Bridge -cut aluminum profile flexible threading and rolling integrated equipment

Abstract

The present application relates to the technical field of profile processing, and discloses a flexible threading and rolling integrated equipment for broken bridge aluminum profile, which comprises a forming machine main body, a main controller, and a feeding module, a threading module, a regulating module and a rolling forming module arranged in sequence along the direction of profile movement on the forming machine main body; the regulating module comprises a reference roller unit, an adjusting roller unit, a fixed-length acquisition triggering unit and a detection unit, the reference roller unit is driven by a first driving source on the forming machine main body to run at a constant rotating speed matching the profile feeding speed. The present application applies differential speed micro-tension to the profile by the rotating speed difference between the reference roller unit and the adjusting roller unit, promotes the lattice slip in the profile, and effectively releases the residual stress accumulated in the previous process, which can be well applied to special profiles sensitive to internal stress and solve the late deformation problem of this type of profile caused by residual stress release after rolling and compounding.

Description

Technical Field

[0001] This invention relates to the field of profile processing technology, and more specifically, to an integrated equipment for flexible strip rolling of thermally broken aluminum profiles. Background Technology

[0002] Thermally broken aluminum window and door profiles typically require three processes: toothing, strip insertion, and rolling. The thermal break strip is inserted into the groove of the aluminum alloy profile, and pressure is applied to the groove using rolling rollers to deform it, thus firmly bonding the thermal break strip to the aluminum alloy profile. Thermally broken profiles are composite profiles made by connecting two parts of the aluminum profile with a thermal break strip; their manufacturing process requires accurate insertion and tight pressing of the thermal break strip.

[0003] During the profile processing, aluminum profiles accumulate a certain degree of residual stress within the material during the preceding toothing, straightening, and strip insertion processes. For most ordinary thermally broken aluminum profiles with conventional cross-sections and uniform wall thickness, the residual stress accumulated in the preceding processes is relatively limited due to their good structural symmetry and high rigidity. Therefore, existing equipment can basically meet the requirements for most profile applications.

[0004] However, with the development of the building curtain wall and high-end door and window industries, some special thermally broken aluminum profiles with irregular cross-sections, asymmetrical structures, thin walls, or extra-long specifications have appeared on the market. These special profiles, due to their asymmetrical cross-sections, large differences in wall thickness, or excessively high slenderness ratios, are more sensitive to internal residual stress. When processing with existing conventional equipment, the residual stress accumulated in previous processes cannot be well released or homogenized after roll forming. If the residual stress is too high, it can easily cause slight deformation of the finished profile during placement. Deformed finished profiles require further straightening, which greatly increases the workload and affects actual production efficiency. Summary of the Invention

[0005] To solve the above-mentioned technical problems, the present invention provides an integrated equipment for flexible strip threading and rolling of thermally broken aluminum profiles, comprising: a forming machine body, a main controller, and a feeding module, a strip threading module, a control module, and a rolling forming module arranged sequentially on the forming machine body along the profile traveling direction;

[0006] The control module includes:

[0007] The reference roller unit is driven by the first drive source on the main body of the forming machine and operates at a constant speed that matches the profile feeding speed;

[0008] The adjusting roller unit, driven by a second drive source independent of the reference roller unit, can apply controllable differential micro-stretching to the profile after strip threading through the speed difference relative to the reference roller unit;

[0009] The fixed-length acquisition trigger unit is used to detect the travel length of the profile in real time, and triggers an acquisition signal every time the preset travel length is reached.

[0010] The detection unit is used to respond to the acquisition signal and acquire the macroscopic springback deflection value of the profile after differential micro-stretching treatment to characterize the residual stress release state of the aluminum profile.

[0011] The main controller is electrically connected to the first drive source, the second drive source, the fixed-length acquisition trigger unit, and the detection unit, respectively, and is configured as follows:

[0012] Based on the signal from the fixed-length acquisition trigger unit, the detection unit is triggered to acquire the macroscopic rebound deflection value of the profile at the exit section of the control module according to the preset travel length;

[0013] Based on the deviation between the macroscopic rebound deflection value and the preset target deflection value, the required speed difference adjustment amount for the adjusting roller unit is calculated;

[0014] The control adjustment roller unit performs speed difference adjustment to maintain the springback deflection of the profile within the preset target range.

[0015] Preferably, the reference roller unit includes three first rollers mounted side-by-side on the same mounting base along the profile traveling direction, and the adjusting roller unit includes two second rollers mounted side-by-side on the same mounting base along the profile traveling direction.

[0016] Preferably, both the first driving source and the second driving source include a servo motor and a sprocket structure, and the output end of each servo motor is connected to the corresponding first roller and second roller through the sprocket structure.

[0017] Preferably, the mounting bases of the first roller and the second roller are both connected to a linear driver with a self-locking function, which is used to adjust the vertical spacing of each roller and lock the roller position after adjustment.

[0018] Preferably, the fixed-length acquisition triggering unit is a meter encoder linked to the feeding roller, and the preset travel length is 50mm-200mm.

[0019] Preferably, the detection unit is a laser displacement sensor installed on the main body of the molding machine, and a shock-absorbing pad is installed at the connection between the laser displacement sensor and the main body of the molding machine.

[0020] Preferably, the control module further includes a floating buffer unit disposed at the inlet of the control module, which is used to offset the fluctuation of the feeding speed.

[0021] Preferably, the feeding module includes a profile feeding unit, a heat insulation strip feeding unit, and a straightening and centering unit. The straightening and centering unit is used to correct the straightness and coaxiality of the aluminum profile and the heat insulation strip.

[0022] Preferably, the roll forming module includes multiple roll forming rollers of different types arranged sequentially along the profile conveying direction, and a third drive source for driving each roll forming roller to rotate synchronously.

[0023] Preferably, the third drive source includes a servo motor and a sprocket structure, and the output end of the servo motor is connected to each rolling wheel group through the sprocket structure for transmission.

[0024] The beneficial effects of this invention are as follows:

[0025] This invention adds a control module between the strip-threading module and the roll forming module. Utilizing the speed difference between the reference roller unit and the adjusting roller unit, differential micro-stretching is applied to the profile, causing lattice slippage within the profile and effectively releasing residual stress accumulated in previous processes. Simultaneously, a fixed-length acquisition trigger unit and a detection unit work together to monitor the macroscopic springback deflection of the profile at the control module's exit section in real time. The main controller then performs closed-loop adjustment of the speed difference based on the deflection deviation, thus achieving precise control of residual stress during continuous profile processing. This invention is not only well-suited for special profiles sensitive to internal stress, solving the problem of post-deformation due to residual stress release after roll forming, eliminating the need for subsequent offline straightening or adjustment processes and improving production efficiency; it also further improves finished product quality when processing general profiles, broadening its applicability and better meeting diverse profile processing needs. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0027] Figure 2 This is a schematic diagram of the structure between the feeding module, the strip threading module and the control module in this invention;

[0028] Figure 3 This is a schematic diagram of the structure on the back of the control module in this invention;

[0029] Figure 4 This is the logic control block diagram of the present invention;

[0030] Figure 5 This is a schematic diagram of the workflow of the present invention.

[0031] Explanation of markings in the attached diagram:

[0032] 1. Molding machine body; 2. Main controller; 3. Feeding module; 4. Strip threading module; 5. Control module; 51. Reference roller unit; 511. First roller; 512. First drive source; 52. Adjusting roller unit; 521. Second roller; 522. Second drive source; 53. Fixed length acquisition trigger unit; 54. Detection unit; 55. Floating buffer unit; 56. Linear driver; 6. Roll forming module. Detailed Implementation

[0033] The subject matter described herein will now be discussed with reference to exemplary embodiments. It should be understood that these embodiments are discussed only to enable those skilled in the art to better understand and implement the subject matter described herein, and changes may be made to the function and arrangement of the elements discussed without departing from the scope of this specification. Various processes or components may be omitted, substituted, or added as needed in the examples. Furthermore, some features described in the examples may be combined in other examples.

[0034] Please see Figures 1 to 4 This embodiment provides an integrated equipment for flexible strip threading and rolling of thermally broken aluminum profiles. The equipment mainly includes a forming machine body 1, a main controller 2, and a feeding module 3, a strip threading module 4, a control module 5, and a rolling forming module 6 arranged sequentially on the forming machine body 1 along the aluminum profile traveling direction.

[0035] The main body 1 of the molding machine provides a mechanical support platform for the entire machine, and all functional modules are installed on it. The main controller 2 can be an industrial PLC, which is electrically connected to each drive source and sensor to perform logic control and data processing.

[0036] The feeding module 3 is used to transport the pre-cut aluminum profiles and thermal insulation strips to the strip threading station and perform preliminary posture correction. Specifically, the feeding module 3 adopts a conventional structure, which generally includes an aluminum profile feeding unit, a thermal insulation strip feeding unit, and a straightening and centering unit, etc. (not specifically shown in the figure). Since the feeding module is a conventional technical means in this field, the feeding unit, the thermal insulation strip feeding unit, and the straightening and centering unit all adopt known structural forms in this field, and their specific structures and working processes will not be described in detail here.

[0037] The strip insertion module is used to insert the thermal insulation strip into the thermal insulation strip groove of the aluminum profile, forming an aluminum profile with the upper and lower aluminum profiles and the thermal insulation strip initially assembled. The strip insertion module 4 can adopt a strip insertion mechanism known in the art, such as a strip insertion machine with guide grooves and push wheels, the specific structure of which will not be described in detail here.

[0038] The control module 5 is the core innovation of this invention, located between the strip threading module 4 and the roll forming module 6. Its function is to adaptively adjust the residual stress state of the aluminum profile after strip threading.

[0039] Please refer to further information. Figure 2 and Figure 3 The control module 5 includes a reference roller unit 51, an adjustment roller unit 52, a fixed length acquisition trigger unit 53, and a detection unit 54.

[0040] The reference roller unit 51 is driven by a first drive source 512 on the forming machine body 1, and operates at a constant rotational speed matching the feeding speed of the aluminum profile. In this embodiment, the reference roller unit 51 includes three first rollers 511 mounted side by side on the same mounting base along the traveling direction of the aluminum profile. The three first rollers 511 rotate synchronously under the drive of the first drive source 512, and their outer circumferential linear velocity is consistent with the upstream feeding speed, mainly playing the role of smoothly conveying the aluminum profile and initially releasing stress.

[0041] The adjusting roller unit 52 is located downstream of the reference roller unit 51 and is driven by a second drive source 522 independent of the first drive source 512. The adjusting roller unit 52 includes two second rollers 521 mounted side-by-side on the same mounting base along the aluminum profile travel direction. The two second rollers 521 are synchronously driven by the second drive source 522 and can apply controllable differential micro-stretching to the threaded aluminum profile through the speed difference relative to the reference roller unit 51.

[0042] Furthermore, both the first drive source 512 and the second drive source 522 include a servo motor and a sprocket structure. The output end of each servo motor is connected to the corresponding first roller 511 and second roller 521 via the sprocket structure. The sprocket structure ensures that multiple rollers in the same group maintain strict synchronous rotation, avoiding uneven stretching caused by transmission slippage.

[0043] To accommodate aluminum profiles of different specifications, the mounting bases of the first roller 511 and the second roller 521 are both connected to linear actuators 56 with self-locking functions, such as servo electric cylinders or hydraulic cylinders with self-locking mechanisms. The linear actuators 56 are used to adjust the vertical spacing of each roller to change the degree of pressure of the rollers on the aluminum profile, and lock the roller positions after adjustment to ensure a constant roller gap during micro-stretching.

[0044] The fixed-length acquisition trigger unit 53 is used to detect the travel length of the aluminum profile in real time, and triggers an acquisition signal every time the preset travel length is reached. In this embodiment, the fixed-length acquisition trigger unit 53 is preferably a meter encoder linked to the feeding roller, and the preset travel length can be set between 50mm and 200mm according to the specifications of the aluminum profile.

[0045] The detection unit 54 is used to respond to the acquired signal and acquire the macroscopic springback deflection value of the aluminum profile after differential micro-stretching treatment. In this embodiment, the detection unit 54 is a laser displacement sensor installed on the forming machine body 1, and its detection beam is directed towards the side of the aluminum profile at the free section of the control module 5 outlet. To suppress mechanical vibration interference under high-speed production conditions, a shock-absorbing pad is installed at the connection between the laser displacement sensor and the forming machine body 1. At the same time, the main controller 2 performs a sliding mean filtering algorithm on the raw signal acquired by the laser displacement sensor, and only responds to effective deflection deviations greater than a preset threshold.

[0046] In addition, a floating buffer unit 55 is provided at the inlet of the control module 5. The floating buffer unit 55 can adopt a floating roller structure with springs or cylinders to offset the instantaneous fluctuations in the upstream feeding speed and avoid the impact of sudden tension changes on the differential micro-stretching accuracy.

[0047] The roll forming module 6 receives the aluminum profile processed by the control module 5 and rolls the groove of the aluminum profile to firmly bond the heat insulation strip to the aluminum profile. The roll forming module 6 includes multiple different types of roll forming rollers (e.g., upper and lower pressing rollers and left and right closing rollers) arranged sequentially along the aluminum profile conveying direction, as well as a third drive source for driving each roll forming roller to rotate synchronously. The third drive source also includes a servo motor and a sprocket structure. The output end of the servo motor is connected to each roll forming roller through the sprocket structure to ensure that the linear speed of the roll forming roller is matched with the feeding speed.

[0048] The main controller 2 is electrically connected to the servo driver of the first drive source 512, the servo driver of the second drive source 522, the fixed-length acquisition trigger unit 53, the detection unit 54, and the third drive source of the roll forming module 6.

[0049] Combination Figure 4 As shown, the control logic of the main controller 2 is as follows:

[0050] In the first stage, the main controller 2, based on the signal from the fixed-length acquisition trigger unit 53 (meter encoder), triggers the detection unit 54 (laser displacement sensor) to acquire the current macroscopic rebound deflection value f once every time the aluminum profile travels a preset length L (e.g., 100mm). real .

[0051] In the second stage, the main controller 2 will collect f real Compared with the pre-set and stored target deflection value f set (For example, 0.1 mm / m) are compared, and the deflection deviation Δf = f is calculated. real -f set ;

[0052] If Δf>0: the deflection exceeds the standard, the risk of deformation in the later stage is high, and it is necessary to increase the rotation speed difference, strengthen micro-stretching, release residual stress and reduce deflection;

[0053] Δf<0: The deflection is too small and the wire rigidity is insufficient. It is necessary to reduce the speed difference, reduce the amount of tension, retain appropriate stress, and increase the deflection to the qualified value.

[0054] Δf=0: Deflection is acceptable, no adjustment is needed, maintain the current roller parameters.

[0055] Then, the main controller 2 calculates the required speed difference adjustment amount Δn of the adjusting roller unit 52 based on the deflection deviation Δf. The calculation method can adopt the linear mapping relationship calibrated on site: Δn=k×Δf;

[0056] Among them, the coefficient k is the field calibration value. The k value is different for different specifications and grades of wire. It is stored in the process parameter library and can be directly called when changing models.

[0057] In the third stage, the main controller 2 sends the calculated speed difference adjustment amount Δn to the servo driver of the second drive source 522, controlling the actual speed of the regulating roller unit 52 to be n. rear =n front +Δn(n front (The reference speed of the reference roller unit 51).

[0058] If Δf is positive (deflection exceeds the standard, stress is too high), then Δn is positive, the speed of the adjusting roller is increased, and the micro-stretching is increased to release more residual stress.

[0059] If Δf is negative, then Δn is negative, and the speed of the adjusting roller is slowed down to reduce the amount of micro-stretching in order to retain appropriate stress.

[0060] In addition, the present invention also sets a safety limit, as follows:

[0061] Speed ​​difference limit: Δn∈[-5,+5]r / min. When the speed exceeds the range, the limit value will be applied and an alarm will be triggered. No forced adjustment will be performed.

[0062] Elongation limit: 0.05% ≤ elongation ≤ 0.5%, elongation = (rear roller speed - front roller speed) / front roller speed × 100%, if the range is exceeded, the machine will stop immediately and an alarm will sound;

[0063] Deflection over-limit alarm: f real >0.3mm / m or f real If the value is less than 0.05 mm / m, an alarm will be triggered, prompting you to check the adjustment parameters or materials.

[0064] Through the closed-loop iteration of fixed-length acquisition, deviation calculation, and speed difference adjustment, the main controller 2 continuously regulates until the macroscopic springback deflection of the aluminum profile converges to the preset target range (i.e., within the dead zone range), thereby ensuring that the aluminum profile entering the roll forming module 6 has a stable and qualified residual stress state.

[0065] It should be noted that, in this embodiment, the main controller 2 also has a built-in process parameter library, which stores the target deflection values ​​f corresponding to different specifications and models of thermally broken aluminum profiles. set Calibration coefficient k, reference speed n front The parameters include the distance between each roller; when changing models, the operator only needs to select the corresponding model on the touch screen, and the main controller 2 will automatically call the corresponding parameter group and adjust the equipment into position through each linear driver 56 and servo driver, so as to achieve rapid and flexible model changeover.

[0066] It should be noted that the specific calibration steps for the calibration coefficient k are as follows:

[0067] a. After the equipment is tested under no-load conditions, the aluminum profiles of the current production specifications and the heat insulation strips are threaded together to form a profile assembly, which is then sent to the control module;

[0068] b. The main controller controls the first drive source to adjust the reference roller unit to a constant speed n that matches the feeding speed. front Manually adjust the output speed of the second drive source to stabilize the springback deflection of the profile assembly at the preset target deflection value f. set Record the initial speed difference n0 at this time;

[0069] c. Manually adjust the output speed of the second drive source to increase the speed difference by a fixed value Δn1 (e.g., 0.5 r / min). After the equipment has been running stably for 30 seconds, collect the real-time rebound deflection f of the profile assembly through a laser displacement sensor. real1 Calculate the rebound deflection deviation Δf1=f real1 -f set ;

[0070] d. Calculate the calibration coefficient k using the formula k=Δn1 / Δf1, bind the k value to the corresponding profile specification, and store it in the process parameter library of the main controller;

[0071] e. Repeat steps c and d at least three times, and take the average of the multiple calculation results as the final calibration coefficient k to ensure calibration accuracy.

[0072] When changing the profile specifications or grade, you only need to recalibrate once by following the steps above.

[0073] Combination Figure 5 As shown, the specific working process of the integrated flexible strip rolling equipment for thermally broken aluminum profiles of the present invention is as follows:

[0074] Step 1: After the previous tooth-cutting process, the upper and lower aluminum alloy profiles are fed into the equipment through the aluminum profile feeding unit, while the heat insulation strip is fed in simultaneously through the heat insulation strip feeding unit. The two enter the straightening and centering unit, where multiple sets of guide wheels correct the straightness and relative position of the aluminum profiles and heat insulation strips respectively, ensuring that the two enter the subsequent strip insertion module 4 with accurate coaxiality and preset posture.

[0075] Step 2: After straightening and centering, the aluminum profile and the heat insulation strip enter the strip insertion module 4 to complete the initial assembly of the heat insulation strip entering the slot of the aluminum profile, forming the aluminum profile; at this time, the aluminum profile still has residual stress accumulated from the previous process.

[0076] Step 3: After the aluminum profile is output from the threading module 4, it enters the control module 5. The floating buffer unit 55 buffers and absorbs the fluctuation of the feeding speed to ensure stable tension. The aluminum profile passes through the reference roller unit 51 and the adjusting roller unit 52 in sequence. The reference roller unit 51 conveys the aluminum profile at a constant speed, while the adjusting roller unit 52 applies differential micro-tension according to the instructions of the main controller 2.

[0077] During this process, the fixed-length acquisition trigger unit 53 triggers the detection unit 54 to acquire the macroscopic rebound deflection value of the aluminum profile exit section according to the preset travel length; the main controller 2 dynamically calculates and adjusts the speed difference of the second roller 521 according to the deviation between the deflection detection result and the preset target value, so that the rebound deflection of the aluminum profile converges and stabilizes within the preset target range; at this point, the internal residual stress of the aluminum profile has been precisely controlled to a state suitable for roll forming composite.

[0078] Step 4: The aluminum profile, after stress adaptive control, enters the roll forming module 6; multiple sets of roll forming rollers apply rolling pressure to the groove of the aluminum profile step by step, causing the aluminum alloy groove to undergo plastic deformation and tightly wrapping and biting the heat insulation strip, finally forming the finished thermal break aluminum profile.

[0079] Step 5: When it is necessary to change the specifications of aluminum profiles, the operator selects the corresponding model through the main controller 2. The main controller 2 automatically calls the preset parameters in the process parameter library and drives each actuator to complete the rapid model change.

[0080] The embodiments of the present invention have been described above. However, the embodiments are not limited to the specific implementation methods described above. The specific implementation methods described above are merely illustrative and not restrictive. Those skilled in the art can make more equivalent embodiments under the guidance of the present embodiments, and all of them are within the protection scope of the present embodiments.

Claims

1. A flexible strip rolling integrated equipment for thermally broken aluminum profiles, characterized in that, include: The molding machine body, the main controller, and the feeding module, strip threading module, control module, and roll forming module are sequentially arranged on the molding machine body along the profile traveling direction; The control module includes: The reference roller unit is driven by the first drive source on the main body of the forming machine and operates at a constant speed that matches the profile feeding speed; The adjusting roller unit, driven by a second drive source independent of the reference roller unit, can apply controllable differential micro-stretching to the profile after strip threading through the speed difference relative to the reference roller unit; The fixed-length acquisition trigger unit is used to detect the travel length of the profile in real time, and triggers an acquisition signal every time the preset travel length is reached. The detection unit is used to respond to the acquisition signal and acquire the macroscopic springback deflection value of the profile after differential micro-stretching treatment to characterize the residual stress release state of the aluminum profile. The main controller is electrically connected to the first drive source, the second drive source, the fixed-length acquisition trigger unit, and the detection unit, respectively, and is configured as follows: Based on the signal from the fixed-length acquisition trigger unit, the detection unit is triggered to acquire the macroscopic rebound deflection value of the profile at the exit section of the control module according to the preset travel length; Based on the deviation between the macroscopic rebound deflection value and the preset target deflection value, the required speed difference adjustment amount for the adjusting roller unit is calculated; The control adjustment roller unit performs speed difference adjustment to maintain the springback deflection of the profile within the preset target range.

2. The integrated equipment for flexible strip rolling of thermally broken aluminum profiles according to claim 1, characterized in that, The reference roller unit includes three first rollers mounted side-by-side on the same mounting base along the profile travel direction, and the adjusting roller unit includes two second rollers mounted side-by-side on the same mounting base along the profile travel direction.

3. The integrated flexible strip rolling equipment for thermally broken aluminum profiles according to claim 2, characterized in that, Both the first driving source and the second driving source include a servo motor and a sprocket structure. The output end of each servo motor is connected to the corresponding first roller and second roller through the sprocket structure.

4. The integrated equipment for flexible strip rolling of thermally broken aluminum profiles according to claim 2, characterized in that, The mounting bases of the first and second rollers are both connected to linear drivers with self-locking functions, which are used to adjust the vertical spacing of each roller and lock the roller position after adjustment.

5. The integrated equipment for flexible strip rolling of thermally broken aluminum profiles according to claim 1, characterized in that, The fixed-length acquisition triggering unit is a meter encoder that is linked to the feeding roller, and the preset travel length is 50mm-200mm.

6. The integrated equipment for flexible strip rolling of thermally broken aluminum profiles according to claim 1, characterized in that, The detection unit is a laser displacement sensor installed on the main body of the molding machine, and a shock-absorbing pad is installed at the connection between the laser displacement sensor and the main body of the molding machine.

7. The integrated equipment for flexible strip rolling of thermally broken aluminum profiles according to claim 1, characterized in that, The control module also includes a floating buffer unit located at the entrance of the control module, which is used to offset fluctuations in the feeding speed.

8. The integrated equipment for flexible strip rolling of thermally broken aluminum profiles according to claim 1, characterized in that, The feeding module includes a profile feeding unit, a heat insulation strip feeding unit, and a straightening and centering unit. The straightening and centering unit is used to correct the straightness and coaxiality of the aluminum profile and the heat insulation strip.

9. The integrated equipment for flexible strip rolling of thermally broken aluminum profiles according to claim 1, characterized in that, The roll forming module includes multiple roll forming rollers of different types arranged sequentially along the profile conveying direction, and a third drive source for driving each roll forming roller to rotate synchronously.

10. The integrated equipment for flexible strip rolling of thermally broken aluminum profiles according to claim 9, characterized in that, The third drive source includes a servo motor and a sprocket structure. The output end of the servo motor is connected to each rolling wheel group through the sprocket structure.

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