A P-beam forming equipment and process

Abstract

This application relates to the technical field of sheet metal forming, and provides a P-beam forming equipment. A first folding die folds the profile upwards to form a vertical bottom wall in the middle and horizontal flanges on both sides. A second folding die, while maintaining the bottom wall in the middle and the left flange, folds the right side upwards to form a "right flange." A third folding die folds the profile upwards, forming a preliminary right vertical edge near the middle on the right side, further shaping the left flange. A fourth folding die folds the profile upwards, forming a preliminary left vertical edge near the middle on the left side. A combination of rollers forms the left and right vertical edges at a 90° vertical angle, forming a P-beam. A shaping roller group calibrates the final P-beam. Based on the P-beam forming equipment, a P-beam forming process is also provided, in which the profile gradually evolves from a flat coil into a P-beam structure with a vertical bottom wall in the middle, 90° vertical sides on both sides, and a "tightened" top.

Description

Technical Field

[0001] This application relates to the technical field of sheet metal forming, and in particular to a P-beam forming equipment and process. Background Technology

[0002] With the rapid development of green building and prefabricated steel structures, cold-formed thin-walled steel components have been widely used in roof purlins, wall beams, photovoltaic supports, and automated storage racks due to their advantages such as lightweight, high strength, high prefabrication rate, and short construction cycle. Among them, P-shaped beams with a "P"-shaped cross-section and hollow cavity have gradually replaced traditional C / Z-shaped purlins in recent years, becoming the preferred component for large-span, high-load roofing systems because they combine the advantages of easy connection of open sections and high torsional stiffness of closed sections.

[0003] Most existing P-beams are single-cavity closed structures without flanges. They are formed by segmented bending or low-speed rolling. Because there are no flanges for positioning, the closed openings have large springback and uneven locking, requiring manual hammering, which is inefficient. Summary of the Invention

[0004] In view of the above practical problems and the shortcomings of existing technologies, the main technical problem to be solved by the present invention is to provide a P-beam forming equipment and process, a high-speed production line for the entire P-beam, with high production efficiency and controllable closed curve springback.

[0005] To solve the above-mentioned technical problems, this application provides a P-beam forming device, which adopts the following technical solution:

[0006] A P-beam forming device includes a frame, wherein the frame is rotatably arranged with multiple upper and lower rotating shafts arranged opposite each other along the profile feeding direction, and the frame is provided with multiple sets of folding modules from the feeding end along the profile feeding direction, wherein the folding module includes upper folding rollers and lower folding rollers respectively sleeved and fixed on the upper rotating shaft and the lower rotating shaft;

[0007] The multiple folding modules are arranged sequentially along the profile feeding direction, including a first folding mold, a second folding mold, a third folding mold, a fourth folding mold, a first combined roller, a second combined roller, a first shaping roller group, and a second shaping roller group;

[0008] The lower folding roller corresponding to the first folding mold has a first upper folding slope in the middle and a first upper folding edge slope on both sides of the lower folding roller. The upper folding roller corresponding to the first folding mold has a matching slope in the middle that corresponds to the first upper folding slope.

[0009] The second folding mold has a second upper folding slope in the middle of the lower folding roller, a second upper folding edge slope on the left side of the lower folding roller, and a right folding edge slope on the right side of the lower folding roller. The upper folding roller corresponding to the second folding mold has a matching slope in the middle that corresponds to the second upper folding slope.

[0010] The third folding mold has a first right upper folding slope on the right side of the lower folding roller near the middle, and a left folding slope on the left side of the lower folding roller. The upper folding roller and the lower folding roller corresponding to the third folding mold are provided with a "Z" shaped shaping cavity at a 90° angle in the middle.

[0011] The lower folding roller corresponding to the fourth folding mold has a first upper left folding slope near the middle position on the left side, and the upper folding roller and the lower folding roller corresponding to the fourth folding mold have a "Z" shaped shaping cavity with a 90° angle in the middle, and the lower folding roller corresponding to the fourth folding mold has a shaping slope near the middle position on the right side.

[0012] The first combined roller includes a first upper pressure roller and a first lower pressure roller. The middle part of the first lower pressure roller is provided with a first shaping pressure surface in the shape of a "Z" with a 90° included angle and a second upper right folding surface connected to the first shaping pressure surface. The first upper pressure roller includes a first left support roller, and the first left support roller is provided with a first left pressure folding surface.

[0013] The second combined roller includes a second upper pressure roller and a second lower pressure roller. The second lower pressure roller is provided with a "Z"-shaped second shaping pressure surface at a 90° angle. The second upper pressure roller includes a second left support roller and a second right support roller. The second left support roller is provided with a second left pressure slope, and the second right support roller is provided with a second right pressure slope.

[0014] The first shaping roller group includes a first upper shaping roller, a first lower shaping roller, a first left shaping roller, and a first right shaping roller. The first lower shaping roller is located in the middle of the profile and is provided with a "Z"-shaped third shaping pressure surface at a 90° angle. The first upper shaping roller is positioned corresponding to the first lower shaping roller. The first upper shaping roller is provided with a planar pressure surface. The first left shaping roller and the first right shaping roller are both provided with vertical pressure surfaces at a 90° angle.

[0015] The second shaping roller group includes a second lower shaping roller, a second left shaping roller, and a second right shaping roller. The second lower shaping roller is provided with a fourth shaping pressure surface in the shape of a "Z" at a 90° angle. The second left shaping roller and the second right shaping roller are both provided with vertical pressure surfaces at a 90° angle. Furthermore, a welding gun bracket is added to the outlet end of the second shaping roller group, and the welding gun bracket is used to fix the welding gun.

[0016] In a preferred embodiment, the slope of the adjacent first upward folding slope and the first upward flange slope gradually increases along the profile transport direction; five first folding molds are arranged sequentially along the profile transport direction, and the profile is folded upward by the first folding molds to form a 120° bottom facade structure in the middle of the profile, and a 150° left flange structure and a 90° right flange structure on the left and right sides respectively.

[0017] In a preferred embodiment, the slopes of adjacent second upper folding slopes, second upper flange slopes, and right folding slopes gradually increase along the profile transport direction; five second folding molds are sequentially arranged along the profile transport direction, and the profile is folded upward by the second folding molds to form a 90° bottom facade structure in the middle of the profile, and a 90° left flange structure and a near 90° right folding structure on the left and right sides respectively.

[0018] In a preferred embodiment, the slopes of the adjacent first upper right folding slope and left folding slope gradually increase along the profile transport direction; five third folding molds are sequentially arranged along the profile transport direction, and the profile is folded upward by the third folding molds, forming a left folding structure of nearly 90° and a right standing edge structure of 160° on the left and right sides of the profile, respectively.

[0019] In a preferred embodiment, the slope of the adjacent first upper left folding slope gradually increases along the profile transport direction; five fourth folding molds are arranged sequentially along the profile transport direction, and the profile is folded upward by the fourth folding molds to form a 120° left vertical side structure on the left side of the profile.

[0020] In a preferred embodiment, the slopes of the adjacent second upper right folding surface and the first left pressure folding surface gradually increase along the profile transport direction; the first left pressure folding surface is used to further shape the 120° left vertical edge structure into a left vertical edge structure of nearly 90°.

[0021] In a preferred embodiment, the slope of the adjacent second right pressure slope gradually increases along the profile transport direction; the second left pressure slope is used for the fixed pressure of the 90° left vertical side structure, and the second right pressure slope is used to further shape the 120° right vertical side structure into a right vertical side structure close to 90°.

[0022] In a preferred embodiment, the first upper pressure roller further includes a first right support roller, the first right support roller being provided with a first right pressure slope, the first right pressure slope being used to press against the bottom corner of the left vertical side structure.

[0023] In a preferred embodiment, the second upper pressure roller further includes a fixed pressure mold, the fixed pressure mold having a cross-section in the shape of a "┐", and a pressure roller is provided on the opposite side of the transverse protrusion of the fixed pressure mold; the fixed pressure mold is used to press against the bottom corner of the left vertical structure, and the pressure roller is used to apply pressure to the bottom of the P-shaped beam.

[0024] To solve the above-mentioned technical problems, this application also provides a P-beam forming process, which adopts the following technical solution:

[0025] A P-beam forming process, based on the aforementioned P-beam forming equipment, wherein the forming process is divided into a first forming stage, a second forming stage, a third forming stage, and a fourth forming stage along the profile transport direction;

[0026] The specific molding steps are as follows:

[0027] The first forming stage is based on the basic folding and forming, which is divided into the following steps:

[0028] Step 1: Use the first folding die to pre-form the bottom and side edges of the profile. Through multiple first folding dies, gradually form the bottom facade structure in the middle of the profile and the preliminary folding structure on both sides.

[0029] Step 2: Use the second folding die to pre-form the profile at the end. Through multiple second folding dies, the right side of the profile is gradually folded to form a right folded edge structure, preparing for the final "locking".

[0030] Step 3: Use the third folding die to pre-form the right vertical edge of the profile. Through multiple third folding dies, gradually form a vertical right vertical edge structure on the right side of the profile near the middle position, and simultaneously fold the left edge structure of the profile further on the left side.

[0031] Step 4: Use the fourth folding die to gradually form the left side of the profile. Through multiple fourth folding dies, a vertical left side structure is gradually formed on the left side of the profile near the middle.

[0032] The second forming stage involves shaping the left and right vertical structures at a 90° angle and finishing the bottom corners, which is divided into the following steps:

[0033] Step 5: Use the first combination roller to fold the left vertical side structure and "finish" the bottom corner of the left vertical side structure. Through the gradual shaping of multiple first combination rollers, fold the left vertical side structure to close to 90°.

[0034] Step 6: Use the second combination roller to fold the right vertical side structure and shape it together with the left vertical side structure. Through the gradual shaping of multiple second combination rollers, the right vertical side structure is pressed to 90° simultaneously, and the left side is coordinated to complete the symmetrical structure.

[0035] The third forming stage is the overall shaping and calibration of the P-shaped beam, which consists of the following steps:

[0036] Step 7: Use the first shaping roller group to shape the top and bottom surfaces of the P-shaped beam. Apply micro pressure to the top and bottom surfaces of the P-shaped beam simultaneously through multiple first shaping roller groups to eliminate springback fluctuations in the height direction of the cavity and provide a precise height reference for subsequent closing and fastening.

[0037] Step 8: Use the second shaping roller group to shape the left and right sides of the P-shaped beam. The left and right vertical sides of the P-shaped beam are simultaneously clamped by multiple second shaping roller groups to correct the verticality and eliminate side bending, so that the cavity width remains constant and provides a parallel and vertical side wall reference for the final locking.

[0038] The fourth forming stage is the welding of the P-shaped beam's closing gap. By adding a welding gun bracket at the exit end of the second forming roller group, the welding gun flame or laser beam is used to weld the closing gap that has been corrected by the facade pressing surface.

[0039] In summary, this application has the following beneficial effects:

[0040] This invention provides a P-shaped beam forming device, which ultimately forms a P-shaped beam by setting up multiple sets of folding dies for continuous roller forming. A first folding die folds the profile upwards, forming a vertical bottom wall in the middle and horizontal flanges on both sides. The formation of the first folding die lays the foundation for the "skeleton" of the P-shaped beam, determining the subsequent structural symmetry. A second folding die, while maintaining the bottom wall in the middle and the left flange, folds the right side upwards to form a "right folded edge." A third folding die folds the profile upwards, forming a preliminary right vertical edge near the middle on the right side, while the left flange is further formed. A fourth folding die folds the profile upwards, forming a preliminary left vertical edge near the middle on the left side. Then, a combination of rollers forms the left and right vertical edges at a 90° vertical angle, ultimately forming the P-shaped beam. A shaping roller group is used to calibrate the final formed P-shaped beam.

[0041] This invention provides a P-shaped beam (similar to a "P" shaped cross-section) forming process with a bottom facade + left and right vertical edges + locking structure. It adopts multiple sets of precision folding modules + combined pressure rollers + shaping rollers working together. The profile gradually evolves from a flat rolled material to a vertical bottom wall in the middle, 90° vertical vertical edges on the left and right sides, a "closing" at the top of the right vertical edge, and a self-locking interlocking structure between the top of the left vertical edge and the right closing. The overall structure is stable, without springback, without gaps, with accurate dimensions, and no surface damage. Attached Figure Description

[0042] Figure 1 This is a complete machine drawing and a schematic diagram of the forming process of the P-beam forming equipment in this embodiment;

[0043] Figure 2 This is a schematic diagram of one of the forming processes of the first folding mold in this embodiment;

[0044] Figure 3 This is a schematic diagram of one of the forming processes of the second folding mold in this embodiment;

[0045] Figure 4 This is a schematic diagram of one of the forming processes of the third folding mold in this embodiment;

[0046] Figure 5 This is a schematic diagram of one of the forming processes of the fourth folding mold in this embodiment;

[0047] Figure 6 This is a schematic diagram of one of the forming processes of the first combined roller in this embodiment;

[0048] Figure 7 This is a schematic diagram of one of the forming processes of the second combined roller in this embodiment;

[0049] Figure 8 This is a schematic diagram of one of the forming processes in the first forming roller group of this embodiment;

[0050] Figure 9 This is a schematic diagram of one of the forming processes in the second forming roller group of this embodiment;

[0051] Figure 10 This is a schematic diagram of the overall structure of the second shaping roller group in this embodiment.

[0052] Explanation of reference numerals in the attached drawings: 1. First folding mold; 11. First upper folding slope; 12. First upper folding edge slope; 2. Second folding mold; 21. Second upper folding slope; 22. Second upper folding edge slope; 23. Right folding edge slope; 3. Third folding mold; 31. First upper right folding slope; 32. Left folding edge slope; 33. "Z" shaped shaping cavity; 4. Fourth folding mold; 41. First upper left folding slope; 42. Shaping slope; 5. ... 51. First combined roller; 511. First lower pressure roller; 512. First shaping pressure surface; 513. Second upper right folding slope; 52. First left support roller; 521. First left pressure slope; 53. First right support roller; 531. First right pressure slope; 6. Second combined roller; 61. Second lower pressure roller; 611. Second shaping pressure surface; 62. Second left support roller; 621. Second left pressure slope; 63. Second right support roller; 631. Second right pressure slope 64. Fixed pressure mold; 65. Pressure roller; 7. First shaping roller group; 71. First upper shaping roller; 711. Flat pressing surface; 72. First lower shaping roller; 721. Third shaping pressing surface; 73. First left shaping roller; 74. First right shaping roller; 75. Vertical pressing surface; 8. Second shaping roller group; 81. Second lower shaping roller; 811. Fourth shaping pressing surface; 82. Second left shaping roller; 83. Second right shaping roller; 84. 101 Welding torch support; 102 Frame; 102 Folding module; 1021 Upper folding roller; 1022 Lower folding roller; 103 Profile; 1031 Bottom facade structure; 1032 Left folding structure; 1033 Right folding structure; 1034 Right folding structure; 1035 Left folding structure; 1036 Right vertical edge structure; 1037 Left vertical edge structure; 104 P-beam; 1041 Finishing seam. Detailed Implementation

[0053] 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.

[0054] 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.

[0055] 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.

[0056] The following is in conjunction with the appendix Figure 1-10 The figure provides a further detailed description of this application.

[0057] This embodiment provides a P-shaped beam 104 forming device, including a frame 101. The frame 101 has multiple upper and lower rotating shafts arranged vertically opposite each other along the feeding direction of the profile 103. The frame 101 has multiple sets of folding modules 102 arranged from the feeding end along the feeding direction of the profile 103. Each folding module 102 includes an upper folding roller 1021 and a lower folding roller 1022 respectively sleeved and fixed on the upper and lower rotating shafts. The upper folding roller 1021 and the lower folding roller 1022 are equipped with a folding structure for folding the profile 103. The profile 103 is sandwiched between the upper folding roller 1021 and the lower folding roller 1022. The profile 103 is folded upward by the folding structure. Through the gradual forming by the multiple sets of folding modules 102, it is formed into a P-shaped beam 104 with a "P"-shaped cross section and a hollow cavity.

[0058] refer to Figure 1By setting multiple sets of folding modules 102 for progressive bending in multiple passes, the profile 103 sequentially passes through 10 to 30 folding modules 102. Each pair of upper folding rollers 1021 and lower folding rollers 1022 only completes a small portion of the bending deformation, and the deformation amount in each pass is very small, which can avoid material cracking or wrinkling. Through multiple sets of folding modules 102, the final "P" shaped cross-section is gradually approached. The specific forming structure of the folding module 102 is as follows:

[0059] refer to Figure 2 The folding module 102 includes a first folding mold 1 for pre-forming the bottom and the closing of the P-shaped beam 104. The lower folding roller 1022 corresponding to the first folding mold 1 has a first upper folding slope 11 in the middle and a first upper folding edge slope 12 on both sides of the lower folding roller 1022. The upper folding roller 1021 corresponding to the first folding mold 1 has a matching slope corresponding to the first upper folding slope 11 in the middle. The profile 103 is folded upward by the first folding mold 1, and a bottom vertical structure 1031 is formed in the middle of the profile 103. A left folding edge structure 1032 and a right folding edge structure 1033 are formed on the left and right sides respectively.

[0060] The slopes of adjacent first upper folding slopes 11 and first upper flange slopes 12 gradually increase along the transport direction of profile 103. Five first folding dies 1 are sequentially arranged along the transport direction of profile 103. Through the gradual forming of the five first folding dies 1, a 120° bottom facade structure 1031, a 150° left flange structure 1032, and a 90° closed right flange structure 1033 are finally formed on profile 103 by bending.

[0061] refer to Figure 3 The folding module 102 includes a second folding mold 2 for forming the P-shaped beam 104. The lower folding roller 1022 corresponding to the second folding mold 2 has a second upper folding slope 21 in the middle, a second upper folding edge slope 22 on the left side of the lower folding roller 1022, and a right folding edge slope 23 on the right side. The upper folding roller 1021 corresponding to the second folding mold 2 has a matching slope corresponding to the second upper folding slope 21 in the middle. The profile 103 is folded upward by the second folding mold 2, and a bottom vertical structure 1031, a left folding edge structure 1032, and a right folding edge structure 1034 are formed on the profile 103.

[0062] The slopes of the adjacent second upper folding slope 21, second upper flange slope 22, and right folding slope 23 gradually increase along the transport direction of the profile 103. Five second folding dies 2 are sequentially arranged along the transport direction of the profile 103. Through the gradual forming of the five second folding dies 2, the profile 103 is finally bent to form a 90° closed bottom facade structure 1031, a 90° closed left flange structure 1032, and a near 90° right flange structure 1034.

[0063] refer to Figure 4 The folding module 102 includes a third folding mold 3 for preforming the right vertical edge of the P-shaped beam 104. The lower folding roller 1022 corresponding to the third folding mold 3 has a first upper right folding slope 31 near the middle on the right side and a left folding slope 32 on the left side. The profile 103 is folded upward by the third folding mold 3, forming a left folding structure 1035 on the left side of the profile 103 and a right vertical edge structure 1036 near the middle on the right side of the profile 103.

[0064] The upper folding roller 1021 and the lower folding roller 1022 corresponding to the third folding mold 3 are provided with a "Z"-shaped shaping cavity 33 at a 90° angle in the middle. The shaping cavity allows the bottom vertical structure 1031 formed at 90° to pass through. When the material passes through, it is clamped and shaped to prevent the bottom surface from twisting due to subsequent folding, and to ensure the stability of the bottom cavity angle of the P-shaped beam 104.

[0065] The slopes of the adjacent first upper right folding slope 31 and left folding slope 32 gradually increase along the transport direction of the profile 103. Five third folding dies 3 are sequentially arranged along the transport direction of the profile 103. Through the gradual forming of the five third folding dies 3, a left folding structure 1035 with an angle of nearly 90° and a right standing edge structure 1036 with an angle of 160° are finally formed on the profile 103.

[0066] refer to Figure 5 The folding module 102 includes a fourth folding mold 4 for pre-forming the left vertical side of the P-shaped beam 104. A first upper left folding slope 41 is provided near the center of the left side of the lower folding roller 1022 corresponding to the fourth folding mold 4. The profile 103 is folded upwards by the third folding mold 3, forming a left vertical side structure 1037 near the center of the left side of the profile 103. The slope of adjacent first upper left folding slopes 41 gradually increases along the transport direction of the profile 103. Five fourth folding molds 4 are sequentially arranged along the transport direction of the profile 103. Through the gradual forming by the five fourth folding molds 4, a 120° left vertical side structure 1037 is finally formed on the profile 103 by bending.

[0067] The upper folding roller 1021 and the lower folding roller 1022 corresponding to the fourth folding mold 4 are provided with a "Z"-shaped shaping cavity 33 at a 90° angle in the middle. The shaping cavity allows the bottom vertical structure 1031 formed at 90° to pass through. The lower folding roller 1022 corresponding to the fourth folding mold 4 has a first upper right folding slope 31 near the middle position on the right side as a shaping slope 42, which allows the right vertical side structure 1036 formed at 160° to pass through.

[0068] refer to Figures 6-7The folding module 102 includes multiple combined rollers for the simultaneous forming of the left vertical structure 1037 and the right vertical structure 1036. To avoid quality problems such as bulging, wavy lines, and cracks during the simultaneous 90° bending forming of the left vertical structure 1037 and the right vertical structure 1036 of the P-shaped beam 104, this embodiment employs two different combined roller structures and adds an internal support structure for step-by-step unloading, thereby avoiding problems such as bottom surface deformation, corner cracks, and flanging interference. The specific structure is as follows:

[0069] refer to Figure 6 The folding module 102 includes a first combined roller 5, which includes a first upper pressure roller and a first lower pressure roller 51. The first lower pressure roller 51 is a horizontal roller, and the first upper pressure roller is composed of two guide rollers. The middle of the first lower pressure roller 51 is provided with a first shaping pressure surface 511 with a 90° included angle "Z" and a second right upper folding slope 512 connected to the first shaping pressure surface 511. The first upper pressure roller includes a first left guide roller 52 and a first right guide roller 53. The first left guide roller 52 is provided with a first left pressure slope 521, and the first right guide roller 53 is provided with a first right pressure slope 531. The first left pressure slope 521 is used to further shape the 120° left vertical side structure 1037 into a left vertical side structure 1037 with an angle close to 90°, thus completing the large-angle convergence. The first right pressure slope 531 is used to press against the bottom corner of the left vertical structure 1037, applying pressure only to the root. Its function is to "tighten the root" and eliminate the opening caused by the elastic recovery of the bend rounded corner area, so that the bottom corner is truly close to 90° and locked.

[0070] The slopes of the adjacent second upper right folding slope 512 and the first left pressing slope 521 gradually increase along the transport direction of the profile 103. Five first combined rollers 5 are arranged in sequence along the transport direction of the profile 103. Through the gradual forming by the five first combined rollers 5, a 120° right vertical side structure 1036 and a 90° left vertical side structure 1037 are finally formed on the profile 103 by bending.

[0071] refer to Figure 7The folding module 102 includes a second combined roller 6, which includes a second upper pressure roller and a second lower pressure roller 61. The second lower pressure roller 61 is a horizontal roller, and the second upper pressure roller consists of two guide rollers and a fixed pressure mold 64. The second lower pressure roller 61 is located in the middle of the profile 103. The second lower pressure roller 61 is provided with a "Z"-shaped second shaping pressure surface 611 at a 90° angle. The second upper pressure roller includes a second left guide roller 62 and a second right guide roller 63. The second left guide roller 62 is provided with a second left pressure slope 621, and the second right guide roller 63 is provided with a second right pressure slope 631. The second left pressure slope 621 is used for fixed pressure on the 90° left vertical side structure 1037, and the second right pressure slope 631 is used to further shape the 120° right vertical side structure 1036 into a right vertical side structure 1036 that is close to 90°.

[0072] The cross-section of the fixed pressure mold 64 is "┐" shaped. A pressure roller 65 is provided on the opposite side of the transverse protrusion of the fixed pressure mold 64. The fixed pressure mold 64 is used to press against the bottom corner of the left vertical structure 1037 and apply pressure to the connection position between the bottom corner and the bottom vertical structure 1031. The pressure roller 65 provided on it is used to apply pressure to the bottom of the P-shaped beam 104 to avoid deformation of the bottom surface, corner cracks or deformation.

[0073] The slope of the adjacent second right pressure slope 631 gradually increases along the transport direction of the profile 103. Two second combined rollers 6 are arranged in sequence along the transport direction of the profile 103. Through the gradual forming by the two second combined rollers 6, a 90° right vertical side structure 1036 is finally formed on the profile 103.

[0074] refer to Figures 8-9 The folding module 102 includes multiple shaping rollers for shaping the P-shaped beam 104 at the end. The rollers gradually narrow along the discharge direction, applying symmetrical micro-pressure to the formed cavity of the P-shaped beam 104 to eliminate springback opening and ensure that the closing angle is in place in one go and maintains straightness, providing a uniform and stable fit gap for subsequent fastening.

[0075] refer to Figure 8The folding module 102 includes a first shaping roller group 7, which is used for shaping the upper and lower surfaces of the P-shaped beam 104. The first shaping roller group 7 includes a first upper shaping roller 71, a first lower shaping roller 72, a first left shaping roller 73, and a first right shaping roller 74. The first lower shaping roller 72 is located in the middle of the profile 103 and is provided with a "Z"-shaped third shaping pressure surface 721 at a 90° angle. The first upper shaping roller 71 and the first lower shaping roller 72 are positioned correspondingly. The first upper shaping roller is provided with a planar pressure surface 711. The first left shaping roller 73 and the first right shaping roller 74 are both provided with vertical pressure surfaces 75 at a 90° angle. The profile 103 is sandwiched between the first upper shaping roller 71 and the first lower shaping roller 72. The top and bottom surfaces of the P-shaped beam 104 are simultaneously subjected to micro-pressure by two sets of first shaping roller groups 7 to eliminate the rebound fluctuation in the height direction of the cavity and provide a precise height reference for subsequent closing and fastening.

[0076] refer to Figure 9 The folding module 102 includes a second shaping roller group 8, which is used to shape the left and right sides of the P-shaped beam 104. The second shaping roller group 8 includes a second lower shaping roller 81, a second left shaping roller 82, and a second right shaping roller 83. The second lower shaping roller 81 is composed of two shaping rollers, which cooperate to form a "Z"-shaped fourth shaping pressure surface 811 with a 90° included angle. The second left shaping roller 82 and the second right shaping roller 83 are both provided with vertical surface pressure surfaces 75 at a 90° angle. The profile 103 is clamped between the second left shaping roller 82 and the second right shaping roller 83. By simultaneously clamping and pressing the left and right vertical sides of the P-shaped beam 104 with the three sets of second shaping roller groups 8, the verticality is corrected and the side bending is eliminated, so that the cavity width remains constant, providing a parallel and vertical side wall reference for the final locking.

[0077] refer to Figure 10 In this embodiment, a welding gun bracket 84 can be added to the outlet end of the second shaping roller group 8 so that the welding gun flame or laser beam is precisely aligned with the closing gap 1041 after being corrected by the vertical pressing surface 75. Utilizing the 90° vertical sidewall and constant cavity width provided by the shaping roller group, welding can be performed simultaneously with shaping, completing the form and position locking and weld formation in one go, eliminating the need for subsequent secondary positioning processes. The closing gap 1041 is the joint between the left flange structure 1032 and the right flange structure 1033 of the final P-shaped beam 104. After being corrected by the second shaping roller group 8, the gap remains vertical and has a uniform width. The welding gun is directly applied to the joint at the roller group outlet to achieve synchronous fusion of the left and right flange locking joints, completing the final fixation of the closed cavity body, and the closed welding fixation is free of springback.

[0078] This embodiment, based on the provided P-beam 104 forming equipment, also provides a P-beam 104 forming process, with the specific forming steps along the transport direction of the profile 103 as follows:

[0079] The first forming stage is based on the basic folding and forming, which is divided into the following steps:

[0080] Step 1: The bottom and side edges of the profile 103 are pre-formed using the first folding mold 1. The bottom vertical structure 1031 is gradually formed in the middle of the profile 103 through five first folding molds 1, and the side edges are formed into preliminary folding structures.

[0081] Step 2: Use the second folding mold 2 to pre-form the profile 103 at the end. Through five folding molds 2, the right side of the profile 103 is gradually folded to form a right folded edge structure 1034, which is in preparation for the final "locking".

[0082] Step 3: Use the third folding mold 3 to pre-form the right vertical edge of the profile 103. Through five third folding molds 3, the vertical right vertical edge structure 1036 is gradually formed on the right side of the profile 103 near the middle position. At the same time, the left folding edge structure 1035 of the profile 103 is further folded on the left side.

[0083] Step 4: Use the fourth folding die 4 to gradually form the left side of the profile 103. Through five fourth folding dies, the vertical left side structure 1037 is gradually formed on the left side of the profile 103 near the middle.

[0084] The second forming stage involves the 90° forming of the left vertical structure 1037 and the right vertical structure 1036, as well as the finishing of the bottom corners, and consists of the following steps:

[0085] Step 5: Use the first combined roller 5 to fold the left vertical side structure 1037 and "tuck in" the bottom corner of the left vertical side structure 1037. Through the gradual shaping of the five first combined rollers 5, the left vertical side structure 1037 is folded to nearly 90°.

[0086] Step 6: Use the second combined roller 6 to fold the right vertical side structure 1036 and shape it together with the left vertical side structure 1037. Through the gradual shaping of the two second combined rollers 5, the right vertical side structure 1036 is pressed into 90° simultaneously, and the left side is coordinated to complete the symmetrical structure.

[0087] The third forming stage is the overall shaping and calibration of P-type beam 104, which consists of the following steps:

[0088] Step 7: Use the first shaping roller group 7 to shape the upper and lower surfaces of the P-shaped beam 104. Apply micro pressure to the top and bottom surfaces of the P-shaped beam 104 simultaneously through two first shaping roller groups 7 to eliminate the rebound fluctuation in the height direction of the cavity and provide a precise height reference for subsequent closing and fastening.

[0089] Step 8: The left and right sides of the P-beam 104 are shaped using the second shaping roller group 8. The left and right vertical sides of the P-beam 104 are simultaneously clamped by three second shaping roller groups 8 to correct the verticality and eliminate side bending, so that the cavity width remains constant and provides a parallel and vertical side wall reference for the final locking.

[0090] The fourth forming stage is the welding of the closing gap 1041 of the P-shaped beam 104. By adding a welding gun bracket 84 at the exit end of the second forming roller group 8, the welding gun flame or laser beam is used to weld the closing gap 1041 that has been corrected by the facade pressing surface 75.

[0091] 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 P-beam forming device, characterized in that: The machine includes a frame, which is rotatably provided with multiple upper and lower rotating shafts arranged opposite each other along the profile feeding direction. The machine includes multiple sets of folding modules arranged from the feeding end along the profile feeding direction. Each folding module includes an upper folding roller and a lower folding roller respectively sleeved and fixed on the upper and lower rotating shafts. The multiple folding modules are arranged sequentially along the profile feeding direction, including a first folding mold, a second folding mold, a third folding mold, a fourth folding mold, a first combined roller, a second combined roller, a first shaping roller group, and a second shaping roller group; The lower folding roller corresponding to the first folding mold has a first upper folding slope in the middle and a first upper folding edge slope on both sides of the lower folding roller. The upper folding roller corresponding to the first folding mold has a matching slope in the middle that corresponds to the first upper folding slope. The second folding mold has a second upper folding slope in the middle of the lower folding roller, a second upper folding edge slope on the left side of the lower folding roller, and a right folding edge slope on the right side of the lower folding roller. The upper folding roller corresponding to the second folding mold has a matching slope in the middle that corresponds to the second upper folding slope. The third folding mold has a first right upper folding slope on the right side of the lower folding roller near the middle, and a left folding slope on the left side of the lower folding roller. The upper folding roller and the lower folding roller corresponding to the third folding mold are provided with a "Z" shaped shaping cavity at a 90° angle in the middle. The lower folding roller corresponding to the fourth folding mold has a first upper left folding slope near the middle position on the left side, and the upper folding roller and the lower folding roller corresponding to the fourth folding mold have a "Z" shaped shaping cavity with a 90° angle in the middle, and the lower folding roller corresponding to the fourth folding mold has a shaping slope near the middle position on the right side. The first combined roller includes a first upper pressure roller and a first lower pressure roller. The middle part of the first lower pressure roller is provided with a first shaping pressure surface in the shape of a "Z" with a 90° included angle and a second upper right folding surface connected to the first shaping pressure surface. The first upper pressure roller includes a first left support roller, and the first left support roller is provided with a first left pressure folding surface. The second combined roller includes a second upper pressure roller and a second lower pressure roller. The second lower pressure roller is provided with a "Z"-shaped second shaping pressure surface at a 90° angle. The second upper pressure roller includes a second left support roller and a second right support roller. The second left support roller is provided with a second left pressure slope, and the second right support roller is provided with a second right pressure slope. The first shaping roller group includes a first upper shaping roller, a first lower shaping roller, a first left shaping roller, and a first right shaping roller. The first lower shaping roller is located in the middle of the profile and is provided with a "Z"-shaped third shaping pressure surface at a 90° angle. The first upper shaping roller is positioned corresponding to the first lower shaping roller. The first upper shaping roller is provided with a planar pressure surface. The first left shaping roller and the first right shaping roller are both provided with vertical pressure surfaces at a 90° angle. The second shaping roller group includes a second lower shaping roller, a second left shaping roller, and a second right shaping roller. The second lower shaping roller is provided with a fourth shaping pressure surface in the shape of a "Z" at a 90° angle. The second left shaping roller and the second right shaping roller are both provided with vertical pressure surfaces at a 90° angle. A welding gun bracket is provided at the outlet end of the second shaping roller group. The welding gun bracket is used to fix the welding gun.

2. The P-beam forming equipment according to claim 1, characterized in that: The slope of the adjacent first upward folding slope and the first upward flange slope gradually increases along the profile transportation direction; five first folding molds are set in sequence along the profile transportation direction, and the profile is folded upward through the first folding molds to form a 120° bottom facade structure in the middle of the profile, and a 150° left flange structure and a 90° right flange structure on the left and right sides respectively.

3. The P-beam forming equipment according to claim 2, characterized in that: The slopes of the adjacent second upper folding slope, second upper flange slope, and right folding slope gradually increase along the profile transport direction; five second folding molds are set sequentially along the profile transport direction, and the profile is folded upward through the second folding molds to form a 90° bottom vertical structure in the middle of the profile, and a 90° left flange structure and a 90° right folding structure on the left and right sides respectively.

4. The P-beam forming equipment according to claim 3, characterized in that: The slopes of the adjacent first upper right folding slope and left folding slope gradually increase along the profile transport direction; five third folding molds are set sequentially along the profile transport direction, and the profile is folded upward through the third folding molds, forming a 90° left folding edge structure and a 160° right standing edge structure on the left and right sides of the profile respectively.

5. The P-beam forming equipment according to claim 4, characterized in that: The slope of the adjacent first upper left folding slope gradually increases along the profile transport direction; five fourth folding molds are set in sequence along the profile transport direction, and the profile is folded upward by the fourth folding molds to form a 120° left vertical side structure on the left side of the profile.

6. The P-beam forming equipment according to claim 5, characterized in that: The slopes of the adjacent second upper right folding slope and the first left pressure slope gradually increase along the profile transport direction; the first left pressure slope is used to gradually shape the 120° left vertical edge structure into a 90° left vertical edge structure.

7. A P-beam forming device according to claim 6, characterized in that: The slope of the adjacent second right pressure slope gradually increases along the profile transport direction; the second left pressure slope is used for the fixed pressure of the 90° left vertical side structure, and the second right pressure slope is used to form the 120° right vertical side structure into a 90° right vertical side structure.

8. The P-beam forming equipment according to claim 1, characterized in that: The first upper pressure roller also includes a first right support roller, which has a first right pressure slope, and the first right pressure slope is used to press against the bottom corner of the left vertical side structure.

9. A P-beam forming device according to claim 1, characterized in that: The second upper pressure roller also includes a fixed pressure mold, the cross-section of which is "┐" shaped, and a pressure roller is provided on the opposite side of the transverse protrusion of the fixed pressure mold; the fixed pressure mold is used to press against the bottom corner of the left vertical structure, and the pressure roller is used to apply pressure to the bottom of the P-shaped beam.

10. A P-shaped beam forming process, characterized in that: According to any one of claims 1-9, the P-beam forming equipment is divided into a first forming stage, a second forming stage, a third forming stage and a fourth forming stage along the profile transportation direction; The specific molding steps are as follows: The first forming stage is based on the basic folding and forming, which is divided into the following steps: Step 1: Use the first folding die to pre-form the bottom and side edges of the profile. Through multiple first folding dies, gradually form the bottom facade structure in the middle of the profile and the preliminary folding structure on both sides. Step 2: Use the second folding die to pre-form the profile at the end. Through multiple second folding dies, the right side of the profile is gradually folded to form a right folded edge structure, which is in preparation for the final "locking". Step 3: Use the third folding die to pre-form the right vertical edge of the profile. Through multiple third folding dies, gradually form the vertical right vertical edge structure on the right side of the profile near the middle position, and simultaneously fold the left edge structure of the profile on the left side. Step 4: Use the fourth folding die to gradually form the left side of the profile. Through multiple fourth folding dies, a vertical left side structure is gradually formed on the left side of the profile near the middle. The second forming stage involves shaping the left and right vertical structures at a 90° angle and finishing the bottom corners, which is divided into the following steps: Step 5: Use the first combination roller to fold the left vertical side structure and "finish" the bottom corner of the left vertical side structure. Through the gradual shaping of multiple first combination rollers, fold the left vertical side structure to 90°. Step 6: Use the second combination roller to fold the right vertical side structure and shape it together with the left vertical side structure. Through the gradual shaping of multiple second combination rollers, the right vertical side structure is pressed to 90° simultaneously, and the left side is coordinated to complete the symmetrical structure. The third forming stage is the overall shaping and calibration of the P-shaped beam, which consists of the following steps: Step 7: Use the first shaping roller group to shape the top and bottom surfaces of the P-shaped beam. Apply micro pressure to the top and bottom surfaces of the P-shaped beam simultaneously through multiple first shaping roller groups to eliminate springback fluctuations in the height direction of the cavity and provide a precise height reference for subsequent closing and fastening. Step 8: Use the second shaping roller group to shape the left and right vertical sides of the P-shaped beam. The left and right vertical sides of the P-shaped beam are simultaneously clamped by multiple second shaping roller groups to correct the verticality and eliminate side bending, so that the cavity width remains constant and provides a parallel and vertical side wall reference for the final locking. The fourth forming stage is the welding of the P-shaped beam's closing gap. A welding gun support is set at the exit end of the second forming roller group, and the welding gun flame or laser beam is used to weld the closing gap that has been corrected by the facade pressing surface.

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