A method of forming a profiled roof panel

Abstract

The application provides a forming method of a special-shaped roof panel, and a forming device for the forming method, the forming device comprising a first forming module, a second forming module, a third forming module and a fourth forming module arranged in sequence along a conveying direction; the forming method comprises the following forming processes; the first forming process adopts the first forming module to form a convex rib in the middle of the panel and Z-shaped bending sections on both sides of the convex rib; the second forming process adopts the second forming module to form a protrusion in the middle of the upwardly folded part of the Z-shaped bending section; the third forming process adopts the third forming module to form a male buckle edge and a female buckle edge on the edge of the upwardly folded part of the Z-shaped bending section; and the fourth forming process adopts the fourth forming module to fold the part with the protrusion upward to form a facade, and the protrusion facade is synchronously erected to become an outer convex guide rail in the middle of the facade.

Description

Technical Field

[0001] This application relates to the technical field of sheet metal cold bending forming machines, and more particularly to a method for forming irregularly shaped roof panels. Background Technology

[0002] With the rapid advancement of "building-integrated photovoltaics" (BIPV), metal roofing panels are required to possess three functions: waterproofing, wind resistance, and photovoltaic module installation. The traditional approach involves drilling holes in the roofing panel, riveting aluminum guide rails, and then fixing the photovoltaic panels to the rails. This method is complex, costly, and the rivets damage the coating, making it prone to corrosion and leakage. To achieve "panel-rail integration," the industry is experimenting with directly extruding continuous protrusions on the male and female sides of irregularly shaped roofing panels to replace the subsequent guide rails.

[0003] In recent years, the industry has attempted to replace bending-stamping with roll forming in order to achieve continuous online forming. However, conventional roller sets can only uniformly thin or bend profiles with equal cross-sections, and cannot complete different strain paths such as "facade folding + local boss + male and female edge forming" in one go within the same forming machine. If the number of passes is simply increased, the length of the equipment will be further lengthened, and fishtail patterns will still appear at the corners of the bosses due to abrupt changes in deformation rate. In addition, the thickness of irregular roof panels is generally between 0.6-1.2mm, and the materials are mostly aluminum-magnesium-manganese or aluminum-zinc coated steel, with low yield strength and limited elongation. Slippage will occur when the roller linear speed is slightly higher, resulting in inconsistent boss heights, loose fit with fasteners, and a significant reduction in wind uplift resistance. Summary of the Invention

[0004] In view of the above practical problems and the shortcomings of the existing technology, the main technical problem to be solved by the present invention is to provide a method for forming irregular roof panels, so as to realize the forming of protrusions, male and female edge snapping and facade folding in the same forming equipment.

[0005] To solve the above-mentioned technical problems, this application provides a method for forming irregularly shaped roof panels, which adopts the following technical solution:

[0006] A method for forming an irregularly shaped roof panel includes forming equipment for the forming method, the forming equipment including a first forming module, a second forming module, a third forming module and a fourth forming module arranged sequentially along the transport direction; the forming method includes the following forming process;

[0007] In the first forming process, the entire panel enters the first forming module through the input port of the forming equipment. The first forming module has four sets of first forming punches that are continuously rolled along the transport direction. Three sets of first punches are set at intervals corresponding to the middle position of the panel, and two sets of folding dies are set on both sides of the three sets of first forming punches. After the panel passes through the first forming module, a rib is formed in the middle, and Z-shaped bending sections are formed on both sides of the rib. The upward folded part of the Z-shaped bending section continues to participate in the forming of the second, third and fourth forming modules.

[0008] In the second forming process, the panel enters the second forming module from the first forming module. The second forming module is equipped with four sets of second forming punches, three sets of third forming punches, and two sets of fourth forming punches along the transport direction. The four sets of second forming punches and the three sets of third forming punches are alternately arranged. The third forming punches are formed by single rollers arranged in pairs. After the panel passes through the second forming module, a protrusion is formed in the middle of the upward folding part of the Z-shaped bending section.

[0009] In the third forming process, the panel enters the third forming module from the second forming module. The third forming module has a total of six sets of first bending modules and five sets of second bending modules arranged along the transport direction. The second bending modules adopt the form of rollers. After the panel passes through the third forming module continuously, the male and female buckle edges are formed on the edge of the upward folding part of the Z-shaped bending section.

[0010] In the fourth forming process, the panel enters the fourth forming module from the third forming module. The fourth forming module has three sets of third bending modules and four sets of fourth bending modules arranged sequentially along the transport direction. The third bending module adopts the form of horizontal rollers, and the fourth bending module adopts the form of guide rollers. After the panel passes through the fourth forming module continuously, it is folded upward with the protruding part to form the facade. The protrusion rises up synchronously with the facade to become the outward protruding guide rail in the middle section of the facade.

[0011] In a preferred embodiment, in the second forming process, the second forming die group is provided with a second forming gap, the third forming die group is provided with a third forming gap, and the difference in forming angle between adjacent second forming gaps and third forming gaps is in the range of 10°-12°.

[0012] In a preferred embodiment, the second forming die group includes a second forming die, the second forming die including a second concave forming groove and a second convex forming block disposed vertically on a pair of pressure rollers, and a second forming gap is formed between the second concave forming groove and the second convex forming block.

[0013] In a preferred embodiment, the third forming die group includes a third forming die, which includes a third concave forming groove and a third convex forming block disposed vertically on two pressure rollers, and a third forming gap is formed between the third concave forming groove and the third convex forming block.

[0014] In a preferred embodiment, in the second forming process, the fourth forming die group includes a first roller group, which includes a first pressure roller arranged horizontally, a second roller and a third roller arranged vertically, and the second roller and the third roller are inclined towards each other at an included angle of 5°–8°.

[0015] When the panel passes through the fourth protrusion assembly, the second and third guide rollers press the bottom corners on both sides of the protrusion inward and downward, and the bottom corners bend again within an angle of 5°–10°.

[0016] In a preferred embodiment, in the fourth forming process, the third bending module includes an upper pressure roller and a lower pressure roller for bending the facade corner, the lower pressure roller is provided with a third bending mold, and the upper pressure roller is provided with a clearance space corresponding to the position of the third bending mold;

[0017] The bending angles of the three bending dies corresponding to the three sets of the third bending dies are set to 10°, 25° and 40° respectively along the transport direction.

[0018] In a preferred embodiment, in the fourth forming process, the fourth bending module includes a third support wheel group for facade corner bending. The third support wheel group includes a left support wheel and a right support wheel arranged left and right. The left support wheel and the right support wheel are respectively provided with a left bending die and a right bending die that cooperate with each other.

[0019] The bending angles of the four sets of left and right bending dies corresponding to the fourth bending module are set sequentially to 55°, 70°, 85°, and 95° along the transport direction.

[0020] In a preferred embodiment, the molding equipment includes a fifth molding module disposed after the fourth molding module along the transport direction; the molding method further includes a fifth molding process, wherein the panel enters the fifth molding module from the fourth molding module, and the fifth molding module is provided with a fifth guide roller molding group and a sixth guide roller molding group arranged sequentially along the transport direction; the panel continuously passes through the fifth molding guide roller group and the sixth guide roller molding group, wherein the fifth molding guide roller group presses the upper bottom corner of the boss downward and inward, and the sixth guide roller molding group presses the lower bottom corner of the boss upward and inward.

[0021] In a preferred embodiment, both the fifth and sixth wheel forming groups include a first punch and a second punch, and the first punch of the fifth wheel forming group and the first punch of the sixth wheel forming group are vertically offset.

[0022] During molding, the first punch exerts a downward and inward or upward and inward squeezing force on the upper or lower corner of the boss by facing the upper or lower end face of the second punch.

[0023] In summary, this application has the following beneficial effects:

[0024] 1. This invention comprises a first forming module, a second forming module, a third forming module, and a fourth forming module. The first forming module has a first punch in the middle, forming only the bottom plate rib area. The second forming module uses an alternating layout of "horizontal roller + single wheel + guide wheel": the second and third punch forming modules progressively increase the height of the protrusions, and the fourth punch forming module uses the first guide wheel group to correct the bottom corners by 5°–8° inward, eliminating bulging and springback. The third forming module inserts a second bending module in the male and female edge area, using the inclined surfaces of the guide wheels that are positioned vertically or horizontally to avoid the already formed protrusions, thus preventing damage to the protrusions. The fourth forming module allocates ≤40° bend angles to the third bending module (horizontal roller inclined surface), and the >40° portion is modified by using the vertical roller of the third guide wheel group to inward, so that the 90° vertical surface springback is ≤0.5°. All modules share the same transverse reference axis system, and the bottom rib, the two side protrusions, the male and female edge, and the vertical bend angle are positioned and formed in one step.

[0025] 2. The first forming module, the second forming module, the third forming module and the fourth forming module are set up in the same frame in sequence to complete the whole process of "bottom pressing ribs → bulging of both sides → male and female edge fastening → vertical corner bending" in sequence. At the same time, the length of the whole machine is ≤12 m and can be loaded into a 40-foot container. Attached Figure Description

[0026] Figure 1 This is a process diagram of the overall molding of the irregular roof panel in this embodiment;

[0027] Figure 2 This is a schematic diagram of the overall structure of the first molding module in this embodiment;

[0028] Figure 3 This is a schematic diagram of the structure of the first convex mold assembly in this embodiment;

[0029] Figure 4 This is a schematic diagram of the overall structure of the second molding module in this embodiment;

[0030] Figure 5 This is a structural schematic diagram of the third convex module assembly in this embodiment;

[0031] Figure 6 This is a schematic diagram of the structure of one of the second forming punches in the second forming punch assembly of this embodiment;

[0032] Figure 7 This is a schematic diagram of the third convex gap in the third convex die assembly of this embodiment;

[0033] Figure 8 This is a schematic diagram of the overall structure of the fourth punch assembly in this embodiment.

[0034] Figure 9This is a schematic diagram of the overall structure of the third molding module in this embodiment.

[0035] Figure 10 This is a schematic diagram of the structure of the first bending module (with one bending mold and two bending molds) in this embodiment;

[0036] Figure 11 This is a structural diagram of the second bending module (with two rollers arranged vertically) in this embodiment;

[0037] Figure 12 This is a structural diagram of the second bending module (with two guide wheels arranged on the left and right sides) in this embodiment;

[0038] Figure 13 This is a schematic diagram of the structure of the first bending module (with three bending modules and four bending modules) in this embodiment;

[0039] Figure 14 This is a schematic diagram of the structure of the first bending module (with five-bending and six-bending modules) in this embodiment;

[0040] Figure 15 This is a schematic diagram of the overall structure of the fourth molding module in this embodiment;

[0041] Figure 16 This is a schematic diagram of the overall structure of the third bending module in this embodiment;

[0042] Figure 17 This is a schematic diagram of the overall structure of the fourth bending die in this embodiment;

[0043] Figure 18 This is a schematic diagram of the overall structure of the fifth molding module in this embodiment;

[0044] Figure 19 This is a side view of the overall structure of the fifth molding module in this embodiment. Detailed Implementation

[0045] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0046] In the description of this invention, it should be noted that the terms "upper," "lower," "inner," "outer," "top / bottom," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0047] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installed", "equipped", "sleeved / connected", "connected", etc., should be interpreted broadly. For example, "connection" can be a wall-mounted connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be a connection within two components. For those skilled in the art, the specific meaning of the above terms in this invention can be understood according to the specific circumstances.

[0048] The following is in conjunction with the appendix Figures 1-19 This application will be described in further detail.

[0049] This embodiment provides a method for forming irregularly shaped roof panels, used for forming an entire irregularly shaped roof panel 6, such as... Figure 1 The integral forming of the irregular roof panel 6 includes: 1. bottom ribs 61; 2. two side protrusions 62, and a raised structure formed by the facade folding angle 63; 3. male and female fastening edges 64 and 65 on both sides; 4. facade folding angle 63 on both sides, finally forming the structure of the irregular roof panel 6.

[0050] To enable the simultaneous completion of "bottom rib 61, protrusion 62, male and female edge clips 65, and vertical folding" within a single device, the molding method provided in this embodiment is divided into a first molding process 101, a second molding process 102, a third molding process 103, a fourth molding process 104, and a fifth molding process 105 according to the local molding requirements. Based on the molding process, the molding equipment is sequentially equipped with a first molding module 1, a second molding module 2, a third molding module 3, a fourth molding module 4, and a fifth molding module 5 along the transport direction. For example... Figure 1 The molding process is divided into 5 steps according to molding requirements:

[0051] The first molding module 1 is the first molding process 101, such as Figure 2 In the middle of the panel, the forming of the rib and the forming of the Z-shaped bending section 66 on both sides of the rib are completed continuously through 4 sets of first forming punch groups 11. The forming of the bottom rib and the raising of the rib can eliminate the bottom water ripples. At the same time, it plays a limiting role in the subsequent forming process to prevent the board from deviating.

[0052] The second molding module 2 is the second molding process 102, such as Figure 4 The Z-shaped bending sections 66 on both sides of the panel are folded upwards and formed into "protrusions 62" through four sets of second forming convex molds 21, three sets of third forming convex molds 22 and two sets of fourth forming convex molds 23. This is used to extrude the protrusion structure required for photovoltaic installation in one go. The protrusion is used to form a boss structure after the rear facade bends 63, which serves as a guide rail for placing the photovoltaic panel.

[0053] The third molding module 3 is the third molding process 103, such as Figure 9 The edges of the Z-shaped bending sections 66 on both sides of the panel are folded upwards and formed by six sets of first bending modules 31 and five sets of second bending modules 32 to form the male buckle edge 64 and the female buckle edge 65. Since the male buckle edge 64 and the female buckle edge 65 are a mating structure, the forming modules of the two sides of the panel are not the same.

[0054] The fourth molding module 4 is the fourth molding process 104, such as Figure 15 On both sides of the panel, three sets of third bending modules 41 and four sets of fourth bending modules 42 continuously bring together the part including the "protrusion 62" to form the facade angle 63. The bulge rises synchronously with the facade and becomes the outward convex guide rail in the middle section of the facade.

[0055] The fifth molding module 5 is the fifth molding process 105, such as Figure 18 The fifth forming module 5 is used as a shaping module to reduce the upper bottom corner 621 and lower bottom corner 622 of the boss structure by a micro angle of 5°–8° after final forming, so as to eliminate the springback during the forming process and correct the height of the two bosses at the same time.

[0056] The specific structure of each molding module is as follows:

[0057] refer to Figure 2-3 The first forming module 1 includes four sets of first forming punches 11. Each set of first forming punches 11 includes two sets of rotating shafts arranged vertically and several pressure rollers coaxially arranged on the rotating shafts. The pressure rollers are arranged in pairs, one vertically and one horizontally. Each set of first forming punches 11 also includes a first forming punch 12, which is installed on the outer periphery of the corresponding pressure roller in the middle of the rotating shaft. Figure 3 Each first forming die set 11 has three sets of first forming punches 12. Each first forming punch 12 includes a first concave forming groove 13 and a first convex forming block 14 arranged vertically on a pair of pressure rollers. A first forming gap 15 is formed between the first concave forming groove 13 and the first convex forming block 14, so that the panel can be formed with three convex ribs in the middle at the same time when it passes through. The four first forming gaps 15 corresponding to the four sets of first forming punches 11 gradually increase in height along the transport direction.

[0058] The first forming module 1 also includes folding molds 16 located on both sides of the three sets of first forming punches 12. When the panel passes through, the two sides of the panel near the three protruding ribs are folded upwards step by step by the folding molds 16, eventually forming a Z-shaped bending section 66. The upward-folded part of the Z-shaped bending section 66 continues to participate in the forming of the protrusions, facade corners, and male and female snap edges.

[0059] refer to Figures 4-8 The second forming module 2 includes four sets of second forming punches 21, three sets of third forming punches 22, and two sets of fourth forming punches 23. The second forming punches 21 and the third forming punches 22 are arranged alternately along the transport direction, and the fourth forming punches 23 are arranged last along the transport direction.

[0060] Each set of second forming punches 21 includes two sets of rotating shafts arranged vertically and several pressure rollers coaxially arranged on the rotating shafts, with the pressure rollers arranged in pairs. Each set of second forming punches 211 also includes a second forming punch 211, which is symmetrically distributed at both ends along the axial direction of the rotating shaft and is mounted on the outer periphery of the corresponding pressure rollers at both ends of the rotating shaft. Figure 6 The second forming die 211 includes a second concave forming groove 212 and a second convex forming block 213 arranged vertically on a pair of pressure rollers. A second forming gap 214 is formed between the second concave forming groove 212 and the second convex forming block 213. The panel can be formed by simultaneously forming the side protrusions in the middle of the upward folded part of the Z-shaped bending section 66 on both sides when passing through once. The four second forming gaps 214 corresponding to the four sets of second forming dies 21 gradually increase in height along the transport direction.

[0061] like Figure 5 The third punch group 22 consists of single-roller pressing rollers arranged in pairs, one above the other. Each third punch group 22 includes two sets of roller groups 221 arranged in pairs, one above the other. Each roller group 221 consists of upper and lower rotating shafts and a single pressure roller coaxially mounted on the upper and lower rotating shafts. The two roller groups 221 are symmetrically distributed at both ends along the axial direction of the rotating shafts. Figure 7 The third forming die group 22 includes a third forming die 222, which includes a third concave forming groove 223 and a third convex forming block 224 arranged vertically on the two pressure rollers. A third forming gap 225 is formed between the third concave forming groove 223 and the third convex forming block 224. The position of the third forming gap 225 corresponds to the position of the second forming gap 214. The height of the three third forming gaps 225 corresponding to the three sets of third forming die groups 22 gradually increases along the transport direction.

[0062] The second convex gap 214 and the third convex gap 225 are formed alternately, and the height of the gap between them gradually increases along the transport direction. The difference in the convex angle between adjacent second convex gaps 214 and third convex gaps 225 is 10°-12°, so that a longitudinal protrusion 62 can be formed in the end.

[0063] The third punch assembly 22 follows the second punch assembly 21 and is specifically used for "heightening-finishing" composite molding of the pre-formed protrusions. For example... Figure 4 A third forming die group 22 is added between every two sets of second forming die groups 21. The third forming die group 22 is a single-roll forming group, which can add a roll forming process without changing the length of the frame. It ensures that the forming angle of each step is designed with a progressive bending angle of 10°-12°, so that the bending angle of a single step does not exceed 15°, and avoids the formation of fish tail marks caused by the forming angle being too fast at one time. At the same time, by using the single-roll short pitch arrangement, the heightening process is compressed into one step, ensuring that the length of the whole machine is ≤12m, and it can be loaded into a 40-foot container.

[0064] The fourth convex mold group 23 is used to perform the final correction of the already "raised" protrusion 62 through "bottom corner reduction - deepening - shaping". For example... Figure 8 Each fourth punch assembly 23 includes two sets of mirror-symmetrically arranged first guide roller assemblies 231. The two sets of first guide roller assemblies 231 are arranged in pairs along the center line of the panel. Each set of first guide roller assemblies 231 adopts a "one horizontal and two vertical" spatial layout. Each set of first guide roller assemblies 231 includes a horizontally arranged first rotating shaft and a vertically arranged second and third rotating shafts. A first pressure roller 232 is coaxially arranged on the first rotating shaft, and a second guide roller 233 and a third guide roller 234 are coaxially arranged on the second and third rotating shafts. The second and third rotating shafts are inclined towards each other at an angle of 5°–8°. A fourth punch gap 235 is formed between the first pressure roller 232, the second guide roller 233, and the third guide roller 234. The first punch gap 15, the second punch gap 214, and the fourth punch gap 235 share the same axial reference to ensure the coaxiality of the protrusion 62 in the entire production line.

[0065] The fourth protrusion gap 235 allows the formed protrusion 62 to pass through. The second and third guide rollers 233 and 234 are trapezoidal cross-section guide rollers 322. The second and third guide rollers 233 and 234 are used to press the bottom corners on both sides of the protrusion 62 inward and downward, so that the bottom corners bend again within an angle of 5°–10°. The root material is forced to be drawn inward by 0.1–0.15mm, increasing the total height of the protrusion 62, offsetting the rebound of the panel, further compacting the transition rounded corners between the side wall and the bottom plate, eliminating the risk of micro-cracks, and controlling the symmetry of the left and right protrusions 62.

[0066] refer to Figures 9-14 The third forming module 3 has a total of 6 sets of first bending modules 31 arranged along the transport direction, interspersed with 5 sets of second bending modules 32, forming a "6+5" composite roller array. For example... Figure 1 The third forming process 103 breaks down the male buckle 64 and the female buckle 65 into two steps: "first bending the edge and then bending the edge" to avoid the formation of fishtail patterns from a single large-angle bend.

[0067] Each first bending module 31 includes two sets of rotating shafts arranged vertically and several pressure rollers coaxially arranged on the rotating shafts. The pressure rollers are arranged in pairs, one vertically and one horizontally. Each second bending module 32 includes a second guide roller forming group 321. The second guide roller forming group 321 includes two sets of rotating shafts arranged in pairs and two guide rollers 322 coaxially arranged on the rotating shafts. Each guide roller 322 includes a first roller pressing inclined surface 323. The two first roller pressing inclined surfaces 323 of the two guide rollers 322 are used to draw inward so that the inner angle of the folded edge is less than 90°.

[0068] The first bending edge is formed by continuously arranging three sets of first bending modules 31, such as... Figure 10 Each first bending module 31 includes a bending die and a bending die distributed axially on the outer periphery of the pressure rollers at both ends of the rotating shaft. The upper pressure roller has a bending die (upward slope) 311, and the lower pressure roller 425 has two bending dies (downward slope) 312 with slopes of 30°, 60°, and 85° respectively, so that the first bending edge of the male buckle 64 is bent upward step by step, and the first bending edge of the female buckle 65 is bent downward step by step, with an end angle of 90°±1°.

[0069] The second bending module 32 is inserted for the first time at the fourth stage, as follows: Figure 11 The two rollers 322 of the second bending module 32 are arranged in pairs, one above the other. The first roller pressing slope 323 of the two rollers 322 has an inclination angle of 10°, and the male buckle edge 64 is pressed inward to the first bending edge, and the inner angle is tightened from 90° to ≤80°.

[0070] Starting from the fifth step, the second bending edge is bent. From the fifth step onwards, the first bending die and the second bending die are arranged alternately. The second bending die is arranged in one or two sets between two adjacent sets of the first bending die.

[0071] The forming of the second bent edge, such as Figure 13 The first bending module 31 of the fifth and seventh passes is changed to a "triangular roller pressing area". Each first bending module 31 includes a three-bending mold 313 and a four-bending mold 314. The three-bending mold 313 and the four-bending mold 314 are distributed axially on the outer periphery of the corresponding pressure rollers at both ends of the rotating shaft. Both the three-bending mold 313 and the four-bending mold 314 include an upper pressing surface 317 and a lower pressing surface 318. The upper pressing surface 317 is set on the upper pressure roller, and the lower pressing surface 318 is set on the lower pressure roller 425. A cavity with an included angle of 30°-60° is formed between the upper pressing surface 317 and the lower pressing surface 318, which avoids the already formed first bending edge and applies a 0.5° slight contraction to it to eliminate springback.

[0072] The three-bending die 313 is used to bend the panel upwards to form the male snap-fit ​​edge 64, the second bent edge; the four-bending die 314 is used to bend the panel downwards to form the female snap-fit ​​edge 65, the second bent edge. To facilitate better bending of the female snap-fit ​​edge 65, the sixth, eighth, ninth, and eleventh bends employ a second bending die 32, such as... Figure 12 The two guide wheels 322 of the second bending module 32 are arranged left and right, and the positions of the two guide wheels 322 correspond to the positions of the four bending modules 314. The slope of the two guide wheels 322 and the slope of the first roller pressing slope 323 increases from 40° to 60° to 80° to 95°, which is used to reduce the inward bending of the second bending edge of the female buckle edge 65, so that the second bending edge of the male buckle edge 64 and the female buckle edge 65 gradually tends to bend at 90°, and then a 0.5° slight reduction is applied to eliminate the springback.

[0073] In the second bending module 32 of the eleventh stage, a second bending module 32 is set at the position corresponding to the third bending module 313. The two rollers 322 of the second bending module 32 are positioned vertically opposite each other. The first roller pressing inclined surface 323 of the two rollers 322 has an inclination angle of 10°, and the male buckle edge 64 is pressed inward to the second bending edge, and the inner angle is tightened from 90° to ≤80°.

[0074] like Figure 14 The tenth step uses a first bending module 31, which includes a five-bending mold 315 and a six-bending mold 316. The five-bending mold 315 and the six-bending mold 316 are axially distributed on the outer periphery of the pressure rollers at both ends of the rotating shaft. The five-bending mold 315 includes an upper pressure surface 317 and a lower pressure surface 318. The five-bending mold 315 seals the first bent edge of the male buckle 64, and the first bent edge is then parallel to the second bent edge after bending. The six-bending mold 316 includes a flat pressure surface 319, and the lower pressure roller 425 is provided with a clearance space. The upper flat pressure surface 319 presses on the transition area where the root of the second bent edge connects to the panel. The corresponding position of the lower roller is hollowed out to form a clearance cavity to prevent damage to the formed female buckle 65 second bent edge. By applying a slight downward pressure of 0.1mm, the elastic recovery of the material is eliminated, and the upward curling of the second bent edge is prevented.

[0075] refer to Figures 15-17 The fourth forming module 4 includes three sets of third bending modules 41 and four sets of fourth bending modules 42 arranged sequentially along the transport direction. Both the third bending module 41 and the fourth bending module 42 include an upper rotating shaft, a lower rotating shaft, and several pressure rollers arranged coaxially on the upper rotating shaft and the lower rotating shaft. The third bending module 41 adopts the form of horizontal rollers, and the fourth bending module 42 adopts the form of guide rollers 322.

[0076] The third bending module 41 includes a third bending die 411 mounted on the lower pressure roller 425 of the paired pressure rollers. To avoid interference with the pre-formed protrusions on both sides of the panel during the vertical bending angle 63, an open clearance space 412 is provided at the upper rotating shaft corresponding to the position of the third bending die 411 in the paired pressure rollers of the third bending module 41, thus preventing interference. The third bending dies 411 are symmetrically distributed at both ends along the axial direction of the corresponding rotating shaft, and each third bending die 411 includes a second roller pressing slope 413. The slope of the second roller pressing slope 413 gradually increases along the transport direction, causing the bending angle to increase progressively.

[0077] In this embodiment, the third bending die 411 used for corner pressing is set entirely on the pressure roller of the lower rotating shaft, and the corresponding position of the upper rotating shaft forms a free transfer displacement. This retains the bending torque and completely eliminates the risk of interference, ensuring the integrity of the protrusion height and realizing the progressive forming of the facade corner 63.

[0078] The three third bending dies 411 of the three sets of third bending dies adopt a "gradual advance" design, with bending angles of 10°, 25° and 40° respectively. When the bending angle is greater than 40°, the pressure roller (horizontal roller) of the lower rotating shaft alone cannot press the bending angle. Continuing to press upward will only interfere with the boss. Therefore, the fourth bending die 42 uses the guide roller 322 to replace the pressing of the bending angle. The fourth bending die 42 follows the third bending die and is dedicated to the final bending of the 40°→90° facade.

[0079] The fourth bending module 42 includes a third guide wheel forming group 421, which includes two sets of mirror-symmetrically arranged third guide wheel groups 422. The two sets of third guide wheel groups 422 are arranged in pairs along the center line of the panel and share the same axial reference with the third bending module. Each set of third support roller group 422 adopts a "three-axis three-dimensional constraint" structure. Taking the left support roller group 322 as the main example, its structure is introduced as follows: Each set of third support roller group 422 includes a left rotating shaft and a left support roller 423 set on the left rotating shaft, a right rotating shaft and a right support roller 424 set on the right rotating shaft, and a lower pressure roller 425 set on the lower rotating shaft. The left and right rotating shafts are set vertically, and the right rotating shaft is set at an angle relative to the vertical plane. The left support roller 423 has a left bending die 4231 on its outer periphery, and the right support roller 424 has a right bending die 4241 on its outer periphery. The left bending die 4231 and the right support roller 424 include a left roller pressure inclined surface 4232 and a right roller pressure inclined surface 4242. The slope of the left roller pressure inclined surface 4232 and the right roller pressure inclined surface 4242 increases gradually along the transportation direction in the order of "55°, 70°, 85°, 95°", so that the bending angle increases gradually until it approaches a 90° bending angle. The lower pressure roller 425 on the lower rotating shaft supports the bottom of the plate to prevent the vertical surface from sinking during bending. At the same time, it forms a closed cavity with the left support roller 423 and the right support roller 424 to completely eliminate springback.

[0080] refer to Figures 18-19The fifth forming module 5 includes a fifth guide wheel forming group 51 and a sixth guide wheel forming group 52 arranged sequentially along the transport direction. Both the fifth guide wheel forming group 51 and the sixth guide wheel forming group 52 include two sets of mirror-symmetrically arranged fifth guide wheel groups 511 and sixth guide wheel groups 521. Taking the left guide wheel group 322 as the main example, its structure is described as follows: The fifth guide wheel group 511 includes a fifth left rotating shaft, a fifth right rotating shaft, and a fifth left guide wheel 512 and a fifth right guide wheel 513 coaxially arranged on the fifth left rotating shaft and the fifth right rotating shaft. The sixth guide wheel group 521 includes a sixth left rotating shaft, a sixth right rotating shaft, and a sixth left guide wheel 522 and a sixth right guide wheel 523 coaxially arranged on the sixth left rotating shaft and the sixth right rotating shaft. The positions of the fifth left guide wheel 512, the fifth right guide wheel 513, the sixth left guide wheel 522, and the sixth right guide wheel 523 correspond to the positions of the protruding bosses in the middle section of the facade.

[0081] A first punch 53 is provided on the outer periphery of the fifth left support roller 512 and the sixth left support roller 522, and a second punch 54 is provided on the outer periphery of the fifth right support roller 513 and the sixth right support roller 523. The side of the second punch 54 away from the first punch 53 is an inclined surface. During forming, the first punch 53 exerts a downward and inward or upward and inward squeezing force on the upper or lower corner of the boss facing the upper or lower end face of the second punch 54. Figure 19 The first punches 53 of the fifth and sixth support roller forming groups 51 and 52 are staggered vertically. The end of the first punch 53 corresponds to the upper bottom corner 621 and lower bottom corner 622 of the boss in the middle section of the facade. The first punches 53 and second punches 54 of the fifth left support roller 512 and the fifth right support roller 513 first close the upper bottom corner 621 and perform a "downward + inward" compound extrusion on the upper bottom corner 621. The first punches 53 and second punches 54 of the sixth left support roller 522 and the sixth right support roller 523 then close the lower bottom corner 622 and perform a "upward + inward" reverse extrusion on the lower bottom corner 622 to further compact the transition rounded corner between the facade and the base plate, eliminate the springback caused by the second bending module, and at the same time use these two extrusions to calibrate the total height of the boss and maintain left and right symmetry.

[0082] The above description is merely a preferred embodiment of the present invention, but the design concept of the present invention is not limited thereto. Any non-substantial modifications made to the present invention by those skilled in the art within the scope of the technology disclosed in the present invention using this concept shall be deemed as an infringement of the protection scope of the present invention.

Claims

1. A method for forming an irregularly shaped roof panel, characterized in that: The molding equipment includes molding equipment for the molding method, the molding equipment comprising a first molding module, a second molding module, a third molding module and a fourth molding module arranged sequentially along the transport direction; the molding method includes the following molding process; In the first forming process, the entire panel enters the first forming module through the input port of the forming equipment. The first forming module has four sets of first forming punches that are continuously rolled along the transport direction. Three sets of first punches are set at intervals corresponding to the middle position of the panel, and two sets of folding dies are set on both sides of the three sets of first forming punches. After the panel passes through the first forming module, a rib is formed in the middle, and Z-shaped bending sections are formed on both sides of the rib. The upward folded part of the Z-shaped bending section continues to participate in the forming of the second, third and fourth forming modules. In the second forming process, the panel enters the second forming module from the first forming module. The second forming module is equipped with four sets of second forming punches, three sets of third forming punches, and two sets of fourth forming punches along the transport direction. The four sets of second forming punches and the three sets of third forming punches are alternately arranged. The third forming punches are formed by single rollers arranged in pairs. After the panel passes through the second forming module, a protrusion is formed in the middle of the upward folding part of the Z-shaped bending section. In the third forming process, the panel enters the third forming module from the second forming module. The third forming module has a total of six sets of first bending modules and five sets of second bending modules arranged along the transport direction. The second bending modules adopt the form of rollers. After the panel passes through the third forming module continuously, the male and female buckle edges are formed on the edge of the upward folding part of the Z-shaped bending section. In the fourth forming process, the panel enters the fourth forming module from the third forming module. The fourth forming module has three sets of third bending modules and four sets of fourth bending modules arranged sequentially along the transport direction. The third bending module adopts the form of horizontal rollers, and the fourth bending module adopts the form of guide rollers. After the panel passes through the fourth forming module continuously, it is folded upward with the protruding part to form the facade. The protrusion rises up synchronously with the facade to become the outward protruding guide rail in the middle section of the facade.

2. The method for forming an irregularly shaped roof panel according to claim 1, characterized in that: In the second forming process, the second forming die group is provided with a second forming gap, and the third forming die group is provided with a third forming gap. The difference in forming angle between adjacent second forming gaps and third forming gaps is in the range of 10°-12°.

3. The method for forming an irregularly shaped roof panel according to claim 2, characterized in that: The second forming die assembly includes a second forming die, which includes a second concave forming groove and a second convex forming block arranged vertically on a pair of pressure rollers, with a second forming gap formed between the second concave forming groove and the second convex forming block.

4. The method for forming an irregularly shaped roof panel according to claim 2, characterized in that: The third forming die assembly includes a third forming die, which includes a third concave forming groove and a third convex forming block arranged vertically on two pressure rollers, with a third forming gap formed between the third concave forming groove and the third convex forming block.

5. The method for forming an irregularly shaped roof panel according to claim 2, characterized in that: In the second forming process, the fourth forming die group includes a first roller group, which includes a first pressure roller arranged horizontally, a second roller and a third roller arranged vertically, and the second roller and the third roller are inclined towards each other at an angle of 5°–8°. When the panel passes through the fourth protrusion assembly, the second and third guide rollers press the bottom corners on both sides of the protrusion inward and downward, and the bottom corners bend again within an angle of 5°–10°.

6. The method for forming an irregularly shaped roof panel according to claim 1, characterized in that: In the fourth forming process, the third bending module includes an upper pressure roller and a lower pressure roller for bending the facade corner. The lower pressure roller is provided with a third bending mold, and the upper pressure roller is provided with a clearance space corresponding to the position of the third bending mold. The bending angles of the three bending dies corresponding to the three sets of the third bending dies are set to 10°, 25° and 40° respectively along the transport direction.

7. The method for forming an irregularly shaped roof panel according to claim 6, characterized in that: In the fourth forming process, the fourth bending module includes a third support wheel group for the vertical corner bending. The third support wheel group includes a left support wheel and a right support wheel arranged to the left and right. The left support wheel and the right support wheel are respectively provided with a left bending die and a right bending die that cooperate with each other. The bending angles of the four sets of left and right bending dies corresponding to the fourth bending module are set sequentially to 55°, 70°, 85°, and 95° along the transport direction.

8. The method for forming an irregularly shaped roof panel according to claim 1, characterized in that: The molding equipment includes a fifth molding module arranged after the fourth molding module along the transport direction; the molding method also includes a fifth molding process, in which the panel enters the fifth molding module from the fourth molding module, and the fifth molding module has a fifth guide roller molding group and a sixth guide roller molding group arranged sequentially along the transport direction. The panel continuously passes through the fifth molding guide roller group and the sixth guide roller molding group. The fifth molding guide roller group presses the upper bottom corner of the boss downward and inward, and the sixth guide roller molding group presses the lower bottom corner of the boss upward and inward.

9. A method for forming an irregularly shaped roof panel according to claim 8, characterized in that: The fifth and sixth wheel forming groups each include a first punch and a second punch, and the first punch of the fifth wheel forming group and the first punch of the sixth wheel forming group are staggered vertically. During molding, the first punch exerts a downward and inward or upward and inward squeezing force on the upper or lower corner of the boss by facing the upper or lower end face of the second punch.

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