A continuous production equipment for concave-shaped thin plate cold bending profile and a method of using the same

Abstract

A kind of concave character type sheet cold bending section bar continuous production equipment and its using method, including equipment body, equipment body two sides are connected with electric cabinet and hydraulic station respectively, electric cabinet is electrically connected with equipment body, for controlling the automatic operation of whole production line, hydraulic station provides power for equipment main body inside, the present application is by integrating sheet material leveling, flat plate stamping, cold bending forming, flanging and cutting and other core processes, realize the continuous automatic production of concave character type sheet cold bending section bar raw material to finished product, improve production efficiency;Through the cooperation of feed length counter and electric cabinet control, ensure the positioning accuracy of stamping hole and finished product cutting, reduce human error;Cold bending forming area adopts staged progressive rolling, optimizes roller group division for concave character section, reduces forming springback and distortion, integrates multiple flanging dies and cutting functions with stamping device, simplifies equipment layout and station investment, reduces floor space and maintenance cost, adapts to large-scale production demand.

Description

Technical Field

[0001] This invention relates to the field of profile processing technology, and in particular to a continuous production equipment for U-shaped thin sheet cold-bent profiles and its usage method. Background Technology

[0002] Cold-formed steel is a plastic forming process that uses sequentially arranged multi-pass forming rolls to continuously bend metal sheets and strips laterally to produce profiles with specific cross-sections. This process has advantages such as high production efficiency, high material utilization, and good product strength, and is widely used in construction, machinery, transportation and other fields.

[0003] Due to their compact cross-sectional structure and excellent load-bearing performance, U-shaped thin sheet cold-formed profiles are widely used in various support structures and assembly components. However, currently known cold-forming equipment has significant shortcomings in producing such complex structural profiles: First, the processes are fragmented, with complex punching, flanging, and flange forming processes requiring separate steps on different equipment, resulting in low production efficiency, poor positioning accuracy, and difficulty in achieving continuous and automated production. Second, the functional integration is low; for holes and flangings with different positions and functions on the profile (such as diamond hook holes and end flanges), traditional equipment requires multiple independent stamping stations, resulting in a lengthy equipment layout and high costs. Third, forming accuracy is difficult to guarantee; the stepped staggered webs and multiple right-angle bends and hook structures of U-shaped profiles place extremely high demands on roll design and process sequence. Traditional equipment is prone to problems such as insufficient forming, excessive springback, and profile distortion, seriously affecting the geometric accuracy and structural performance of the product.

[0004] Therefore, in order to address the shortcomings of existing technologies, it is essential to provide a continuous production equipment for U-shaped thin sheet cold-formed profiles and its usage method to overcome the deficiencies of existing technologies. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of existing technologies by providing a continuous production equipment and method for cold-formed concave-shaped thin sheet profiles. This invention integrates core processes such as sheet leveling, flatbed stamping, cold bending, and flanging / cutting into the equipment body, achieving continuous automated production of concave-shaped thin sheet cold-formed profiles from raw materials to finished products. This significantly reduces process connection time and greatly improves production efficiency. Through the coordinated control of the feed length counter and the electrical control cabinet, the accuracy of stamping hole positioning and finished product cutting length is ensured, effectively reducing human error. The cold bending forming area adopts a phased progressive roller pressing design, optimizing the functional division of each roller group for the special cross-sectional structure of the concave-shaped profile. This effectively reduces springback and profile twisting during the forming process, ensuring the geometric accuracy and structural stability of the product. The combined stamping device integrates multiple flanging dies and cutting functions, simplifying the equipment layout, reducing investment in independent workstations, lowering production space occupation and equipment maintenance costs, and better meeting the actual needs of large-scale production.

[0006] The above-mentioned objectives of the present invention are achieved by the following technical means. A continuous production equipment for cold-formed U-shaped thin sheet profiles and its usage method are provided. The equipment includes a main body, a feeding machine connected to one end of the main body, on which a metal sheet is carried, a feeding rack connected to the other end of the main body, an electrical control cabinet and a hydraulic station connected to both sides of the main body, the electrical control cabinet being electrically connected to the main body and used to control the automated operation of the entire production line, and the hydraulic station providing power to the inside of the main body of the equipment. The equipment body is arranged in sequence along the sheet material travel direction as follows: sheet material leveling zone, flat plate stamping zone, cold bending forming zone, and flanging and cutting zone. The sheet material leveling zone is equipped with a leveling wheel set, and the leveling wheel set is equipped with a feed length counter. The flat plate stamping zone is located at the rear of the sheet material leveling zone. The flat plate stamping zone is equipped with several sets of combined stamping devices, which are connected to the hydraulic station pipeline. The cold bending forming zone is equipped with cold bending roller sets evenly arranged inside. The flanging and cutting zone is equipped with a combined stamping device.

[0007] Specifically, at least three sets of combined hole stamping devices inside the flat plate stamping zone punch out connecting holes and mounting holes on the metal strip in the flat plate state according to a preset pattern.

[0008] Specifically, the equipment body is equipped with a front shearing mechanism and a rear shearing mechanism at both ends, respectively. The feed length counter is connected to the electrical control cabinet via electrical signals. The electrical control cabinet controls the cutting length of the front shearing mechanism and the rear shearing mechanism according to the feed length counter.

[0009] Specifically, the cold bending roll group in the cold bending forming area includes the intermediate web preforming group, the intermediate flange forming group, the outer web expansion group, the right angle bending forming group, the outer flange forming group, and the hook bending group.

[0010] Specifically, the combined stamping device includes a diamond hook opening and flanging stamping die and an end flange flanging and cutting stamping die.

[0011] Specifically, the usage method includes the following steps: S1: Place the metal strip into the feeder, which continuously conveys the metal strip into the main body of the equipment. S2: The metal strip enters the plate leveling area of ​​the main body of the equipment. The metal strip is straightened in multiple passes by the leveling wheel set to eliminate the curling stress generated during storage and unwinding, so that the surface of the metal strip is flat and the internal stress is uniform. S3: After being leveled, the metal strip passes through a feed length counter. The feed length counter measures the feed length of the metal strip in real time and sends a pulse signal to the electrical control cabinet to achieve accurate monitoring of the feed length. S4: The metal strip enters the flat plate stamping area of ​​the main body of the equipment. The feeding length is calculated by the feeding length counter, and the start time of the combined stamping device is controlled to punch out various connection holes and mounting holes on the metal strip in the flat plate state. S5: The pre-punched metal strip enters the cold bending forming zone. The cold bending forming zone rolls and bends the metal one pass at a time in a phased and progressive forming logic to produce the formed metal profile. S6: After forming, the metal profile enters the flanging and cutting area. The electrical control cabinet controls the movement of the diamond hook opening flanging stamping die and the end flange flanging and cutting stamping die in the flanging and cutting area according to the fixed length signal of the feeding length counter. Together with the rear shearing mechanism, the finished profile is separated from the continuous metal profile. S7: The cut finished profiles are smoothly conveyed to the designated collection area through the unloading rack, completing the unloading production.

[0012] Specifically, in step S5, the cold bending forming area includes a middle web preforming group, a middle flange forming group, an outer web extension group, a right-angle bend forming group, an outer flange forming group, and a hook bending group. The roller surface of the middle web preforming group is a flat surface with a shallow groove structure; the roller surface of the middle flange forming group is a stepped groove; the roller surface of the outer web extension group is a wide groove with an inclined guide surface; the roller surface of the right-angle bend forming group is a right-angle groove; the roller surface of the outer flange forming group is a groove that matches the outer flange; and the roller surface of the hook bending group is an arc shape with a clamping structure.

[0013] This invention integrates core processes such as sheet metal leveling, flatbed stamping, cold bending, and flanging / cutting into the main body of the equipment, achieving continuous automated production of U-shaped thin sheet cold-bent profiles from raw materials to finished products. This significantly reduces process connection time and greatly improves production efficiency. Through the coordinated control of the feed length counter and the electrical control cabinet, the accuracy of stamping hole positioning and finished product cutting length is ensured, effectively reducing human error. The cold bending forming area adopts a phased, progressive roller pressing design, optimizing the functional division of each roller group for the special cross-sectional structure of the U-shaped profile. This effectively reduces springback and profile twisting during the forming process, ensuring the geometric accuracy and structural stability of the product. The combined stamping device integrates multiple flanging dies and cutting functions, simplifying the equipment layout, reducing investment in independent workstations, lowering production space occupation and equipment maintenance costs, and better meeting the actual needs of large-scale production. Attached Figure Description

[0014] The invention will be further described with reference to the accompanying drawings, but the contents of the drawings do not constitute any limitation on the invention.

[0015] Figure 1 This is a top view of the main body of the continuous production equipment for concave-shaped thin plate cold-formed profiles and its usage method according to the present invention.

[0016] Figure 2 This is a front view of the main body of the continuous production equipment for concave-shaped thin plate cold-formed profiles and its usage method according to the present invention.

[0017] Figure 3 This is a partial three-dimensional view of the main body of the equipment in the continuous production equipment and its usage method for concave-shaped thin plate cold-formed profiles of the present invention.

[0018] Figure 4 This is a flowchart of a continuous production equipment for concave-shaped thin sheet cold-formed profiles and its usage method according to the present invention.

[0019] from Figures 1 to 4 Including: 1. Equipment body; 2. Feeding machine; 3. Unloading rack; 4. Electrical control cabinet; 5. Hydraulic station; 6. Sheet leveling area; 7. Flat plate stamping; 8. Cold bending forming area; 9. Flanged cutting area; 10. Front shear mechanism; 11. Rear shearing mechanism; 12. Feed length counter. Detailed Implementation

[0020] The present invention will be further described in conjunction with the following embodiments.

[0021] Example 1.

[0022] like Figure 1-4 As shown, a continuous production equipment for U-shaped thin sheet cold-formed profiles and its usage method are disclosed. The equipment body adopts an integrated frame structure to ensure the overall rigidity and stability of the equipment during operation. One end of the equipment body is connected to a feeding machine through a conveying structure. The feeding machine has the functions of fixing raw materials and continuous conveying, and can be adapted to metal sheet and strip raw materials of common specifications. The other end of the equipment body is connected to a unloading rack, which is equipped with protective and guiding structures to ensure that the finished profiles can be smoothly conveyed to the collection area.

[0023] An electrical control cabinet is installed on one side of the equipment body. The cabinet has a built-in control system and operating interface, allowing operators to set production parameters, start and stop the equipment, and monitor the production status. A hydraulic station is connected to the other side of the equipment body. The hydraulic station provides stable power output to the internal stamping device, shearing mechanism, etc. It is connected to each actuator through pipelines to ensure the timeliness and stability of action response. The electrical control cabinet is connected to each actuator of the equipment body through circuits to realize the automated control of the entire production line, including functions such as process linkage, parameter adjustment, and fault early warning.

[0024] Along the direction of the metal strip's movement, the equipment body is sequentially equipped with a sheet leveling area, a flat stamping area, a cold bending forming area, and an edge-flanging and cutting area. These areas are closely connected to form a continuous processing line.

[0025] The sheet metal leveling area is equipped with symmetrically arranged leveling wheel sets, which consist of multiple sets of high-strength wear-resistant wheels. The spacing between the upper and lower wheel sets can be adjusted according to the thickness of the metal sheet to ensure the straightening effect. The input end of the leveling wheel set is equipped with a feed length counter, which can capture the conveying speed and feed length of the metal sheet in real time and transmit the data to the electrical control cabinet in real time, providing a basis for the precise control of subsequent processes.

[0026] The flat plate stamping area is located at the rear of the sheet metal leveling area. Several sets of combined stamping devices are fixedly installed inside by brackets. The number of combined stamping devices can be adjusted according to the product hole design requirements. At least three sets are set to meet the hole processing requirements at different positions. Each set of combined stamping devices includes a power unit and a stamping die. The power unit is connected to the hydraulic station to obtain power. The stamping die can be replaced according to the hole specifications. Each set of devices is arranged according to the preset hole distribution pattern to ensure that the required connection holes, mounting holes and flange-specific openings are accurately stamped on the flat metal strip.

[0027] Several sets of cold bending rollers are evenly arranged inside the cold bending forming area. The roller sets are arranged in the following order according to the forming logic: the middle web pre-forming group, the middle flange forming group, the outer web expansion group, the right angle bend forming group, the outer flange forming group, and the hook roll forming group. The roller surface structure of each group is specifically designed to meet the forming requirements of different parts of the U-shaped profile. Through successive roller bending, the gradual processing from flat plate to formed profile is achieved, avoiding material damage or insufficient forming caused by one-time forming. All cold bending roller sets are connected to the drive mechanism and are adjusted and controlled by the electrical control cabinet to ensure that the linear speed of each roller set is kept synchronized, avoiding defects such as stretching and wrinkling of the metal strip during the forming process.

[0028] The flanging and cutting area is equipped with a combined stamping device, which integrates a diamond hook opening and flanging stamping die and an end flange flanging and cutting stamping die. The two dies are installed side by side on the same mounting frame and share a power unit, enabling synchronous operation. The diamond hook opening and flanging stamping die has built-in punching and flanging components. The punching component is used to punch out square diamond hook holes, and the flanging component can immediately flanging and shaping the holes. The end flange flanging and cutting stamping die has built-in flanging components and a cutting blade. The flanging component is used to fold the end of the middle web plate into a flange structure, and the cutting blade is used for the final cutting of the blank. The flanging and cutting area is also equipped with a guiding and positioning structure to ensure that the formed profile can be accurately aligned after entering the area, ensuring the flanging processing accuracy and the flatness of the cutting edge.

[0029] The front end of the equipment body is equipped with a front shearing mechanism to cut off defective sections at the head of metal sheets and strips, ensuring the integrity of raw materials for subsequent processing. The rear end of the equipment body is equipped with a rear shearing mechanism for assisting in the fixed-length cutting of finished profiles. Both the front and rear shearing mechanisms are connected to a hydraulic station to obtain shearing power and establish a signal connection with the electrical control cabinet to receive control commands from the control cabinet. Based on the length data fed back by the feed length counter, the timing and length of shearing are precisely controlled. The specific implementation process of using the above-mentioned continuous production equipment for U-shaped thin sheet cold-formed profiles is as follows: S1: Feeding and conveying, the coiled metal strip raw material is installed and fixed on the feeder. The tensioning mechanism of the feeder ensures that the raw material is firmly fixed and avoids deviation or loosening during the conveying process. Start the feeder and the conveying mechanism pulls the free end of the metal strip to the feed port of the equipment body. Adjust the conveying speed so that the metal strip enters the equipment body in a continuous and stable state.

[0030] S2: Sheet metal leveling. After the metal strip enters the sheet metal leveling area, the distance between the upper and lower rollers of the leveling roller set is adjusted according to the thickness and curvature of the metal strip. The leveling roller set is started, and the metal strip undergoes multiple straightening processes under the squeezing and conveying action of the upper and lower roller sets. This eliminates the curvature stress generated during storage and uncoiling, ensuring that the surface of the metal strip meets the flatness requirements and the internal stress is evenly distributed, thus ensuring the processing accuracy of subsequent stamping and forming processes.

[0031] S3: Length monitoring. The leveled metal strip is continuously conveyed forward, passing through the feed length counter. The counter captures the feed length of the metal strip in real time and converts the measurement data into an electrical signal, which is then sent to the electrical control cabinet. The electrical control cabinet processes and analyzes the received signal, displays the feed length in real time, and stores the relevant data to provide data support for the precise control of subsequent stamping, cutting, and other processes.

[0032] S4: Flatbed stamping. After the metal strip enters the flatbed stamping area, the electrical control cabinet, based on the feeding length data fed back by the feeding length counter and combined with the preset hole spacing parameters, immediately sends a control signal to the combined stamping device when the metal strip reaches the preset stamping position. The power unit of the combined stamping device starts, driving the stamping die downward to punch the corresponding connecting holes, mounting holes, and openings on the flange on the flat metal strip. After stamping is completed, the power unit drives the die to reset, and the metal strip continues to be conveyed forward to enter the next processing stage. This cycle repeats to complete the stamping of all holes.

[0033] S5: Cold Bending Forming. The pre-punched metal strip enters the cold bending forming area. Driven by the drive mechanism, it sequentially passes through the intermediate web preforming group, intermediate flange forming group, outer web expansion group, right-angle bend forming group, outer flange forming group, and hook bending group. The intermediate web preforming group first performs preliminary shaping on the middle part of the strip, laying the foundation for the subsequent flange forming. The intermediate flange forming group shapes the flanges on both sides of the middle of the strip. The outer web expansion group expands and shapes the two sides of the strip to form the outer web structure. The right-angle bend forming group precisely bends the key right-angle parts to ensure angle accuracy. The outer flange forming group completes the forming of the outer flange. The hook bending group performs the final shaping of the hook structure of the profile. The roller groups work together to gradually process the flat strip into a U-shaped profile.

[0034] S6: Flanging and Cutting. After forming, the metal profile enters the flanging and cutting area and is precisely aligned under the guidance and positioning structure. The electrical control cabinet sends a control signal to the combined stamping device when the profile reaches the set length, based on the total feeding length feedback from the feeding length counter and the preset finished product length parameters. The combined stamping device starts, and the diamond hook opening and flanging stamping die descends first, punching out a square diamond hook hole at the designated position on the outer web through the punching component. Then, the flanging punch or slider in the die immediately moves to flanging the hole, forming a hook structure that meets the usage requirements. At the same time, the end flange flanging and cutting stamping die descends synchronously, folding the end of the middle web upward at the end of the profile to form a flange (the opening on the flange has been stamped in the flat plate stamping area). After the flanging action is completed, the cutting knife in the die immediately moves to precisely cut the finished profile from the continuous blank, ensuring that the cut is flat and free of defects such as burrs and deformation.

[0035] S7: Material collection. The cut finished profiles enter the unloading rack under the action of gravity and conveying mechanism. The finished profiles that have completed all processing and cutting are smoothly output through the unloading rack and enter the designated collection area or subsequent processing stage. The staff regularly sorts the finished products in the collection area and conducts spot checks on the dimensional accuracy and appearance quality of the finished products according to the inspection standards. Qualified products are classified and stacked, and unqualified products are processed separately to complete the entire production process.

[0036] The continuous production equipment of this invention, through multi-process integrated design, breaks through the limitations of dispersed processes in traditional cold bending production, realizing one-stop continuous production of U-shaped thin sheet cold-bent profiles from raw materials to finished products, significantly improving production efficiency and reducing manual intervention costs. A precise automated control system ensures consistent product processing accuracy, effectively solving problems such as large positioning errors and unstable dimensions in traditional production. The optimized cold bending forming process effectively reduces material springback and profile twisting, ensuring the structural performance of the product. The highly integrated equipment structure simplifies the production layout, reduces equipment investment and site occupancy costs, and is suitable for large-scale production scenarios of different scales, possessing significant practical value and promotional significance.

[0037] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit the scope of protection of the present invention. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the essence and scope of the technical solutions of the present invention.

Claims

1. A continuous production equipment for U-shaped thin sheet cold-formed profiles and its method of use, characterized in that: The equipment includes a main body, one end of which is connected to a feeding machine that carries metal strips, and the other end of which is connected to a unloading rack. An electrical control cabinet and a hydraulic station are connected to both sides of the main body, respectively. The electrical control cabinet is electrically connected to the main body and is used to control the automated operation of the entire production line. The hydraulic station provides power to the inside of the main body of the equipment. The equipment body is arranged in sequence along the sheet material travel direction as follows: a sheet material leveling area, a flat plate stamping area, a cold bending forming area, and a flanging and cutting area. The sheet material leveling area is equipped with a leveling wheel set, and a feed length counter is installed on the leveling wheel set. The flat plate stamping area is located at the rear of the sheet material leveling area. The flat plate stamping area is equipped with several sets of combined stamping devices, and the combined stamping devices are connected to the hydraulic station pipeline. The cold bending forming area is equipped with cold bending roller sets evenly arranged inside. The flanging and cutting area is equipped with a combined stamping device.

2. The continuous production equipment for U-shaped thin sheet cold-formed profiles and its method of use according to claim 1, characterized in that: Inside the flat plate stamping zone, at least three sets of combined hole stamping devices punch connecting holes and mounting holes on the metal strip in the flat plate state according to a preset pattern.

3. The continuous production equipment for U-shaped thin sheet cold-formed profiles and its method of use according to claim 2, characterized in that: The equipment body is equipped with a front shearing mechanism and a rear shearing mechanism at both ends, respectively. The feed length counter is electrically connected to the electrical control cabinet. The electrical control cabinet controls the cutting length of the front shearing mechanism and the rear shearing mechanism according to the feed length counter.

4. The continuous production equipment for U-shaped thin sheet cold-formed profiles and its method of use according to claim 3, characterized in that: The cold bending roll group in the cold bending forming area includes a middle web preforming group, a middle flange forming group, an outer web expansion group, a right angle bending forming group, an outer flange forming group, and a hook bending group.

5. The continuous production equipment for U-shaped thin sheet cold-formed profiles and its method of use according to claim 4, characterized in that: The combined stamping device includes a diamond hook opening and flanging stamping die and an end flange flanging and cutting stamping die.

6. The continuous production equipment for U-shaped thin sheet cold-formed profiles and its method of use according to claim 5, characterized in that: The usage method includes the following steps: S1: The metal strip is placed in the feeder, and the feeder continuously conveys the metal strip into the main body of the equipment. S2: The metal strip enters the plate leveling area of ​​the main body of the equipment, and the metal strip is straightened in multiple passes by the leveling wheel set to eliminate the curling stress generated by the metal strip during storage and unwinding, so that the surface of the metal strip is flat and the internal stress is uniform. S3: After being leveled, the metal strip passes through the feed length counter, which measures the feed length of the metal strip in real time and sends a pulse signal to the electrical control cabinet to achieve accurate monitoring of the feed length. S4: The metal strip enters the flat plate stamping area of ​​the main body of the equipment. The feeding length is calculated by the feeding length counter, and the start time of the combined stamping device is controlled to punch out various connection holes and mounting holes on the metal strip in the flat plate state. S5: The pre-punched metal strip enters the cold bending forming zone, where the cold bending forming zone rolls and bends the metal in stages and progressive forming logic to produce the formed metal profile. S6: The formed metal profile enters the flange cutting area. The electrical control cabinet controls the movement of the diamond hook opening flange stamping die and the end flange flange cutting stamping die in the flange cutting area according to the fixed length signal of the feeding length counter. The finished profile is separated from the continuous metal profile in cooperation with the rear shearing mechanism. S7: The cut finished profiles are smoothly conveyed to the designated collection area by the feeding rack to complete the feeding process.

7. The continuous production equipment for U-shaped thin sheet cold-formed profiles and its method of use according to claim 6, characterized in that: The cold bending forming area in step S5 includes the intermediate web preforming group, the intermediate flange forming group, the outer web extension group, the right-angle bend forming group, the outer flange forming group, and the hook bending group. The roller surface of the intermediate web preforming group is a flat surface with a shallow groove structure; the roller surface of the intermediate flange forming group is a stepped groove; the roller surface of the outer web extension group is a wide groove with an inclined guide surface; the roller surface of the right-angle bend forming group is a right-angle groove; the roller surface of the outer flange forming group is a groove that matches the outer flange; and the roller surface of the hook bending group is an arc shape with a clamping structure.

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