mm to 1.6mm from right to left; and the thickness of the third transition section 516 gradually changes from 1.6mm to 2.3mm from right to left. The length of the third transition section 516 is... .

[0028] like Figure 2 As shown, each roll forming assembly 10 includes two roll forming rollers and a drive component for adjusting the roll forming distance between the two roll forming rollers. The roll forming distance refers to the distance between the two roll forming rollers.

[0029] The roll forming assembly 10 has two rolling rollers, an upper rolling roller 11 and a lower rolling roller 12, which are spaced apart vertically. The roll forming assembly 10 includes a base 17. Two left columns 13 are vertically arranged on one side of the base 17, and two right columns 14 are vertically arranged on the other side of the base 17. The two left columns 13 and two right columns 14 are arranged in a rectangular pattern. A left fixed seat 122 and a left sliding seat 112 are fixedly mounted on the two left columns 13. The left fixed seat 122 is fixedly mounted on the two left columns 13, and the left sliding seat 112 is slidably mounted on the two columns. On the left column 13, the left sliding seat 112 is located above the left fixed seat 122. The right fixed seat 123 and the right sliding seat 113 are fixedly installed on the two right columns 14. The right fixed seat 123 is fixedly installed on the two right columns 14, and the right sliding seat 113 is slidably installed on the two right columns 14. The right sliding seat 113 is located above the right fixed seat 123. The left fixed seat 122 and the right fixed seat 123 are rotatably connected by a first roller shaft 121, and the left sliding seat 112 and the right sliding seat 113 are rotatably connected by a second roller shaft 111.

[0030] All the lower rolling rollers 12 of the roll forming assembly 10 are driving rollers, that is, the geared motor is connected to the first roller shaft 121 to drive the first roller shaft 121 to rotate, and the lower rolling roller 12 is fixedly sleeved on the first roller shaft 121, so that the lower rolling roller 12 is the driving roller.

[0031] The upper rolling rollers 11 of the first eight rolling forming assemblies 10 in the forward direction of the material belt 50 are all driving rollers. That is to say, in these rolling forming assemblies 10, the reduction motor is connected to the second roller shaft 111 to drive the second roller shaft 111 to rotate, and the upper rolling rollers 11 are fixedly sleeved on the second roller shaft 111, so that the upper rolling rollers 11 of the first eight rolling forming assemblies 10 in the forward direction of the material belt 50 are driving rollers.

[0032] Starting with the ninth roll forming assembly 10 in the forward direction of the material belt 50, the upper roll forming rollers 11 in the subsequent roll forming assemblies 10 are all driven rollers. In these roll forming assemblies 10, the upper roll forming rollers 11 are fixedly sleeved on the second roller shaft 111. The second roller shaft 111 is not driven by a reduction motor. The upper roll forming rollers 11 rotate with the rotation of the lower roll forming roller 12, so that starting with the ninth roll forming assembly 10 in the forward direction of the material belt 50, the upper roll forming rollers 11 in these roll forming assemblies 10 are driven rollers.

[0033] The strip 50 passes through each roll forming assembly 10 in sequence. The strip 50 is located between the upper rolling roller 11 and the lower rolling roller 12 of each roll forming assembly 10. Both the upper rolling roller 11 and the lower rolling roller 12 roll forward to drive the strip 50 forward. The upper rolling roller 11 and the lower rolling roller 12 are arranged vertically at intervals so that the strip 50 is continuously rolled and formed when passing through each roll forming assembly 10. After continuous roll forming by multiple roll forming assemblies 10, the strip is rolled into a tubular structure.

[0034] The driving components of the roll forming assembly 10 include two servo cylinders 15 and two servo valves 16. Hydraulic oil is supplied to the two servo cylinders 15 one-to-one through the two servo valves 16. The two servo valves 16 are coupled to the controller. The output shafts of the two servo cylinders 15 are both set downwards. The output shafts of the two servo cylinders 15 are respectively connected to the left sliding seat 112 and the right sliding seat 113. The two servo cylinders 15 synchronously drive the left sliding seat 112 and the right sliding seat 113 to move up and down. When the left sliding seat 112 and the right sliding seat 113 move up and down, they drive the second roller shaft 111 to move up and down synchronously, thereby making the upper rolling roller 11 move up and down synchronously to adjust the rolling distance between the upper rolling roller 11 and the lower rolling roller 12. This allows the rolling distance of the roll forming assembly 10 to be adjusted accordingly with the change of the thickness of the strip 50, so that the rolling distance of each roll forming assembly 10 can always match the thickness of the strip 50 segment currently being rolled.

[0035] The displacement detection device is located upstream of the conveyor belt 50 in the forward direction. The displacement detection device is used to detect the forward displacement data of the conveyor belt 50. The displacement detection device includes an encoder and a pressure roller 22. The encoder includes an encoding roller 21. The pressure roller 22 and the encoding roller 21 are arranged vertically. The rotation axes of the pressure roller 22 and the encoding roller 21 are both set horizontally and are perpendicular to the forward direction of the conveyor belt 50. The conveyor belt 50 is located between the pressure roller 22 and the encoding roller 21. The pressure roller 22 can float up and down. The pressure roller 22 presses the conveyor belt 50 tightly onto the encoding roller 21, so that the conveyor belt 50 can drive the encoding roller 21 to rotate synchronously when it moves forward. The encoder converts the forward displacement of the conveyor belt 50 into an electrical signal through the encoding roller 21, so that the displacement of the conveyor belt 50 can be detected by the encoder.

[0036] A fixed plate 23 and a spring 24 are provided above the pressure roller 22. The lower end of the spring 24 abuts against the pressure roller 22, and the upper end of the spring 24 abuts against the fixed plate 23. The spring 24 applies a downward elastic force to the pressure roller 22, so that the pressure roller 22 can float up and down, so that the pressure roller 22 can press the material strip 50 onto the coding roller 21. When the thickness of the material strip 50 changes, the pressure roller 22 can float up and down.

[0037] The thickness sensor 30 is located upstream of the material belt 50 in the forward direction. The thickness sensor 30 is used to detect the thickness of the material belt 50 once every certain distance the material belt 50 advances.

[0038] The controller is coupled to the encoder, thickness sensor 30 and servo valve 16 of multiple roll forming components 10. The controller adjusts the rolling gap of each roll forming component 10 according to the data of the encoder and thickness sensor 30 so that the rolling gap of each roll forming component 10 is always adapted to the thickness of the strip 50 during the forward movement of the strip 50.

[0039] In this embodiment, the number of roll forming components 10 is: The roll forming assembly 10 is marked sequentially according to its distance from the thickness sensor 30. , ... , The distance to the thickness sensor is closest; the conveyor belt moves forward at a constant speed and the forward speed is... Thickness sensor 30 and roll forming assembly The spacing is The spacing between any two adjacent roll forming components 10 is , This refers to the detection point of the thickness sensor 30 and the roll forming assembly. The distance at the middle position of the conveyor belt in the forward direction of 50. The forming method includes the following steps, where the distance between the midpoints of any two adjacent roll forming components 10 in the forward direction of the strip 50 is defined as:

[0040] The encoder detects the forward displacement data of the conveyor belt 50 and sends the data to the controller;

[0041] In time (Time t is a certain moment), the thickness sensor 30 performs the first thickness detection on the material strip 50, and then the material strip 50 advances a certain distance. If the thickness sensor 30 performs a thickness detection on the material strip 50, the thickness sensor 30 sends the detection data to the controller. The controller arranges and stores the detection data of the thickness sensor 30 in chronological order of detection time to form a data list. This data list is updated in real time. Every time the thickness sensor 30 performs a detection on the material strip 50, the data list is updated to add the latest detection data to the end of the data list.

[0042] For roll forming components Its time The thickness sensor's detection data is then executed sequentially from the beginning, meaning the data in the above data list is executed in order, starting with the first data point. ;

[0043] For roll forming components Its time The detection data from the thickness sensor 30 is executed sequentially from the beginning, whereby... ;

[0044] By analogy, for roll-formed components... Its time The thickness sensor's detection data is then processed sequentially from the beginning. , =1, 2, ..., n; When each roll forming component executes the detection data of the thickness sensor, the controller sends the corresponding detection data to the corresponding roll forming component, and the roll forming components adjust the rolling gap to be consistent with the detection data of the thickness sensor; the action of each roll forming component executing the detection data of the thickness sensor is synchronized with the action of the thickness sensor detecting the thickness of the strip. In this way, when the strip of unequal thickness moves forward, the rolling gap of each roll forming component can be adjusted so that the rolling gap of each roll forming component is always consistent with the thickness of the strip segment currently being rolled.

[0045] As shown in the table below, the thickness sensor 30 performs the first thickness detection of the strip 50 at time t, and then performs a thickness detection of the strip 50 every 10ms thereafter, obtaining the following data list:

[0046] Measurement time t t+10ms t+20ms t+30ms t+40ms t+50ms t+60ms t+70ms t+80ms t+90ms 。。。 t+91250ms Measuring material thickness 1.6mm 1.61mm 1.62mm 1.63mm 1.64mm 1.65mm 1.66mm 1.67mm 1.68mm 1.69mm 。。。 2.3mm

[0047] Each roll forming assembly executes the thickness sensor's detection data sequentially from the beginning. This means that each roll forming assembly starts with the first data point in the data list, 1.6 mm, and then executes the next data point in the data list every 10 ms from left to right.

[0048] When the rolling forming assembly 10 is adjusting the rolling gap, the two servo valves 16 receive data sent by the controller to adjust the oil circuit opening of the two servo cylinders 15, thereby precisely controlling the stroke of the two servo cylinders 15 so that the two servo cylinders 15 can precisely drive the left sliding seat 112 and the right sliding seat 113 to move up and down to adjust the rolling gap between the upper rolling roller 11 and the lower rolling roller 12.

[0049] Thickness sensor 30 and roll forming assembly A punching device 40 is installed between them, and the distance between the thickness sensor 30 and the punching device is [missing information]. , The distance between the detection point of the thickness sensor 30 and the marking point of the punching device 40.

[0050] During the forward movement of the conveyor belt 50, whenever the thickness sensor 30 detects a change in the thickness of the conveyor belt 50 from the third equal thickness section 515 to the third transition section 516, the controller records this moment, and then the conveyor belt 50 advances a further distance after that moment. During the process, the punching device punches the strip to create a process notch. After the strip is rolled to form a profile, the cutting device locates the cutting position of the profile by detecting the process notch. In this way, the punching device can punch the middle position of each third transition section 516 of the strip 50 to form a process gap. After the strip 50 is formed and welded to obtain a profile, once the sensor on the cutting device detects the process gap during the profile's forward movement, the cutting device will cut the profile at the process gap to obtain segmented profiles with consistent specifications.

[0051] like Figure 4 As shown, after the strip 50 is continuously rolled by multiple roll forming components 10, it forms a profile 60 with a rectangular cross section. After the strip 50 is bent and closed, straight connection points 61 are formed on both sides of the strip 50. The connection points 61 are fixed by welding so that the profile 60 is formed. Then, the profile 60 is subjected to subsequent cooling, shaping, straightening, cutting and other operations.

[0052] The above description is only a preferred embodiment of this application and is not intended to limit this application. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

[0053] This specification and accompanying drawings are merely illustrative examples of this application and are intended to cover any and all modifications, variations, combinations, or equivalents within the scope of this application. Clearly, those skilled in the art can make various alterations and modifications to this application without departing from its scope. Therefore, if such modifications and modifications fall within the scope of this application and its equivalents, this application intends to include such modifications and modifications.

Claims

1. A forming method for a continuous roll forming apparatus for profiles with unequal wall thicknesses, characterized in that, A continuous roll forming apparatus is used, the continuous roll forming apparatus comprising: Multiple roll forming assemblies are located downstream of the material strip in the direction of travel. These multiple roll forming assemblies are used to continuously form the material strip until a pre-designed profile is obtained. The material strip has a different thickness along its direction of travel. The multiple roll forming assemblies are arranged at equal intervals along the direction of travel of the material strip. Each roll forming assembly includes two rolling rollers and a drive component for adjusting the rolling distance between the two rolling rollers. The displacement detection device is located upstream of the conveyor belt in the direction of its forward movement and is used to detect the forward displacement data of the conveyor belt. The thickness sensor is located upstream in the direction of the material belt's movement and is used to detect the thickness of the material belt every certain distance it travels. The controller, coupled to the displacement detection device, the thickness sensor and the drive components of the multiple roll forming assemblies, is used to adjust the rolling gap of each roll forming assembly according to the data of the displacement detection device and the thickness sensor, so that the rolling gap of each roll forming assembly is always adapted to the thickness of the strip during the forward movement of the strip. The number of roll forming components is: The roll forming components are marked in order of their distance from the thickness sensor. , ... , The distance to the thickness sensor is closest; the conveyor belt moves forward at a constant speed and the forward speed is... Thickness sensor and roll forming assembly The spacing is The spacing between any two adjacent roll forming components is ; The molding method includes the following steps: The forward displacement data of the conveyor belt is detected by a displacement detection device and sent to the controller; In time The thickness sensor performs the first thickness detection on the strip, and then the strip advances a certain distance each time. Then the thickness sensor performs a thickness detection on the strip and sends the detection data to the controller. The controller arranges and stores the detection data of the thickness sensor in chronological order of detection time. For roll forming components Its time The thickness sensor's detection data is then processed sequentially from the beginning. , =1, 2, ..., n; When each roll forming component executes the detection data of the thickness sensor, the roll forming component adjusts the roll forming gap to be consistent with the detection data of the thickness sensor; The action of each roll forming component executing the detection data of the thickness sensor is synchronized with the action of the thickness sensor detecting the thickness of the material strip.

2. The molding method according to claim 1, characterized in that, The material strip is composed of several segments connected sequentially along its length. Each segment includes a first equal-thickness segment, a first transition segment, a second equal-thickness segment, a second transition region, a third equal-thickness segment, and a third transition region, all connected sequentially along the length of the material strip. The thicknesses of the first, second, and third equal-thickness segments are different. The thicknesses of the first, second, and third transition segments gradually change along the length of the material strip. The length of the third transition segment is... ; Thickness sensor and roll forming assembly A punching device is installed between them, and the distance between the thickness sensor and the punching device is [missing information]. ; During the conveyor belt's forward movement, whenever the thickness sensor detects a change in the belt's thickness from the third equal-thickness section to the third transition section, that moment is recorded. The conveyor belt then advances a further distance after that moment. During the process, the punching device punches the strip to create a process notch. After the strip is rolled to form a profile, the cutting device locates the cutting position by detecting the process notch. .

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