Door frame production process capable of automatically blanking auxiliary holes

Abstract

The invention discloses a door frame production process capable of automatically blanking auxiliary holes. The door frame production process comprises the steps that S1, materials are uncoiled and leveled for the first time; s2, the uncoiled materials are subjected to process hole blanking and secondary leveling on line; in the step S2, according to a preset program, the punching die, the cutting-off length and the punching interval are automatically matched; s3, the blanked material is subjected to process bending forming on line to form a door frame profile semi-finished product; s4, carrying out on-line cutting segmentation on the formed semi-finished product; s5, the two ends of the segmented semi-finished product are cut according to the splicing angle; s6, the cut semi-finished products are spliced into the door frame, and then every two adjacent splicing parts are fixedly connected and formed; after being leveled, the material is firstly subjected to punching, trepanning and notching in a plane state, and then is subjected to rolling forming through a door frame forming machine, so that the requirements on a to-be-machined hole site and a shearing surface are reduced, the door frame forming machine is suitable for producing door frames in various shapes, the door frame process production flow is reduced, and the production efficiency is improved.

Description

[0001] This application is a divisional application of a patent application with an application date of October 26, 2022, an application number of 202211321849.X, and an invention title of "A production process for door frames". Technical Field

[0002] The present invention relates to the technical field of door frame production, and particularly to a production process for door frames with automatic punching of process holes. Background Art

[0003] Door frames are common in daily life. There are many types of door frames on the market. However, currently, manufacturers have chaotic processes when producing door frames, including frame assembly → hot pressing → trimming and precision cutting → milling the door core board → milling the door trim line → skin pasting → door closing → drilling lock holes and hinge holes → trial assembly → spraying. The process route is long and the quality is generally not high. Application No. 201310352415.0 discloses a door frame forming process, in which a metal plate meeting the specifications is preliminarily formed by rolling to make a semi-finished workpiece with a folded structure, and other holes to be opened and cutting surfaces to be sheared on the semi-finished workpiece are on the same stamping and cutting surface; the obtained semi-finished workpiece is placed in a special punching die, hole-opening die, and punching defect die, and the hole-opening die, punching defect die and punching die are assembled on the same combined punching press in cooperation; the punching die, hole-opening die and punching defect die are used to synchronously perform 45-degree chamfering, punching and punching defects on the semi-finished workpiece; a bending machine is used for bending and forming to complete the production of a single-piece door frame border; the upper border and two side borders respectively made according to the above steps are welded at the diagonal corners to make an integral door frame. This door frame production method requires that the holes to be opened and the cutting surfaces to be sheared of the door frame profile are on the same stamping and cutting surface, and has special requirements for the cross-sectional shape of the door frame. The production steps of this process are not conducive to the production of door frames where the holes to be opened and the cutting surfaces to be sheared are not on the same plane, and cannot adapt to the production of door frames with different shapes. Summary of the Invention

[0004] The purpose of the present invention is to solve the above technical problems, and provide a production process for door frames with automatic punching of process holes, which directly punches the sheet without preliminary forming, reduces the requirements for the holes to be processed and the cutting surface, is suitable for the production of door frames of various shapes, reduces the production process flow of door frames, and improves production efficiency.

[0005] To achieve the above purpose, the present invention adopts the following technical scheme: A production process for door frames with automatic punching of process holes, including: S1: Uncoil and level the material for the first time. S2: Punch the process holes and level the material for the second time online for the uncoiled material. S3: Bend the material online after punching to form a semi-finished door frame profile. S4: Cut the formed semi-finished product into segments online. S5: Cut both ends of the semi-finished product after segmentation according to the splicing angle. S6: Splice the cut semi-finished products into a door frame, and then fixedly connect adjacent splicing parts to form a shape.

[0006] In order to continuously perform blanking online, a further preferred technical solution is that in the step S2, according to a preset program, automatically corresponding to the punching die, cutting length, and punching pitch, at least includes: S21: Reserve holes for the stamping process; S22: Punch hinge holes; S23: Punch left and right lock holes; S24: Punch lock piece fixing holes; S25: Punch mounting holes; S26: Punch cut notches.

[0007] In order to continuously form the material online, a further preferred technical solution is that in the step S3, at least includes: S31: Bend one side of the material upward by 89 degrees through a set of continuous forming roller dies to form a first bending part, and at the same time bend the other side of the material downward by 89 degrees to form a second bending part, and a first long side is formed in the middle part; S32: Bend the first bending part downward by 180 degrees through a set of continuous forming roller dies, and at the same time bend the second bending part upward by 180 degrees; S33: Bend the first bending part 89 degrees toward the second bending part to be parallel to the first long side and form a first short side, and at the same time bend the second bending part 89 degrees toward the first bending part to be parallel to the first long side and form a second short side, and then cross-engage the first bending part and the second bending part through a set of continuous forming roller dies to form a second long side.

[0008] In order to continuously form the material online to form the end face required for the profile, a further preferred technical solution is that the semi-finished product cross-section after the material is formed in the step S3 includes a quadrilateral cavity, a first extension part extending outward along a short side of the quadrilateral cavity and formed by two layers of materials stacked, and a second extension part extending outward along the other short side of the quadrilateral cavity and formed by two layers of materials stacked. The end of the second extension part also has a bending part extending toward the long side. The second short side is bent into a U shape, the first short side is bent into a reverse S shape, and a closed structure is pressed and formed by positive and negative cross-engagement at one long side of the quadrilateral cavity.

[0009] Since the forming process and the blanking process have different online speeds, in order to achieve automatic continuous production, a further preferred technical solution is that between the step S2 and the step S3, the material enters the pit downward and leaves the pit upward after passing through a pair of driving rollers.

[0010] In order to achieve stable operation of the uncoiler and ensure the flatness requirement of the material during blanking, a further preferred technical solution is that in the step S1, a single-head vertical uncoiler is used, and after uncoiling, it is leveled once by at least 2 pairs of rollers.

[0011] In order to achieve stable operation of the uncoiler and ensure the flatness of the material after blanking, a further preferred technical solution is that in the step S2, it enters the combined punching machine, continuously punches process holes online, and after being leveled twice by at least 2 pairs of rollers.

[0012] In order to make the forming operation stable and ensure the quality after forming, a further preferred technical solution is that in the step S3, the maximum rolling thickness is 1.2 mm, the feeding expansion is less than 371 mm, and the rolling speed is 0 - 8 m per minute.

[0013] In order to facilitate the splicing of the door frame and have a suitable splicing angle, a further preferred technical solution is that in the step S5, the semi-finished product is placed on the workbench, and the two ends of the door frame are cut at a 45° angle with a corner cutting machine.

[0014] In order to ensure the welding quality of the door frame and improve the welding efficiency, a further preferred technical solution is that the step S6 at least includes: S61: Place the semi-finished product on the workbench, adjust the position of the fixture slider according to the position of the positioning holes on the workbench to position the inner side of the spliced semi-finished product; S62: Adjust the position of the clamping cylinder according to the position of the positioning holes on the workbench to clamp the outer side of the spliced semi-finished product and the splicing part of the semi-finished product; S63: Perform welding with a laser welder.

[0015] Compared with the prior art, the beneficial effects of the present invention are as follows: After leveling, punching, opening holes, and punching notches are first performed in the flat state of the material, and then it is roll-formed by a door frame forming machine, which reduces the requirements for the holes to be processed and the shear surface, is suitable for the production of door frames of various shapes, reduces the door frame process production process, and improves production efficiency; it is convenient to continuously arrange uncoiling, combined blanking, material transition support, door frame forming, and cutting segmentation, and is convenient to realize an automated production line for online punching and forming of door frames without manual operation on site. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 is the process flow chart of the present invention; Figure 2 is the cross-sectional view of the formed door frame of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0017] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all of the embodiments. Embodiment

[0018] As Figure 1 shown, a production process for door frames with automatically blanked process holes includes S1: uncoiling and first flattening the material; S2: performing process hole blanking and second flattening on the uncoiled material online; S3: performing process bending on the blanked material online to form a semi-finished door frame profile; S4: cutting the formed semi-finished product into segments online; S5: cutting the two ends of the segmented semi-finished product at the splicing angle; S6: splicing the cut semi-finished products into a door frame, and then fixedly connecting and forming the two adjacent splicing parts.

[0019] Specifically, install galvanized sheet coil materials with a steel plate thickness of 1.0 - 1.2 mm and a steel plate width less than 371 mm in a single-head vertical uncoiler. The weight of the material should be less than 5 kg. Uncoil the material, and there is a 9-pair roller leveling mechanism at the output end of the single-head vertical uncoiler to perform first flattening on the material; The material after uncoiling and first flattening enters the combination punching press through the input end of the combination punching press. The output end of the combination punching press includes a servo feeder, which performs wall-mounted 9-roll flattening, leveling and feeding. The gap between the upper and lower rollers is manually adjusted with a lead screw. There are supporting rollers and guiding mechanisms at the input end. The power of the feeder (servo motor) is 4KW with a reducer. Multiple stamping units are installed on the corresponding stations of the combination punching press. Each stamping unit is equipped with a fine-tuning screw. Rotating the screw can longitudinally adjust the center position of each side stamping unit. Then, lock the stamping unit. The actuating element of the stamping mechanism is a hydraulic cylinder to provide stamping power. There is a mold on the platform, with the material CR12MOV and a quenched hardness of HRC58° - 62° to ensure that a single set of punching dies can be used normally for no less than 100,000 times. There is a blanking hole in the middle of each set of molds. An automatic waste recycling device is provided under the combination punching press. The maximum input power of the main and auxiliary cylinders (single cylinder): 7.5KW, hydraulic pump, with an air cooling system, and the working pressure is 25MPA; According to the preset program, automatically corresponding to the punching die, cutting length and punching spacing, perform the following operations on the material after second flattening in sequence at the corresponding stamping units online: S21: stamping process reserved holes; S22: stamping hinge holes; S23: stamping left and right lock holes; S24: stamping lock piece fixing holes; S25: stamping mounting hole one, mounting hole two, mounting hole three, etc.; S26: stamping cut notch one, notch two and spare holes; After blanking, the material is leveled by the wall-mounted 9-roll and second-leveled and fed through the output end of the combination punching press; Since the online speeds of the forming process and the blanking process are different, in order to achieve automatic continuous production, further, between the step S2 and the step S3, the material descends into a pit, passes through a pair of driving rollers, and then leaves the pit upward; specifically, a pit is provided on the bottom surfaces of the combined punching machine and the door frame forming machine, a pair of driving rollers are provided in the pit, the material enters the pit after being discharged from the output end of the combined punching machine, then passes through between the pair of driving rollers and then enters the door frame forming machine. In this way, the material at the output end of the combined punching machine can be transitioned through the pit to make up for the production capacity of the door frame forming machine being lower than that of the combined punching machine; The blanked material enters the input end of the door frame forming machine after passing through the pit, and is bent and formed online to form a semi-finished door frame profile. The rolling die material of the door frame forming machine is: CGr15 + Cr12MoV, the heat treatment hardness is HRC55 - 58°, it is equipped with a set of water circulation system, the upper and lower shafts are fixed with a combined housing slider, each group is driven by five bevel gears, and the two ends of the shaft are fixed in the slider, and the gap between the upper and lower rollers can be adjusted. There is an auxiliary forming device between the rolls of each pass to ensure the forming process of the product. The feeding expansion is less than 371 mm, the maximum rolling thickness is 1.2 mm, and the rolling speed is 0 - 8 m per minute; the specific rolling and forming process is S31: Through a set of continuous forming roll dies, one side of the material is bent upward by 89 degrees to form a first bent part, and at the same time, the other side of the material is bent downward by 89 degrees to form a second bent part, and a first long side is formed in the middle part; S32: Through a set of continuous forming roll dies, the first bent part is bent downward by 180 degrees, and at the same time, the second bent part is bent upward by 180 degrees, S33: Through a set of continuous forming roll dies, the first bent part is bent 89 degrees toward the second bent part and is parallel to the first long side to form a first short side, and at the same time, the second bent part is bent 89 degrees toward the first bent part and is parallel to the first long side to form a second short side. Then, through a set of continuous forming roll dies, the first bent part and the second bent part are cross-joined to form a second long side. Then, the 180-degree bent part of the first bent part is bent toward the first long side to form a protruding bent part. After continuous rolling, as Figure 2 shown, the cross-section of the semi-finished product after the material is formed includes a quadrilateral cavity, a first extension part extending outward along a short side of the quadrilateral cavity and formed by two layers of materials stacked, and a second extension part extending outward along the other short side of the quadrilateral cavity and formed by two layers of materials stacked. The end of the second extension part also has a bent part extending toward the long side. The second short side is bent into a U shape, the first short side is bent into an inverted S shape, and a closed structure is pressed and formed by positive and negative cross-joining at a long side of the quadrilateral cavity; The formed semi-finished product is cut into segments online. The hydraulic circular saw cuts statically, and the hydraulic circular saw automatically cuts the required length and width. The cut semi-finished product is discharged without power through a galvanized roller blanking rack; The two ends of the semi-finished product after segmentation are cut according to the splicing angle. The semi-finished product is placed on the workbench, and the two ends of the door frame are cut at a 45° angle with a corner cutting machine. The cut semi-finished products are spliced into a door frame, and then the two adjacent splicing parts are fixedly connected and formed. S61: Place the semi-finished product on the workbench, and adjust the position of the fixture slider according to the position of the positioning holes on the workbench to position the inner side of the spliced semi-finished product. S62: Adjust the position of the clamping cylinder according to the position of the positioning holes on the workbench to clamp the outer side of the spliced semi-finished product and the splicing part of the semi-finished product. S63: Weld with a laser welder. Specifically, the workbench is provided with positioning holes and adjustable fixture sliders. There are fixed bases on both sides and in the middle, which are connected to the cylinder components. The fixture is controlled by three joysticks respectively, so that the door frame is accurately positioned and the welding deformation is reduced. The middle cylinder component has a right-angle groove, so that there will be no misalignment phenomenon during assembly, ensuring that the outer angle is a right angle. The inner fixed slider is used as an inner angle positioning part to ensure that the outer angle is a right angle. Welding is carried out with a hand-held laser welder. The production line adopts a PLC control system, which can manually and automatically control the coordinated actions of all components of the entire production line, can receive data and issue production instructions. The processing list is generated into a csv file and transmitted to the PLC system, which automatically corresponds to the punching die, cutting length and punching spacing. Manually select the processing mode, and the processing modes are: four-sided frame, three-sided frame, single frame, and the rolled door frame is formed.

[0020] The above is only a preferred specific embodiment of the present invention, but the protection scope of the present invention is not limited thereto. Any person skilled in the art within the technical scope disclosed by the present invention, according to the technical solution of the present invention and its inventive concept, makes equivalent substitutions or changes, and should be covered by the protection scope of the present invention.

Claims

1. A production process for door frames with automatically punched process holes, characterized in that, Including: S1: Uncoil the material and perform primary leveling. S2: After uncoiling, perform process hole punching and secondary leveling on the material online. In the step S2, according to a preset program, automatically correspond to the punching die, cutting length, and punching spacing, including at least: S21: Punch process reserved holes; S22: Punch hinge holes; S23: Punch lock holes; S24: Punch lock piece fixing holes; S25: Punch mounting holes; S26: Punch cut notches. S3: After punching, perform process bending and forming on the material online to form a semi-finished door frame profile; in the step S3, at least include: S31: Bend one side of the material upward by 89 degrees through a set of continuous forming roller dies to form a first bending part, and at the same time bend the other side of the material downward by 89 degrees to form a second bending part, and a first side long edge is formed in the middle part; S32: Bend the first bending part downward by 180 degrees through a set of continuous forming roller dies, and at the same time bend the second bending part upward by 180 degrees; S33: Bend the first bending part 89 degrees towards the second bending part to be parallel to the first side long edge and form a first side short edge, and at the same time bend the second bending part 89 degrees towards the first bending part to be parallel to the first side long edge and form a second side short edge, then cross-engage the first bending part and the second bending part through a set of continuous forming roller dies to form a second side long edge. After continuous rolling, the cross-section of the semi-finished product formed by the material includes a quadrilateral cavity, and a first extension part extending outward along a short side of the quadrilateral cavity and formed by two layers of materials stacked together, and a second extension part extending outward along the other short side of the quadrilateral cavity and formed by two layers of materials stacked together. The end of the second extension part also has a bending part extending towards the long side direction. The second side short edge is bent into a U shape, and the first side short edge is bent into a reverse S shape. At one long side of the quadrilateral cavity, it is cross-engaged and pressed into a closed structure. S4: Cut the formed semi-finished product into segments online. S5: Cut both ends of the segmented semi-finished product at the splicing angle. S6: Assemble the cut semi-finished products into a door frame, and then fixedly connect adjacent two splicing parts to form.

2. The production process for door frames with automatically punched process holes according to claim 1, characterized in that, In the step S2, enter the combined punching machine, continuously punch process holes online, and then perform secondary leveling by at least 2 pairs of rollers.

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