Railway vehicle cold-bending steel flattening process

Abstract

The application discloses a cold-bending steel flattening process for a rail vehicle, relates to the field of cold-bending steel flattening process, and solves the technical problem of poor roll gap wear compensation effect between an upper flattening roller and a lower flattening roller, and comprises raw material preparation and slitting, selects a cold-rolled high-weather-resistance steel plate as a raw material, performs roller pressing cold bending, and sends the slitted strip into an uncoiler of a cold-bending forming unit, and the strip is sequentially passed through a forming die, and the roller pressing forming is performed according to the sequence of first flattening and then transverse bending in each pass, and the roll gap is compensated on line, and in the flattening operation process, the surface wear state of the lower flattening roller is monitored in real time, four lower flattening rollers are respectively raised to different heights corresponding to wear amounts, and the original roll gap between the upper flattening roller and the lower flattening roller is recovered, when the roll gap between the upper flattening roller and the lower flattening roller is increased due to wear of the lower flattening roller, the four lower flattening rollers are driven to synchronously rise, the roll gap increment is automatically compensated, the wear change can be responded in real time, and there is no need to stop and adjust.

Description

Technical Field

[0001] This invention relates to the field of cold-formed steel straightening technology, specifically a process for straightening cold-formed steel for rail vehicles. Background Technology

[0002] Cold-formed steel is an important component of rail vehicles. During the rolling process, cold-formed steel must be leveled by a leveling machine before it can be roll-formed. The seven-roll leveling machine (with a three-roller upper and four-roller lower or a four-roller upper and three-roller arrangement) is one of the most widely used leveling equipment.

[0003] The leveling machine uses upper and lower leveling rollers to level the strip material. The lower leveling roller is the drive roller, which is driven to roll by the transmission device, thereby moving the strip material. After a period of use, the leveling rollers will wear out, especially the lower leveling roller, which is the drive roller and wears out more severely. Wear causes the gap between the upper and lower leveling rollers to gradually increase, the leveling pressure to decrease, and the leveling accuracy to decrease. The leveling roller that first comes into contact with the strip material wears the most, and the wear decreases sequentially to the other side.

[0004] In the prior art, the common method to solve this problem is to set shims of different thicknesses between the upper and lower frames to adjust the roller gap, or to use a lifting mechanism to drive all the upper rollers to rise and fall at the same time to adjust the gap. However, shim adjustment requires stopping the machine to disassemble and install, and cannot achieve real-time compensation. Although the lifting mechanism can achieve overall lifting, the leveling accuracy will be reduced after overall adjustment due to the different wear levels of each leveling roller.

[0005] Furthermore, the size of the feed inlet between the upper and lower leveling rollers is fixed, usually set to be equal to or slightly smaller than the thickness of the strip itself. When the end of the strip is significantly curved, the height of the curved protrusion cannot fit between the two rollers and is directly stuck at the inlet position. The portion of the strip that has already entered between the two rollers is leveled. Since the strip has become straight, this section is only moved forward by the upper and lower leveling rollers. However, the curved end is always pressed against the inlet edge of the upper leveling roller, forming a hard-on-hard obstruction. At this time, the driving force generated by the rotation of the leveling roller cannot pull the stuck curved part at all, causing the strip to stop moving forward as a whole. The leveling is forced to stop and can only be pushed manually by the staff. When pushing manually, the strip is prone to slippage during the straightening process due to its own curvature, which poses a risk of injury to the staff.

[0006] Based on this, the present invention provides a process for straightening cold-bent steel profiles for rail vehicles to solve the above problems. Summary of the Invention

[0007] In view of the above situation and to overcome the defects of the prior art, the present invention provides a process for straightening cold-bent steel for railway vehicles. The present invention has a novel structure and ingenious design, and effectively solves the technical problems of poor wear compensation between the upper and lower straightening rollers and material jamming during the straightening and bending of the strip material.

[0008] A process for straightening cold-bent steel profiles for rail vehicles includes the following steps: S1: Raw material preparation and slitting: Select cold-rolled high weather-resistant steel plate as raw material, formulate slitting specifications according to product drawings, use slitting equipment to cut the steel plate into strips of the required width, and inspect the appearance of the strips after slitting. S2: Roll forming: The slit strips are fed into the uncoiler of the cold forming unit, and the strips are pulled through the pre-adjusted multi-pass forming dies in sequence, and rolled in the order of first leveling and then bending laterally in each pass. S3: Online Roll Gap Compensation Leveling: During the leveling operation, the wear status of the lower leveling roller surface is monitored in real time. When it is detected that the working radial distance of the lower leveling roller has decreased due to wear, and the roll gap between the upper and lower leveling rollers has increased, the main electric push rod is activated to drive the lifting frame to rise. The lifting frame drives the driven roller to rise, and the first-stage eccentric wheel, second-stage eccentric wheel, third-stage eccentric wheel and fourth-stage eccentric wheel rotate synchronously in their respective working slots, pushing the support plate and bearing seat at the bottom of each lower leveling roller to rise. The four lower leveling rollers rise to different heights corresponding to the amount of wear, restoring the original roll gap between them and the upper leveling roller. After the roll gap compensation is in place, the lifting frame stops moving.

[0009] Preferably, step S4 is also included: Anti-jamming feeding of strips: During the leveling and conveying process, if the strips stop or get stuck between the upper and lower leveling rollers, the secondary electric push rod is activated to push the extension frame to extend outward along the sliding frame, so that the two guide rollers come closer to each other and fit against the strips respectively. The anti-slip strips on the surface of the guide rollers increase the friction and assist in pushing the strips forward.

[0010] Preferably, step S5 is also included: Compensation feeding: If the thrust is still insufficient for feeding, the secondary electric push rod continues to extend to clamp the strip with the two guide rollers. The strip is driven by the clamping force, while the sliding seat on the fixed shaft slides in the groove of the fixed frame and compresses the spring.

[0011] Preferably, step S6 is also included: Strip width limit adjustment: Before the strip enters the leveling plate, it is first placed on the guide plate. According to the two pull plates on the rotating plate, the guide wheels on the two sliding plates are moved towards each other to the position that adapts to the width of the strip. After the adjustment is in place, the clamping frame is inserted into the support to lock the rotating plate.

[0012] Preferably, the bottom of the bearing housing is threaded with a threaded post, and the bottom of the threaded post is rotatably connected to a support plate. The surfaces of the first-stage eccentric wheel, the second-stage eccentric wheel, the third-stage eccentric wheel, and the fourth-stage eccentric wheel all mate with the bottom of the support plate.

[0013] Preferably, each of the two sliding seats is fixedly connected to a fixed shaft, and each of the two fixed shafts is rotatably connected to a push plate. The other ends of the four push plates are respectively rotatably connected to the two ends of the two guide rollers.

[0014] Preferably, the other end of each of the two fixed shafts is fixedly connected to a limiting frame, and the two limiting frames are slidably connected to the two fixed frames respectively.

[0015] Preferably, the guide plate is provided with an adjustment groove, and a frame is slidably connected in each adjustment groove, and a guide wheel is rotatably connected to each frame.

[0016] The present invention has the following technical effects.

[0017] 1. This invention uses a lifting frame, guide wheels, racks and gears to drive four lower leveling rollers to rise synchronously when the gap between the upper and lower leveling rollers increases due to wear of the lower leveling rollers. This automatically compensates for the increase in the gap, responds to wear changes in real time, and does not require machine stoppage for adjustment, effectively ensuring the stability of the strip leveling quality.

[0018] 2. This invention uses a first-stage eccentric wheel, a second-stage eccentric wheel, a third-stage eccentric wheel, and a fourth-stage eccentric wheel to enable the four lower leveling rollers to achieve different rising heights. Among them, the lower leveling roller with the most severe wear and the first to contact the strip material has the largest rising amount, while the rising amount of the other rollers decreases sequentially along the strip material conveying direction. This allows the actual working position of each lower leveling roller to match the degree of wear, ensuring that the strip material is subjected to uniform force.

[0019] 3. The present invention uses an extension frame, a guide frame, guide rollers and a secondary electric push rod to press two guide rollers onto the top and bottom surfaces of the strip material respectively, clamping and coordinating the transmission of the strip material. Through a fixed frame, a sliding seat, a limiting rod and a spring, an auxiliary pushing force is applied to the clamped strip material, which automatically intervenes when the strip material stops, providing both clamping transmission and auxiliary pushing to avoid jamming.

[0020] 4. This invention uses a guide plate, guide wheels, a pulling plate, and a rotating plate to drive two guide wheels to move in opposite directions to accommodate strips of different widths. During the leveling and conveying process, it limits the movement of the strips on both sides, making adjustment simple and quick. It can effectively prevent deviation and improve the leveling adaptability of strips of different specifications. Attached Figure Description

[0021] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used in conjunction with embodiments of the invention to explain the invention and do not constitute a limitation thereof. In the drawings: Figure 1 This is a flow chart of the leveling process in this invention; Figure 2 This is a schematic diagram of the assembly structure of the main support, auxiliary support, upper leveling roller and lower leveling roller in this invention; Figure 3 This is a schematic diagram of the assembly structure of the worm gear, worm, gear and rack in this invention; Figure 4 This is a schematic diagram of the assembly structure of the rotating shaft, the secondary eccentric wheel, the threaded column, and the support plate in this invention; Figure 5 This is a schematic diagram of the assembly structure of the guide frame, roller shaft and guide roller in this invention; Figure 6 This is a schematic diagram of the assembly structure of the sliding frame, the extension frame, and the guide frame in this invention; Figure 7 This is a schematic diagram of the assembly structure of the sliding plate, the pulling plate, and the rotating plate in this invention.

[0022] Reference numerals: 1. Base; 2. Main support; 3. Auxiliary support; 4. Upper leveling roller; 5. Working groove; 6. Lower leveling roller; 7. Bearing seat; 8. Threaded column; 9. Support plate; 10. Rotating shaft; 11. First-stage eccentric wheel; 12. Second-stage eccentric wheel; 13. Third-stage eccentric wheel; 14. Fourth-stage eccentric wheel; 15. Worm gear; 16. Support; 17. Support shaft; 18. Worm; 19. Gear; 20. Main electric push rod; 21. Lifting frame; 22. Rack; 23. Roller support frame; 24. Driven roller; 25. Sliding frame; 6. Extension frame; 27. Guide frame; 28. Roller shaft; 29. ​​Guide roller; 30. Anti-slip strip; 31. Fixed shaft; 32. Sliding seat; 33. Fixed frame; 34. Slide groove; 35. Limiting rod; 36. Spring; 37. Limiting frame; 38. Push plate; 39. Secondary electric push rod; 40. Connecting plate; 41. Guide plate; 42. Adjusting groove; 43. Frame; 44. Guide wheel; 45. Sliding plate; 46. Main shaft; 47. Pulling plate; 48. Support column; 49. Rotating plate; 50. Auxiliary shaft; 51. Clip-on frame. Detailed Implementation

[0023] The foregoing and other technical contents, features and effects of the present invention are described in conjunction with the appendix below. Figures 1 to 7 The detailed description of the embodiments will make this clear. All references to the following embodiments are made with reference to the accompanying drawings.

[0024] Exemplary embodiments of the present invention will now be described with reference to the accompanying drawings.

[0025] This invention relates to a process for straightening cold-bent steel sections used in rail vehicles, comprising the following steps: S1: Raw material preparation and slitting: Select standard atmospheric corrosion resistant hot-rolled steel plates or cold-rolled high weather resistant steel plates as raw materials, formulate slitting specifications according to the product cross-section drawings, use slitting equipment to cut the steel plates into strips of the required width, inspect the appearance of the strips after slitting to confirm that there are no scratches, bumps or other defects, and that the slitting dimensions meet the tolerance requirements. S2: Roll forming: The slit strip is fed into the uncoiler of the cold forming unit. The strip is pulled through the pre-adjusted multi-pass forming mold in sequence. Roll forming is carried out in the order of first leveling and then bending laterally in each pass. During the forming process, the curvature, deflection and twist of each pass are adjusted according to the product sample. The inner radius of the forming mold is Ri = (6~9) × t, where t is the thickness of the sheet and Ri / t≥1 to avoid cracking. At the same time, the springback compensation angle is set according to the BISWAS springback calculation formula. The springback compensation amount is increased for high-strength steel. Cooling liquid is added to the passes that require coolant during the forming process, and lubricating oil is added to the passes that require lubricating oil. BISWAS rebound calculation formula: ; ; r i1 — Bending radius (mm); r i2 —Rebound radius (mm); r f — Yield curvature (mm); E – Young's modulus (MPa); t — Sheet thickness (mm); S—Yield stress of the material (MPa).

[0026] S3: Online Roll Gap Compensation Leveling: During the leveling operation, the wear status of the lower leveling roller 6 is monitored in real time. When it is detected that the working radial distance of the lower leveling roller 6 has decreased due to wear, and the roll gap between the upper leveling roller 4 and the lower leveling roller 6 has increased, the main electric push rod 20 is activated to drive the lifting frame 21 to rise. The rack 22 on the lifting frame 21 drives the gear 19 and the support shaft 17 to rotate, so that the worm gears 18 at both ends of the support shaft 17 synchronously drive the worm wheel 15 and the rotating shaft 10 to rotate on the main support 2 and the auxiliary support 3, thereby driving the first-stage eccentric... Wheel 11, secondary eccentric wheel 12, tertiary eccentric wheel 13, and quaternary eccentric wheel 14 rotate synchronously in their respective working grooves 5, pushing the support plate 9 at the bottom of each lower leveling roller 6 to rise. The four lower leveling rollers 6 rise to different heights corresponding to the amount of wear, restoring the original roller gap between them and the upper leveling roller 4. The eccentricity of the primary eccentric wheel 11, secondary eccentric wheel 12, tertiary eccentric wheel 13, and quaternary eccentric wheel 14 decreases sequentially to adapt to the different wear levels of each lower leveling roller 6. After the roller gap is compensated, the lifting frame 21 stops moving.

[0027] Detailed Implementation Examples:

[0028] The system includes a base 1, a main support 2, an auxiliary support 3, an upper leveling roller 4, and a lower leveling roller 6. Both the main support 2 and the auxiliary support 3 have multiple working grooves 5. Bearing seats 7 are located on both sides of the lower leveling roller 6, with two bearing seats 7 situated within the working grooves 5 on the main support 2 and the auxiliary support 3, respectively. A threaded hole is formed at the bottom of each bearing seat 7, and a threaded post 8 is threaded into the hole. A rectangular support plate 9 is rotatably connected to the bottom of the threaded post 8. Rotating shafts 10 are rotatably connected to both the main support 2 and the auxiliary support 3. Each rotating shaft 10 is fixedly connected to a primary eccentric wheel 11, a secondary eccentric wheel 12, a tertiary eccentric wheel 13, and a fourth eccentric wheel 14. The diameters of the first-stage eccentric wheel 11, second-stage eccentric wheel 12, third-stage eccentric wheel 13, and fourth-stage eccentric wheel 14 decrease sequentially, and their central axes are located on the surface of the rotating shaft 10. The central axes of the first-stage eccentric wheel 11, second-stage eccentric wheel 12, third-stage eccentric wheel 13, and fourth-stage eccentric wheel 14 are on the same line. The first-stage eccentric wheel 11, second-stage eccentric wheel 12, third-stage eccentric wheel 13, and fourth-stage eccentric wheel 14 are located in the four working slots 5 on the main support 2 and the auxiliary support 3, respectively. The surfaces of the first-stage eccentric wheel 11, second-stage eccentric wheel 12, third-stage eccentric wheel 13, and fourth-stage eccentric wheel 14 all mate with the bottom of the support plate 9.

[0029] During the installation of the lower leveling roller 6, the threaded column 8 is turned at the bottom of the bearing seat 7, which drives the support plate 9 to rise and fall, so that the support plates 9 at the bottom of the four lower leveling rollers 6 respectively contact the top of the first-stage eccentric wheel 11, the second-stage eccentric wheel 12, the third-stage eccentric wheel 13 and the fourth-stage eccentric wheel 14, completing the initial position adjustment. During normal operation, the upper leveling roller 4 and the lower leveling roller 6 rotate synchronously to feed the strip between them. Through the coordinated rotation of the upper leveling roller 4 and the lower leveling roller 6, the strip is leveled.

[0030] After long-term use, wear appears on the surface of the lower leveling roller 6, which leads to an increase in the roller gap between the lower leveling roller 6 and the upper leveling roller 4, resulting in a decrease in the leveling effect. Among them, the lower leveling roller 6, which is the first to contact the strip, suffers the most severe wear. Along the strip conveying direction, the wear degree of each subsequent lower leveling roller 6 decreases sequentially. At this time, by driving the rotating shaft 10 to rotate, the first-stage eccentric wheel 11, the second-stage eccentric wheel 12, the third-stage eccentric wheel 13 and the fourth-stage eccentric wheel 14 are driven to rotate synchronously. They cooperate with the support plate 9 at the bottom of the bearing seat 7 to push the four lower leveling rollers 6 to rise synchronously, thereby compensating for the increased roller gap.

[0031] Furthermore, since the sizes of the first-stage eccentric wheel 11, the second-stage eccentric wheel 12, the third-stage eccentric wheel 13, and the fourth-stage eccentric wheel 14 are different, the heights to which the four lower leveling rollers 6 are pushed up are also different. The lower leveling roller 6 with the most wear has the largest rising distance, while the one with the least wear has the smallest rising height. This ensures that the actual working position of each roller matches its degree of wear, thus ensuring that the leveling effect remains stable at all times.

[0032] It should be noted that a motor is fixedly connected to one end of both the upper leveling roller 4 and the lower leveling roller 6. The motor is connected to a power supply and a controller. The motor, power supply and controller are all existing technologies, so they are not described in detail.

[0033] Two worm gears 15 are fixedly connected to one end of each of the two rotating shafts 10. Two supports 16 are fixedly connected to the top of the base 1. Support shafts 17 are rotatably connected to each of the two supports 16. Worms 18 are fixedly connected to both ends of the support shafts 17. The two worms 18 mesh with the two worm gears 15 respectively.

[0034] A gear 19 is fixedly connected to the support shaft 17, and the gear 19 is located at the center of the support shaft 17. A main electric push rod 20 is fixedly connected to the top of the base 1. The output end of the main electric push rod 20 is fixedly connected to the lifting frame 21, which is L-shaped. A rack 22 is fixedly connected to one side of the lifting frame 21. The gear 19 meshes with the rack 22. A roller frame 23 is fixedly connected to the top of the lifting frame 21, which is U-shaped. A driven roller 24 is rotatably connected to the roller frame 23. Multiple distance sensors are provided on the surface of the driven roller 24. The driven roller 24 rolls with the surface of the lower leveling roller 6.

[0035] When wear occurs on the surface of the lower leveling roller 6, which is the first to contact the strip, the lower leveling roller 6 loses contact with the driven roller 24 or exceeds the set range. At this time, the distance sensor sends a detection signal, and the output end of the main electric push rod 20 begins to extend, pushing the lifting frame 21 and the rack 22 fixed on one side to rise synchronously. The rack 22 meshes with the drive gear 19 to rotate, and the gear 19 drives the support shaft 17 to rotate on the support 16. The worm gears 18 at both ends of the support shaft 17 rotate accordingly and mesh with the two worm wheels 15 to rotate synchronously. The worm wheels 15 drive the two rotating shafts 10 to rotate synchronously on the main support 2 and the auxiliary support 3, thereby lifting the lower leveling roller 6.

[0036] When the lower leveling roller 6 is raised to restore the original roller gap distance between it and the upper leveling roller 4, the driven roller 24 rises synchronously with the lifting frame 21 until it re-contacts the surface of the lower leveling roller 6 or reaches the set range. After the distance sensor detects that it has contacted the lower leveling roller 6 or meets the set range, it sends a signal again, the main electric push rod 20 stops extending, and the lifting frame 21 stops rising, completing the automatic compensation operation for the increased roller gap, thereby maintaining the leveling effect on the strip material.

[0037] It should be noted that both the main electric actuator 20 and the distance sensor are connected to a power supply and a controller. The power supply and controller are existing technologies, so they are not described in detail.

[0038] Due to varying degrees of wear, the four lower leveling rollers 6 need to be lifted to different heights by the primary eccentric wheel 11, secondary eccentric wheel 12, tertiary eccentric wheel 13, and quaternary eccentric wheel 14. Although the primary eccentric wheel 11, secondary eccentric wheel 12, tertiary eccentric wheel 13, and quaternary eccentric wheel 14 are synchronously driven by the same shaft 10 (i.e., rotating at the same angle), their structural parameters (eccentricity and initial phase) differ, and with the initial adjustment of the threaded column 8, targeted compensation for different wear levels can be achieved.

[0039] Equilibrium formula for wear amount and compensation displacement: To compensate for the wear of each lower leveling roller 6, the actual required upward compensation for the lower leveling roller 6 is equal to its wear amount: ;

[0040] The height to which the first-stage eccentric wheel 11, the second-stage eccentric wheel 12, the third-stage eccentric wheel 13, and the fourth-stage eccentric wheel 14 push the pallet 9 and the lower leveling roller 6 upward when they rotate is related to the rotation angle of the shaft 10, the eccentricity of the eccentric wheels, and the initial phase.

[0041]

[0042] : The grade number of the lower leveling roller 6 and the corresponding eccentric wheel ( These represent Level 1, Level 2, Level 3, and Level 4, respectively.

[0043] : No. The actual wear of the lower leveling roller 6 (i.e., the target height that needs to be compensated for). .

[0044] : No. The displacement of the leveling roller 6 as it is actually pushed upward after the eccentric wheel rotates.

[0045] : No. The initial adjustment height of the bottom threaded post 8 of the lower leveling roller 6. Used to make the pallet 9 fit against the surface of the eccentric wheel during equipment installation or initial zero-position calibration.

[0046] : No. The eccentricity of the eccentric wheel (i.e., the distance from the center of the shaft 10 to the geometric center of the eccentric wheel). At the same rotation angle, the first-stage eccentric wheel 11 produces the largest lifting displacement, while the fourth-stage eccentric wheel 14 produces the smallest.

[0047] : No. The initial phase angle of the eccentric wheel (i.e., the angle between the geometric center of the eccentric wheel and the horizontal reference direction in the initial state).

[0048] The synchronous rotation angle of shaft 10. Because the four eccentric wheels are fixed on the same shaft 10, the rotation angle of the four eccentric wheels... They are the same.

[0049] During design and manufacturing, the eccentricity of each stage of the eccentric wheel is set according to the conventional wear pattern. Size relationship (i.e.) Thus, when the main electric push rod 20 drives the rotating shaft 10 to rotate at any angle... At that time, the compensation displacement provided by the four eccentric wheels naturally satisfies .

[0050] When the actual wear amount When the design reference is deviated, the height of threaded post 8 can be adjusted during initial assembly or maintenance. To perform benchmark calibration. During operation, the main electric push rod 20 extends, causing the rotating shaft 10 to rotate ( (Continuously increasing), when the driven roller 24 is detected to contact the surface of the first lower leveling roller 6 or reach the set range, the control system will receive a signal and stop the extension of the main electric push rod 20. Locked.

[0051] As an example, it also includes step S4: anti-jamming feeding of strip material: during the leveling and conveying process, if the strip material stops or gets jammed between the upper leveling roller 4 and the lower leveling roller 6, the secondary electric push rod 39 is activated to push the extension frame 26 to extend outward along the sliding frame 25, which drives the guide frame 27 away from the sliding frame 25, so that the two guide rollers 29 approach each other and respectively adhere to the top and bottom surfaces of the strip material. The anti-slip strips 30 on the surface of the guide rollers 29 increase the friction force to assist in pushing the strip material forward.

[0052] As an example, the method also includes step S5: Compensation feeding: If the thrust is still insufficient for feeding, the secondary electric push rod 39 continues to extend so that the two guide rollers 29 clamp the strip material. The strip material is driven by the clamping force. At the same time, the sliding seat 32 on the fixed shaft 31 slides in the groove 34 of the fixed frame 33 and compresses the spring 36. After the jamming is removed, the secondary electric push rod 39 shortens. The restoring force of the spring 36 pushes the sliding seat 32 and the fixed shaft 31 to reset. After the clamping force is reduced, the guide rollers 29 continue to feed the strip material normally by rotating on their own.

[0053] Detailed Implementation Examples: A sliding frame (25) is fixedly connected to one side of each of the main support (2) and the auxiliary support (3), the cross-sectional shape of the sliding frame (25) is a square shape, an extension frame (26) is slidably connected within each of the two sliding frames (25), two guide frames (27) are fixedly connected to one side of each of the two extension frames (26), the two guide frames (27) are arranged in opposite sectors, the two guide frames (27) on the main support (2) are respectively matched with the two guide frames (27) on the auxiliary support (3), a roller shaft (28) is slidably connected on the two guide frames (27), a guide roller (29) is fixedly connected on each of the two roller shafts (28), and a non-slip strip (30) is fixedly connected to the surfaces of the two guide rollers (29).

[0054] In the straightening operation, the upper straightening roller (4) and the lower straightening roller (6) cooperate to convey and straighten the strip. At this time, the extension frame (26) extends outward along the sliding frame (25), driving the two guide frames (27) to synchronously move in a direction away from the lower straightening roller (6), so that the roller shafts (28) on the two guide rollers (29) respectively slide in the two guide frames (27) and approach each other until the two guide rollers (29) respectively fit the top surface and bottom surface of the strip, so as to realize clamping of the strip. Meanwhile, the non-slip strips (30) on the surfaces of the guide rollers (29) can effectively increase the contact friction force, a motor drives the two guide rollers (29) to rotate synchronously, thereby applying conveying force to the clamped strip and assisting in completing the straightening operation.

[0055] It should be noted that a motor is provided at one end of each of the two guide rollers (29), the motor is connected with a power supply and a controller, and the motor, the power supply and the controller are all in the prior art, thus no excessive description is given herein.

[0056] A fixing frame (33) is fixedly connected to one side of each of the main support (2) and the auxiliary support (3), a sliding chute (34) is formed on each of the two fixing frames (33), a sliding seat (32) is slidably connected in each of the two sliding chutes (34), a fixing shaft (31) is fixedly connected to the opposite side of each of the two sliding seats (32), two pushing plates (38) are respectively rotatably connected on the two fixing shafts (31), the other ends of the four pushing plates (38) are respectively rotatably connected to the two ends of the two roller shafts (28), a limiting frame (37) is fixedly connected to the other end of each of the two fixing shafts (31), and the two limiting frames (37) are respectively slidably connected to the two fixing frames (33).

[0057] A limiting rod (35) is fixedly connected to one side of each of the two sliding seats (32), the two limiting rods (35) are respectively slidably connected to one side of the sliding chute (34), a spring (36) is sleeved on each of the two limiting rods (35), a secondary electric push rod (39) is fixedly connected to one side of each of the main support (2) and the auxiliary support (3), a connecting plate (40) is fixedly connected to the output end of each of the two secondary electric push rods (39), and the two connecting plates (40) are respectively fixedly connected to the bottoms of the two extension frames (26).

[0058] When it is necessary to convey the strip material, the output end of the secondary electric push rod 39 extends, driving the connecting plate 40 to move to one side, thereby driving the two extension frames 26 to slide and extend synchronously in the two sliding frames 25, driving the two guide rollers 29 to move closer to each other, clamping the strip material and rotating to convey the strip material.

[0059] When the strip material gets stuck during the leveling process, the output end of the secondary electric push rod 39 is extended by manual control or by adding a sensor to detect the running status of the strip material, pushing the extension frame 26 to move further. The strip material is further clamped by the two guide rollers 29. After clamping, the two guide rollers 29 can no longer get closer to each other. Under the continuous pushing action, the two guide rollers 29 drive the clamped strip material to one side, assisting in pushing the strip material forward, thereby effectively solving the jamming problem. During the movement of the guide rollers 29, the two push plates 38 pull the two fixed shafts 31 and the sliding seat 32 respectively, so that the sliding seat 32 moves synchronously in the slide groove 34 on the fixed frame 33. At the same time, the limiting rod 35 on one side of the sliding seat 32 slides along the side wall of the slide groove 34, compressing the spring 36 and causing the spring 36 to undergo elastic deformation.

[0060] After the jamming problem is resolved, the output end of the secondary electric push rod 39 shortens, causing the two guide rollers 29 to move in the opposite direction. The restoring force of the spring 36 pushes the two sliding seats 32 and the fixed shaft 31 to slide and reset in the opposite direction within the slide groove 34, thereby reducing the clamping force of the two guide rollers 29 on the strip. Subsequently, the guide rollers 29 drive the strip to move normally by rotating on their own, completing the conveying operation.

[0061] It should be noted that the secondary electric actuator 39 is connected to a power supply and a controller, which are existing technologies and therefore not described in detail.

[0062] As an example, the method also includes step S6: strip width limit adjustment: before the strip enters the leveling process, it is first placed on the guide plate 41. According to the strip width, the rotating plate 49 on the rotating support 48 is rotated. The main shaft 46 is pulled by two pulling plates 47, so that the guide wheels 44 on the two sliding plates 45 move towards each other and move closer to the position that adapts to the strip width. During the leveling process, the strip is limited and prevented from deviating. After the adjustment is in place, the snap-fit ​​bracket 51 is inserted into the support 48 to lock the rotating plate 49 and complete the positioning.

[0063] Detailed Implementation Examples: A guide plate 41 is fixedly connected to the other side of the main support 2 and the auxiliary support 3. Four adjustment slots 42 are provided on the guide plate 41. The adjustment slots 42 are rectangular. Frames 43 are slidably connected in each of the four adjustment slots 42. Guide wheels 44 are rotatably connected to each of the four frames 43. Sliding plates 45 are fixedly connected to the bottom of the two frames 43.

[0064] The bottom of each of the two sliding plates 45 is fixedly connected to a main shaft 46, the bottom of the guide plate 41 is fixedly connected to a support column 48, a rotating plate 49 is rotatably connected to the support column 48, and auxiliary shafts 50 are fixedly connected to both ends of the rotating plate 49. Pulling plates 47 are rotatably connected to each of the two main shafts 46, and the other ends of the two pulling plates 47 are rotatably connected to the two auxiliary shafts 50 respectively. A snap-fit ​​bracket 51 is sleeved on the support column 48, and the snap-fit ​​bracket 51 cooperates with the rotating plate 49.

[0065] During the strip straightening process, four guide wheels 44 limit the strip material being conveyed, effectively preventing the strip material from deviating during straightening. When dealing with strip materials with a narrower width, the operator first removes the clamping frame 51 from the support column 48, and then pushes the rotating plate 49 to rotate on the support column 48. The rotating plate 49 pulls two main shafts 46 simultaneously through two pulling plates 47. The two main shafts 46 drive two sliding plates 45 and the guide wheels 44 fixed on them to move synchronously towards each other, so that the guide wheels 44 move closer to each other to accommodate the width of the narrower strip material and achieve the limit. Alternatively, the frames 43 on both sides can be pulled directly to limit the strip material.

[0066] After adjustment, the staff repositioned the clip 51 and inserted it into the support column 48. The two ends of the clip 51 limit and fix the rotating plate 49, thereby keeping the adjusted guide wheel 44 in a stable position and ensuring that the limiting effect is reliable during the subsequent leveling process. The clip 51 is a polygonal block with stop bars on both sides. It is limited by inserting the square block into the support column 48. The two stop bars are located on both sides of the rotating plate 49 to limit the rotation plate 49.

[0067] As an example, precision cutting and shaping: qualified products after roll forming are precision cut using laser processing to ensure the accuracy of product length dimensions. Subsequently, mechanical straightening is used to shape the product so that the curvature in the length direction is no more than 8mm, the twist is no more than 5mm, the upward deflection is no more than 0.05% of the total length, the two lateral upward deflections are less than 2mm, and the flatness is less than 0.5mm / m.

[0068] After precision sizing, the process also includes a bending process: the straight profile after roll forming is fed into a bending machine and bent according to the target arc curvature. After bending, the lateral bend is no more than 6mm, and the arc detection template error is less than 0.1mm.

[0069] As an example, end grinding and surface treatment: the cut and opening positions of the product after precision sizing are ground and cleaned to ensure that there are no burrs and the edges are smooth. The bending radius of the cold-formed steel is subjected to penetrant testing to confirm that there are no cracks at the radius and no delamination defects in the internal crystal phase of the cross section.

[0070] As an example, inspection and packaging: The finished products are inspected for size, weight and appearance. After confirming that the products are straight, without wrinkles, hard bends, bulges and twists, and that the curvature, twist and cross-sectional dimensions meet the technical requirements, the products are placed in the material rack in order, protected by the isolation material between the layers, labeled and packaged for storage.

[0071] As an example, in the roll forming process of S2, when the yield strength of the material is ≥350MPa, the springback compensation is increased by 15% to 25% compared with conventional carbon steel.

[0072] As an example, in the roll forming process of S3, the roll gap compensation method for the four lower leveling rolls 6 is as follows: the eccentricity of the first-stage eccentric wheel 11 is... The eccentricity of the second-stage eccentric wheel 12 is... The eccentricity of the third-stage eccentric wheel 13 is... The fourth-stage eccentric wheel has an eccentricity of 14. ,satisfy Each eccentric wheel corresponds to the wear compensation amount of each lower leveling roller 6, so that the four lower leveling rollers 6 are raised to different heights, and the roller gap compensation accuracy is controlled within ±0.02mm.

[0073] As an example, in S1, the raw material is selected as hot-rolled steel plate Q350EWR1 or cold-rolled high weathering steel plate Q350EWL1 with atmospheric corrosion resistance. The base material thickness is 2mm to 4mm, the yield strength is ≥350MPa, the tensile strength is 490MPa to 690MPa, and the elongation after fracture is ≥22%.

[0074] As an example, in S2, the roll forming process integrates the punching process on the forming line, so that the pre-punching and roll forming are carried out simultaneously. During the forming process, the minimum stretching of the strip is ensured to avoid hole distortion, and the forming line speed is controlled within the range that ensures stable product quality for continuous production.

[0075] As an example, five processes—roll forming, online compensation and leveling of roll gap, anti-jamming feeding of strip, compensation feeding, and strip width limit adjustment—are continuously integrated on the same cold forming production line. The strip is continuously processed without interruption from uncoiling to leveling and discharge. The ambient temperature during production is -40℃ to +40℃, and the maximum relative humidity is ≤95%.

[0076] Working principle of this invention: When in use, the strip is placed on the guide plate 41, and the guide wheel 44 on the guide plate 41 limits the strip to prevent deviation during the straightening process. When straightening a narrow strip, the worker pushes the rotating plate 49, which drives the four guide wheels 44 to move towards the center of the guide plate 41 in sync, so as to adapt to the width of the narrow strip and achieve the limit.

[0077] When the lower leveling roller 6 wears, the main electric push rod 20 drives the lifting frame 21 to rise. The rack 22 on one side of the lifting frame 21 drives the gear 19 and the support shaft 17 to rotate on the support 16. The worm gears 18 at both ends of the support shaft 17 drive the worm wheel 15 and its connected rotating shaft 10 to rotate synchronously on the main support 2 and the auxiliary support 3, thereby causing the first-stage eccentric wheel 11, the second-stage eccentric wheel 12, the third-stage eccentric wheel 13 and the fourth-stage eccentric wheel 14 to rotate synchronously. This pushes the support plate 9 at the bottom of the four lower leveling rollers 6 to rise synchronously, causing the four lower leveling rollers 6 to be lifted as a whole to compensate for the increased roller gap between the upper leveling roller 4 and the lower leveling roller 6. At the same time, the diameters of the first-stage eccentric wheel 11, the second-stage eccentric wheel 12, the third-stage eccentric wheel 13 and the fourth-stage eccentric wheel 14 are different, so that the rising height of the four lower leveling rollers 6 is different to adapt to the different wear levels of each roller.

[0078] During the leveling and conveying process, the strip enters between the two guide rollers 29. The output end of the secondary electric push rod 39 extends, driving the two guide frames 27 to move. This causes the two guide rollers 29 to slide and approach each other within the two guide frames 27 until they contact both sides of the strip. The strip is conveyed by the rotation of the two guide rollers 29, which helps to complete the leveling operation.

[0079] When jamming occurs, the output end of the secondary electric push rod 39 continues to extend, causing the two guide rollers 29 to clamp the strip material. After complete clamping, the output end extends further, driving the two fixed shafts 31 and their sliding seats 32 to slide within the groove 34, compressing the spring 36, thereby moving the clamped strip material forward and resolving the jamming problem. After the jamming is resolved, the output end of the secondary electric push rod 39 shortens, and the restoring force of the spring 36 pushes the sliding seat 32 and fixed shaft 31 to reset, reducing the clamping force on the strip material. Subsequently, the two guide rollers 29 continue to transport the strip material normally by rotating.

[0080] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A process for leveling cold-bent steel sections for rail vehicles, characterized in that, Includes the following steps: S1: Raw material preparation and slitting: Select cold-rolled high weather-resistant steel plate as raw material, formulate slitting specifications according to product drawings, use slitting equipment to cut the steel plate into strips of the required width, and inspect the appearance of the strips after slitting. S2: Roll forming: The slit strips are fed into the uncoiler of the cold forming unit, and the strips are pulled through the pre-adjusted multi-pass forming dies in sequence, and rolled in the order of first leveling and then bending laterally in each pass. S3: Online compensation and leveling of roll gap: During the leveling operation, the wear status of the surface of the lower leveling roller (6) is monitored in real time. When it is detected that the working radial distance of the lower leveling roller (6) is reduced due to wear and the roll gap between the upper leveling roller (4) and the lower leveling roller (6) is increased, the main electric push rod (20) is started to drive the lifting frame (21) to rise. The driven roller (24) is driven to rise through the lifting frame (21), and the first-level eccentric wheel (11), the second-level eccentric wheel (12), the third-level eccentric wheel (13) and the fourth-level eccentric wheel (14) rotate synchronously in their respective working slots (5), pushing the support plate (9) and bearing seat (7) at the bottom of each lower leveling roller (6) to rise. The four lower leveling rollers (6) rise to different heights corresponding to the amount of wear, restoring the original roll gap between them and the upper leveling roller (4). After the roll gap is compensated in place, the lifting frame (21) stops moving. Among them, the main support (2) and the auxiliary support (3) are rotatably connected to the rotating shaft (10), and the two rotating shafts (10) are fixedly connected to the first-stage eccentric wheel (11), the second-stage eccentric wheel (12), the third-stage eccentric wheel (13) and the fourth-stage eccentric wheel (14). The diameters of the first-stage eccentric wheel (11), the second-stage eccentric wheel (12), the third-stage eccentric wheel (13) and the fourth-stage eccentric wheel (14) decrease in sequence, and the central axis is located on the surface of the rotating shaft (10). The central axes of the first-stage eccentric wheel (11), the second-stage eccentric wheel (12), the third-stage eccentric wheel (13) and the fourth-stage eccentric wheel (14) are located on the same line. The first-stage eccentric wheel (11), the second-stage eccentric wheel (12), the third-stage eccentric wheel (13) and the fourth-stage eccentric wheel (14) are respectively located in the four working slots (5) on the main support (2) and the auxiliary support (3); The bottom of the bearing housing (7) is threaded with a threaded column (8), and the bottom of the threaded column (8) is rotatably connected with a support plate (9). The surfaces of the first-stage eccentric wheel (11), the second-stage eccentric wheel (12), the third-stage eccentric wheel (13) and the fourth-stage eccentric wheel (14) are all in contact with the bottom of the support plate (9).

2. The leveling process for cold-bent steel sections of rail vehicles according to claim 1, characterized in that, It also includes step S4: Anti-jamming feeding of strip material: During the leveling and conveying process, if the strip material stops or gets jammed between the upper leveling roller (4) and the lower leveling roller (6), the secondary electric push rod (39) is activated to push the extension frame (26) to extend outward along the sliding frame (25), so that the two guide rollers (29) approach each other and fit against the strip material respectively. The anti-slip strips (30) on the surface of the guide rollers (29) increase the friction force to assist in pushing the strip material forward.

3. The leveling process for cold-bent steel sections of rail vehicles according to claim 2, characterized in that, It also includes step S5: Compensation feeding: If the thrust is still insufficient to feed the material, the secondary electric push rod (39) continues to extend to clamp the strip material with the two guide rollers (29), and the strip material is driven by the clamping force. At the same time, the sliding seat (32) on the fixed shaft (31) slides in the groove (34) of the fixed frame (33) and compresses the spring (36). After the jammed material is removed, the electric push rod (39) shortens, and the restoring force of the spring (36) pushes the sliding seat (32) and the fixed shaft (31) to reset. After the clamping force is reduced, the guide roller (29) continues to transport the strip material normally by its own rotation.

4. The leveling process for cold-bent steel sections of rail vehicles according to claim 3, characterized in that, It also includes step S6: Strip width limit adjustment: Before the strip enters the leveling, it is placed on the guide plate (41). According to the two pull plates (47) on the rotating plate (49), the guide wheels (44) on the two sliding plates (45) are pulled to move towards each other to the position that adapts to the strip width. After the adjustment is in place, the snap-fit ​​bracket (51) is inserted into the support column (48) to lock the rotating plate (49).

5. The leveling process for cold-bent steel sections of rail vehicles according to claim 3, characterized in that, Both sliding seats (32) are fixedly connected to fixed shafts (31), and push plates (38) are rotatably connected to both fixed shafts (31). The other ends of the four push plates (38) are rotatably connected to the two ends of the two guide rollers (29).

6. The leveling process for cold-bent steel sections of rail vehicles according to claim 5, characterized in that, The other ends of the two fixed shafts (31) are fixedly connected to limit frames (37), and the two limit frames (37) are slidably connected to the two fixed frames (33).

7. The leveling process for cold-bent steel sections of rail vehicles according to claim 4, characterized in that, The guide plate (41) is provided with an adjustment groove (42), and a frame (43) is slidably connected in the adjustment groove (42). A guide wheel (44) is rotatably connected in the frame (43).

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