A multi-wheel group roll forming apparatus

Abstract

A kind of multi-wheel group's roll forming equipment, it is related to plate continuous forming processing technical field, including installation base, forming roller group and plate limiting mechanism;Multiple forming roller groups are sequentially arranged along the direction of plate conveying, and the gradual change die of each forming roller group changes step by step, so that plate realizes multistage gradual roll forming in the conveying process;Plate limiting mechanism includes the gradual change limiting plate arranged on the both sides of plate, and the gradual change limiting plate is installed on limiting plate pillar by elastic push rod, and gradually contracts pitch along the direction of conveying, while gradual change limiting plate is provided with the transition section corresponding to each level forming roller group, to realize the synchronous orientation and limiting of plate in different forming stages.

Description

Technical Field

[0001] This invention belongs to the field of sheet metal forming and processing technology, specifically referring to a multi-roller forming equipment. Background Technology

[0002] In the field of sheet metal forming and processing, roll forming equipment is widely used in the processing of building profiles, metal sheets, automotive structural parts, and industrial profiles due to its advantages such as high continuous production efficiency, good forming stability, and suitability for mass production. Traditional roll forming equipment typically uses a single set or a small number of forming rollers to gradually bend or press the sheet metal to achieve the desired cross-sectional shape.

[0003] Existing multi-roller pressing equipment still has certain shortcomings in practical applications. First, existing equipment usually relies only on forming rollers to control the forming of the sheet material in one direction or locally, and lacks a lateral limiting structure that matches the forming process. This makes the sheet material prone to lateral movement, deviation, or local twisting during multi-stage rolling, thus affecting the final forming accuracy.

[0004] Secondly, during multi-stage continuous rolling, the transverse dimensions of the sheet material usually change gradually with plastic deformation. However, the lateral guide structure of existing equipment is mostly a fixed spacing or a simple adjustable structure, which cannot be synchronized with the gradual forming state of each forming roller. This leads to problems such as excessive extrusion or insufficient limiting of the sheet material at different forming stages, which in turn causes defects such as edge wrinkling, cracking or decreased surface quality. Summary of the Invention

[0005] In view of the above situation and to overcome the defects of the prior art, the present invention provides a multi-roller forming equipment to at least partially solve the above technical problems.

[0006] The technical solution adopted by this invention is as follows: This invention proposes a multi-roller forming device, characterized in that it includes a mounting base, forming roller groups, and a sheet material limiting mechanism; multiple roller supports and multiple limiting plate supports are sequentially fixed on the mounting base along the sheet material conveying direction; each roller support is equipped with a set of forming roller groups, each forming roller group including a main shaft, on which a feeding wheel, a gradient mold, a mold limiting block, and a drive motor are mounted. The drive motor is used to drive the main shaft to rotate, the feeding wheel is used to drive the sheet material to move along the conveying direction, the gradient mold is used to perform step-by-step roll forming of the sheet material, and the mold limiting block is used to axially limit the gradient mold; multiple forming roller groups are mounted on the main shaft. The roller sets are arranged sequentially along the sheet material conveying direction. The forming dimensions of the gradient dies of adjacent forming roller sets gradually change, so that the sheet material is gradually rolled and formed after passing through each forming roller set. The sheet material limiting mechanism includes multiple gradient limiting plates respectively set on both sides of the sheet material conveying direction. Each gradient limiting plate is installed on the corresponding limiting plate support through an elastic push rod. The gradient limiting plates are arranged sequentially along the sheet material conveying direction, and the spacing between corresponding pairs of gradient limiting plates gradually decreases along the sheet material conveying direction. Each gradient limiting plate is provided with multiple transition sections. The position of each transition section corresponds to the position of the gradient die of the corresponding forming roller set, so as to continuously guide and limit the edge of the sheet material during the step-by-step deformation process.

[0007] Furthermore, the mounting base has a long strip structure, and multiple roller supports are arranged at equal or varying intervals along the length of the mounting base. Each roller support is respectively equipped with a set of forming rollers, forming a continuous multi-stage roll forming station.

[0008] Furthermore, the main shaft is rotatably mounted on the roller support, and the feeding wheel and the gradient mold are both sleeved on the main shaft. The mold limiting block is set on both sides of the gradient mold and fixedly connected to the main shaft to restrict the gradient mold from moving axially along the main shaft.

[0009] Furthermore, multiple gradient dies sequentially form different forming sections along the sheet material conveying direction, and the forming dimensions between adjacent gradient dies gradually change, so that the sheet material obtains partial plastic deformation each time it passes through a set of forming rollers, and finally completes the continuous progressive forming of the target section.

[0010] Furthermore, the limiting plate support is fixedly installed on the mounting base, the elastic push rod is installed on the limiting plate support, and the gradient limiting plate is installed on the movable end of the elastic push rod. Under the action of the elastic push rod, the gradient limiting plate can generate elastic displacement towards the plate material.

[0011] Furthermore, gradient limiting plates are respectively set on both sides of the sheet material conveying direction. The gradient limiting plates on both sides correspond to each other to form a sheet material guiding channel, and the distance between the two corresponding gradient limiting plates along the sheet material conveying direction gradually decreases to adapt to the process of the sheet material width gradually decreasing.

[0012] Furthermore, the gradient limiting plate is provided with multiple transition sections connected sequentially along the conveying direction of the sheet material. The transition sections are smoothly connected, and the guide width of adjacent transition sections gradually decreases. Each transition section corresponds to the gradient mold of the corresponding forming roller group, so that the sheet material maintains a guide space that matches the corresponding width at each forming station.

[0013] Furthermore, as the sheet material passes through each forming roller group for roll forming, the width of the sheet material gradually decreases as the gradual mold is continuously formed. The edge of the sheet material is simultaneously guided and limited by the corresponding transition section, and under the elastic action of the elastic push rod, it always remains in contact with the gradual limiting plate.

[0014] Furthermore, the drive motor is fixedly mounted on the roller support, and its output end is connected to the main shaft drive to drive the feeding wheel and the gradient mold to rotate synchronously.

[0015] Furthermore, multiple forming roller groups and multiple gradient limiting plates are set one-to-one along the conveying direction of the sheet material. Each forming roller group corresponds to a transition section, so that the sheet material forms a guide area that matches the current forming size during each stage of roll forming, thereby realizing the synchronous change of sheet material forming size and guide limiting change.

[0016] Compared with the prior art, the present invention has the following advantages: By setting up multiple forming roller groups arranged sequentially along the conveying direction of the sheet material and adopting a gradient mold structure, the sheet material can achieve progressive roller forming during the conveying process. Compared with the traditional single-stage or few-stage forming method, it can significantly reduce the amount of deformation per step and improve the overall forming stability and material adaptability.

[0017] By setting a gradient limiting plate for each forming roller group and gradually reducing the spacing between the gradient limiting plates along the conveying direction, the synchronous matching of the change in the forming size of the sheet material and the change in the lateral limiting space is achieved, thereby effectively avoiding the sheet material from running off-center, twisting or becoming locally unstable during the forming process, and improving the forming accuracy and consistency.

[0018] By setting up an elastic push rod structure, the gradient limiting plate has a certain elastic displacement capability, which can achieve adaptive buffer compensation when the plate thickness fluctuates or the force is uneven, thereby reducing edge extrusion damage and lowering the probability of defects such as wrinkling and cracking of the plate.

[0019] By matching the transition section with each level of forming roller group, the sheet material is placed in the corresponding guide area during each level of rolling, which further improves the stability and reliability of multi-level continuous forming.

[0020] The overall structure is simple and highly modular. Each forming roller group and limiting mechanism can be maintained and replaced independently. It has good engineering adaptability and expansion capability. The number of roller groups and gradient parameters can be flexibly adjusted according to different sheet specifications, making it suitable for the continuous production needs of different sheet specifications. Attached Figure Description

[0021] Figure 1 This is a perspective view of a multi-roller forming device according to an embodiment of the present invention; Figure 2 This is a top view of a multi-roller forming apparatus according to an embodiment of the present invention; Figure 3 This is a front view of a multi-roller forming equipment according to an embodiment of the present invention; Figure 4 for Figure 3 A cross-sectional view along the AA direction; Figure 5 for Figure 3 Enlarged view of point I in the middle; Figure 6 for Figure 4 Enlarged view of section II.

[0022] Among them, 100 is the mounting base, 101 is the roller support, 200 is the forming roller group, 201 is the main shaft, 202 is the feeding wheel, 203 is the gradient mold, 204 is the mold limiting block, 205 is the drive motor, 300 is the plate limiting mechanism, 301 is the gradient limiting plate, 302 is the transition section, 303 is the elastic push rod, and 304 is the limiting plate support.

[0023] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used together with the embodiments of the invention to explain the invention and do not constitute a limitation thereof. Detailed Implementation

[0024] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0025] In the description of this invention, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0026] like Figures 1-6 As shown, this embodiment provides a multi-roller forming equipment, including a mounting base 100, forming rollers 200, and a sheet material limiting mechanism 300. The mounting base 100 serves as the load-bearing foundation of the entire machine, preferably employing an integral welded frame structure or a steel assembly structure. Its main material is preferably Q355 or Q460 high-strength structural steel to ensure sufficient rigidity and torsional resistance under multi-stage continuous rolling loads. The overall length of the mounting base 100 can be set to 6m–15m, the width to 1.2m–2.5m, and the height to 800mm–1500mm according to production line process requirements, to accommodate different sheet material thicknesses and forming lengths.

[0027] Multiple roller supports 101 and multiple limiting plate supports 304 are sequentially arranged on the mounting base 100 along the sheet material conveying direction. The roller supports 101 and limiting plate supports 304 can be arranged alternately or symmetrically to ensure uniform stress distribution in the structure. The roller supports 101 support the forming roller assembly 200, and the limiting plate supports 304 support the sheet material limiting mechanism 300. The multiple roller supports 101 are arranged at equal or progressive intervals along the length of the mounting base 100. The distance between adjacent roller supports 101 is preferably 350mm to 950mm to provide sufficient deformation transition space for the sheet material at different forming stages.

[0028] Each roller support 101 is equipped with a set of forming rollers 200, forming a multi-stage series roll forming station structure. During the conveying process, the sheet material passes through each forming roller set 200 in sequence, and each stage applies local plastic deformation to the sheet material, thereby achieving step-by-step cumulative forming.

[0029] The forming roller assembly 200 includes a main shaft 201, a feeding roller 202, a gradient mold 203, a mold limiting block 204, and a drive motor 205. The main shaft 201 is preferably made of high-frequency quenched alloy steel, with a diameter ranging from 50mm to 130mm to accommodate different sheet metal load requirements. The main shaft 201 is mounted on the roller support 101 via bearing seats and can achieve high-speed, stable rotation.

[0030] The feeding wheel 202 is sleeved on the main shaft 201, and its outer circumferential surface is preferably provided with an anti-slip rubber layer or a polyurethane wear-resistant layer, with a friction coefficient preferably of 0.6 to 0.9, to form reliable frictional contact with the surface of the sheet material, thereby providing stable conveying power. In some embodiments, the feeding wheel 202 may also adopt an active clamping structure to improve the conveying stability of the sheet material.

[0031] The gradient mold 203 is also mounted on the main shaft 201, and it is the core component for achieving progressive forming in this invention. The outer contour of the gradient mold 203 is a continuously changing spatial curved surface or a stepped curved surface structure. The gradient mold 203 between different forming roller groups 200 changes its geometric parameters step by step, such as the reduction amount, bending angle, or cross-sectional shrinkage rate increasing step by step. Specifically, in the first forming stage, the reduction amount of the gradient mold 203 can be set to 2% to 6% to eliminate the initial flatness error of the sheet metal; in the intermediate forming stage, the reduction amount gradually increases to 8% to 18% to form the main plastic deformation; in the final forming stage, the reduction amount can reach 20% to 40% to complete the final cross-sectional shaping.

[0032] The mold limiting block 204 is set on both sides of the gradient mold 203 and is rigidly connected to the main shaft 201. It is used to limit the axial movement of the gradient mold 203 under high-speed rotation and high-pressure rolling. Its axial limiting gap is preferably controlled within the range of 0.1mm to 0.5mm to ensure molding accuracy.

[0033] The drive motor 205 is fixedly installed on the roller support 101. It is preferably a servo motor or a variable frequency speed control motor with a power range of 3kW to 18kW. It is connected to the main shaft 201 through a coupling or a gearbox to achieve stable and adjustable speed drive, so that the rolling speed at different stages matches the deformation rate of the sheet.

[0034] The plate limiting mechanism 300 includes a gradient limiting plate 301, a transition section 302, an elastic push rod 303, and a limiting plate support column 304. The limiting plate support column 304 is fixedly installed on the mounting base 100, and its height is preferably 700mm to 1400mm. A mounting seat is provided on its top or side for installing the elastic push rod 303.

[0035] The elastic push rod 303 preferably adopts a spring push rod, gas spring or hydraulic buffer push rod structure, and its elastic stroke is preferably 10mm to 80mm, and the force range is 80N to 500N. It is used to provide flexible compensation when the plate is subjected to force fluctuation, so that the limiting plate 301 has a certain buffering capacity while maintaining the guiding function.

[0036] Gradient limiting plates 301 are installed on the movable end of the elastic push rod 303 and are respectively arranged on both sides of the plate conveying direction, thereby forming a symmetrical plate guiding channel structure. The initial spacing of the guiding channel at the entrance end is preferably the original width of the plate plus a gap of 10mm to 50mm to ensure that the plate can enter smoothly. As the plate enters different forming stages, the spacing between the two gradient limiting plates 301 gradually decreases, for example, it can be gradually reduced from the initial 800mm to 760mm, 720mm, 680mm and finally to the range of 450mm to 600mm, to match the gradual decrease in the transverse dimension of the plate.

[0037] The gradient limiting plate 301 is provided with multiple transition sections 302. The transition sections 302 are arranged sequentially along the conveying direction of the plate and have a continuous and smooth transition structure. The transition between adjacent transition sections 302 adopts an arc transition or an S-shaped curve transition. The transition radius is preferably R30 to R120 to avoid edge scratches or stress concentration of the plate during high-speed conveying.

[0038] Each transition section 302 is spatially matched with the gradient mold 203 in the corresponding forming roller group 200, so that the sheet material enters the matching guide area during each stage of roller deformation, realizing the synchronous control mode of "forming one stage, limiting one stage".

[0039] During operation, the sheet material enters through the equipment inlet and is continuously conveyed along the mounting base 100 under the action of the feeding roller 202. It first enters the first forming roller group 200, where it undergoes primary pressing under the action of the gradient mold 203, causing slight plastic deformation of the sheet material. At the same time, the sheet material is initially guided and limited by the first transition section 302.

[0040] Subsequently, the sheet material enters the second, third and final forming roller groups 200 in sequence. Each time it passes through a forming roller group 200, the gradient mold 203 applies a further deformation effect to the sheet material, causing the sheet material to gradually shrink laterally, change in thickness or adjust in cross-sectional shape. At the same time, the gradient limiting plates 301 on both sides continuously constrain the edges of the sheet material through the corresponding transition sections 302, so that the sheet material is always in a stable guide path.

[0041] During the multi-stage rolling process, since the sheet is subjected to different forces at different stages, the elastic push rod 303 can generate a slight displacement compensation (approximately ±2mm to ±8mm) according to the actual contact pressure of the sheet, thereby avoiding the phenomenon of sheet wrinkling, edge tearing or deviation caused by local stress concentration.

[0042] As the number of forming stages increases, the transverse dimension of the sheet gradually decreases, while the spacing between the gradient limiting plates 301 decreases synchronously, thereby achieving a dynamic matching relationship between the forming space and the guiding space, so that the sheet always remains stably centered throughout the entire rolling path.

[0043] Finally, after the sheet material passes through the end forming roller group 200, its cross-sectional shape meets the design requirements, and it is then exported from the output end of the equipment, completing the entire multi-roll gradual roll forming process.

[0044] The operating procedure is as follows: Start the drive motor 205 to make each main shaft 201 drive the feeding wheel 202 and the gradient mold 203 to rotate synchronously; feed the sheet into the equipment from the inlet end, and enter the first forming roller group 200 under the action of the feeding wheel 202; the sheet passes through multiple forming roller groups 200 in sequence and undergoes plastic deformation step by step; at the same time, the sheet maintains lateral stability under the corresponding limiting action of each transition section 302; as the forming process progresses, the lateral dimension of the sheet decreases step by step, and the spacing of the gradient limiting plates 301 shrinks synchronously; finally, the sheet completes the final forming at the end forming roller group 200 and is output from the equipment.

[0045] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0046] The present invention and its embodiments have been described above. This description is not restrictive, and the accompanying drawings are only one embodiment of the present invention; the actual structure is not limited thereto. In conclusion, if those skilled in the art are inspired by this description and design similar structures and embodiments without departing from the spirit of the invention, such designs should fall within the protection scope of the present invention.

Claims

1. A multi-roller forming equipment, characterized in that: A multi-roller roll forming equipment, characterized in that it includes a mounting base (100), a forming roller group (200), and a sheet material limiting mechanism (300). Multiple roller supports (101) and multiple limiting plate supports (304) are sequentially fixedly installed on the mounting base (100) along the conveying direction of the sheet material; each roller support (101) is equipped with a set of forming roller groups (200), each forming roller group (200) includes a main shaft (201), the main shaft (201) is equipped with a feeding wheel (202), a gradient mold (203), a mold limiting block (204) and a drive motor (205), the drive motor (205) is used to drive the main shaft (201) to rotate, the feeding wheel (202) is used to drive the sheet material to move along the conveying direction, the gradient mold (203) is used to roll the sheet material step by step, and the mold limiting block (204) is used to axially limit the gradient mold (203); Multiple forming roller groups (200) are arranged sequentially along the conveying direction of the sheet material. The forming size of the gradient mold (203) of the adjacent forming roller groups (200) gradually changes, so that the sheet material is gradually rolled after passing through each forming roller group (200). The plate limiting mechanism (300) includes multiple gradient limiting plates (301) respectively disposed on both sides of the plate conveying direction. Each gradient limiting plate (301) is installed on the corresponding limiting plate support (304) by an elastic push rod (303). Each gradient limiting plate (301) is arranged sequentially along the plate conveying direction, and the spacing between a corresponding pair of gradient limiting plates (301) gradually decreases along the plate conveying direction. Each gradient limiting plate (301) is provided with multiple transition sections (302). The position of each transition section (302) corresponds to the position of the gradient mold (203) of the corresponding forming roller group (200) to continuously guide and limit the edge of the plate during the plate's progressive deformation process.

2. The multi-roller forming equipment according to claim 1, characterized in that: The mounting base (100) has a long strip structure, and multiple roller supports (101) are arranged at equal or variable intervals along the length of the mounting base (100). Each roller support (101) is respectively provided with a set of forming roller groups (200) to form a continuous multi-stage roll forming station.

3. The multi-roller forming equipment according to claim 2, characterized in that: The main shaft (201) is rotatably mounted on the roller support (101). The feeding wheel (202) and the gradient mold (203) are both sleeved on the main shaft (201). The mold limiting block (204) is set on both sides of the gradient mold (203) and fixedly connected to the main shaft (201) to restrict the gradient mold (203) from moving axially along the main shaft (201).

4. The multi-roller forming equipment according to claim 3, characterized in that: Multiple gradient dies (203) sequentially form different forming sections along the conveying direction of the sheet material. The forming dimensions between adjacent gradient dies (203) gradually change, so that the sheet material obtains partial plastic deformation each time it passes through a set of forming rollers (200), and finally completes the continuous progressive forming of the target section.

5. The multi-roller forming equipment according to claim 4, characterized in that: The limiting plate support column (304) is fixedly installed on the mounting base (100), the elastic push rod (303) is installed on the limiting plate support column (304), and the gradient limiting plate (301) is installed on the movable end of the elastic push rod (303). Under the action of the elastic push rod (303), the gradient limiting plate (301) can generate elastic displacement in the direction of the plate.

6. The multi-roller forming equipment according to claim 5, characterized in that: The gradient limiting plates (301) are respectively set on both sides of the plate conveying direction. The gradient limiting plates (301) on both sides correspond to each other to form a plate guiding channel. The distance between the two corresponding gradient limiting plates (301) along the plate conveying direction gradually decreases to adapt to the process of the plate width gradually decreasing.

7. The multi-roller forming equipment according to claim 6, characterized in that: The gradient limiting plate (301) is provided with multiple transition sections (302) connected sequentially along the conveying direction of the plate. Each transition section (302) transitions smoothly with each other. The guide width of adjacent transition sections (302) gradually decreases. Each transition section (302) corresponds to the gradient mold (203) of the corresponding forming roller group (200), so that the plate maintains a guide space that matches the corresponding width at each forming station.

8. The multi-roller forming equipment according to claim 7, characterized in that: When the sheet material passes through each forming roller group (200) in sequence for roll forming, the width of the sheet material gradually decreases as the gradual mold (203) continuously forms. The edge of the sheet material is simultaneously guided and limited by the corresponding transition section (302), and always remains in contact with the gradual limiting plate (301) under the elastic action of the elastic push rod (303).

9. The multi-roller forming equipment according to claim 1, characterized in that: The drive motor (205) is fixedly installed on the roller support (101), and its output end is connected to the main shaft (201) for driving the feeding wheel (202) and the gradient mold (203) to rotate synchronously.

10. The multi-roller forming equipment according to claim 1, characterized in that: Multiple forming roller groups (200) and multiple gradient limiting plates (301) are set one-to-one along the conveying direction of the sheet material. Each forming roller group (200) corresponds to a transition section (302), so that the sheet material forms a guide area that matches the current forming size during each stage of roller forming, thereby realizing the synchronous change of sheet material forming size and guide limiting change.

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