Aluminum alloy profile forming composite device for rail

Abstract

The utility model discloses a kind of aluminium alloy section bar forming composite devices for track, comprising: machine table, its machine table surface is equipped with side roll press unit, symmetrically distributed in the both sides of machine table, for the side of aluminium profile is rolled into shape, and according to section bar width self-adapting adjustment roll press interval;Double-sided roll press unit: evenly be equipped with in machine table surface, for the upper and lower surface of aluminium profile is synchronously rolled into shape, and the roll press demand of adaptation different thickness section bar;Roll press positioning roller group is equipped in the interval cavity of adjacent double-sided roll press unit, for in section bar conveying process through pneumatic roll press realizes dynamic positioning and prevents deviation, the utility model is through the cylinder A of side roll press unit and the cylinder B of double-sided roll press unit, realize the pneumatic automatic adjustment of roll press interval and height, without stopping machine manual operation, greatly shorten specification switching time, and can guarantee the symmetry accuracy of two sides roll press wheel, effectively solve the size out-of-tolerance problem when different width, thickness section bar is processed.

Description

Technical Field

[0001] This utility model belongs to the field of aluminum profile processing technology, specifically relating to a composite device for forming aluminum alloy profiles for railway tracks. Background Technology

[0002] In the field of aluminum alloy profile processing for railway tracks, the existing roll forming composite equipment has significant limitations in its dimensional adjustment methods. Traditional equipment relies heavily on manual mechanical adjustment of the roll spacing and height, requiring machine shutdown and manual adjustment of bolt positions using wrenches and other tools. This often results in lengthy intervals between specifications, making it impossible to guarantee the symmetrical accuracy of the roll forming rollers and leading to frequent dimensional differences when switching between profiles of different widths and thicknesses. Furthermore, traditional positioning mechanisms struggle to handle dynamic deformation during the roll forming composite conveying process of aluminum alloy profiles for railway tracks. Existing equipment often uses fixed guide wheels for limiting movement. When the profile experiences slight bending due to roll forming stress release or material inconsistencies, the fixed-spacing guide wheels cannot adjust the positioning force in real time, easily causing profile misalignment and wobbling, leading to scratches and indentations on the roll forming surface. Utility Model Content

[0003] The purpose of this utility model is to provide a composite molding device for aluminum alloy profiles for railway tracks, so as to solve the problems mentioned in the background art.

[0004] To achieve the above objectives, this utility model provides the following technical solution: a composite molding device for aluminum alloy profiles used in railway tracks, comprising:

[0005] The machine tool, the surface of the machine tool is equipped with:

[0006] The side roll forming unit is symmetrically distributed on both sides of the machine table. It is used to roll form the sides of aluminum profiles and adaptively adjusts the roll spacing according to the width of the profile.

[0007] The double-sided roll forming unit, evenly arranged on the machine table, consists of three units, used for synchronous roll forming of the upper and lower surfaces of aluminum profiles, and is adapted to the roll forming requirements of profiles of different thicknesses;

[0008] The roller positioning roller group is located in the interval cavity of adjacent double-sided roller press units and is used to achieve dynamic positioning and prevent deviation through pneumatic roller pressing during the profile conveying process.

[0009] The conveying support platform is connected to the side roller press unit and the roller pressing positioning roller unit to provide continuous roller pressing and conveying support for the profiles.

[0010] Preferably, the side roller press unit includes a roller pressing frame, with cylinders A symmetrically arranged on the fixed upright plates and side plates on both sides. The movable end of cylinder A extends through to the other side of the fixed upright plates and side plates and is fixed with a rectangular block.

[0011] Preferably, the rectangular blocks are vertically rotatable with roller pressing adjustment wheels, and the roller pressing adjustment wheels adjust the side roller pressing spacing through cylinder A; the drive shaft at the bottom of the roller pressing adjustment wheel is connected to a micro motor to realize roller pressing composite of profiles of different widths.

[0012] Preferably, the bottom shaft of the roller pressing composite adjustment wheel is equipped with a synchronous turntable for roller pressing and positioning in the groove on the side of the profile, so as to ensure the accuracy of roller pressing composite on the side surface.

[0013] Preferably, the double-sided roller press unit includes mounting plates, and a surface roller A is rotatably mounted in the cavity between the mounting plates. The drive shaft of the surface roller A is connected to a servo motor. A cylinder B is provided on the upper surface of the mounting plates. The surface roller B is rotatably mounted on the top of the cylinder B through a rotating shaft seat. The height of the surface roller B is adjusted by driving the cylinder B to adapt to profiles of different thicknesses.

[0014] Preferably, the surface roller B and the surface roller A form a synchronous rolling structure for the upper and lower surfaces of the profile.

[0015] Preferably, the structure of the roller pressing positioning roller group is the same as that of the side roller pressing unit, including a fixed vertical plate, cylinder A, rectangular block, roller pressing composite adjusting wheel, micro motor and synchronous turntable, used to position the profile during conveying and prevent deviation and collision.

[0016] Preferably, a strip support plate is provided between the roller positioning roller group at the end of the machine and the double-sided roller press group to support the profile during roller pressing and prevent it from bending and deforming downwards.

[0017] Compared with the prior art, the technical effects and advantages of this utility model are as follows:

[0018] This invention achieves pneumatic automatic adjustment of the roller spacing and height through cylinder A of the side roller press unit and cylinder B of the double-sided roller press unit, eliminating the need for manual operation during machine shutdown, significantly shortening specification switching time, and ensuring the symmetrical accuracy of the rollers on both sides. It effectively solves the problem of dimensional deviations when processing profiles of different widths and thicknesses, and meets the needs of flexible production.

[0019] This utility model of a roller pressing positioning roller group adopts the same pneumatic adjustment structure as the side roller pressing unit. It can adjust the positioning force in real time according to the dynamic deformation of the profile during the conveying process, avoid the offset and shaking caused by the fixed guide wheel not being able to adapt to the deformation, reduce the scratches, indentations and edge collision deformation on the roller pressing surface, and improve the product qualification rate.

[0020] The strip support plate at the end of the machine tool of this utility model can provide targeted support for the profile during the roll forming process, preventing long profiles from bending and deforming downwards due to their own weight. Combined with the continuous support of the conveyor support table, it further ensures the stability of the roll forming process and improves the forming quality. Attached Figure Description

[0021] Figure 1 This is a first-view view of the alloy profile forming composite device of this utility model;

[0022] Figure 2 This is a second-view perspective view of the alloy profile forming composite device of this utility model;

[0023] Figure 3 This is a side view of the alloy profile forming composite device of this utility model;

[0024] Figure 4 This is a first-view view of Embodiment 2 of the present invention;

[0025] Figure 5 This is a bottom view of Embodiment 2 of the present invention;

[0026] Figure 6 This is a second perspective view of Embodiment 2 of this utility model.

[0027] In the diagram: 1. Machine base; 2. Side roller press unit; 3. Double-sided roller press unit; 4. Roller pressing positioning roller group; 5. Conveying support platform; 6. Roller pressing frame; 7. Fixed upright plate; 8. Cylinder A; 9. Rectangular block; 10. Roller pressing composite adjusting wheel; 11. Micro motor; 12. Mounting upright plate; 13. Surface roller pressing wheel A; 14. Servo motor; 15. Synchronous turntable; 16. Cylinder B; 18. Rotary shaft seat; 19. Surface roller pressing wheel B; 20. Strip support plate; 21. Receiving frame; 22. Drop chute; 23. Cylindrical rod; 24. Cleaning scraper. Detailed Implementation

[0028] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0029] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "installed", "equipped with", "sleeved with", "connected", etc., should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be a connection within two components. For those skilled in the art, the specific meaning of the above terms in this utility model can be understood according to the specific circumstances.

[0030] Example 1: Please refer to Figure 1-3 This utility model provides a technical solution: a composite device for forming aluminum alloy profiles for rail tracks. Its core structure revolves around a machine base 1, which is integrally cast from high-strength cast iron and precision ground to ensure the stability and flatness of the overall structure, providing a solid foundation for the subsequent installation and operation of each unit. Simultaneously, the machine base 1 integrates a PLC control system using a Siemens S7-1200 series PLC, possessing powerful data processing capabilities and flexible expansion performance, enabling precise control and coordinated operation of each unit.

[0031] The side roller pressing units 2, mounted on the surface of machine base 1, are symmetrically distributed on both sides of the machine base. Their core component, the roller pressing frame 6, is fixedly connected to machine base 1 by high-strength bolts, ensuring no displacement during high-intensity roller pressing operations. The fixed upright plates 7 and side plates on both sides of the roller pressing frame 6 are welded from 10mm thick alloy steel plates, possessing excellent deformation resistance. The cylinders A8, symmetrically mounted on the fixed upright plates 7 and side plates, are high-thrust models, maintaining a working pressure between 0.6-0.8MPa, providing sufficient power for adjusting the roller pressing gap. The control end of cylinder A8 is connected to a PLC control system. The PLC can precisely adjust the extension and retraction of cylinder A8 by controlling a solenoid valve according to preset profile width parameters, thereby achieving automatic adjustment of the roller pressing gap. The movable end of cylinder A8 extends through the fixed upright plate 7 and the other side plate, and is rigidly connected to a rectangular block 9 by bolts. The rectangular block 9 is made of 45# steel with a heat-treated surface roughness controlled below Ra1.6, ensuring precise fit with the roller pressing composite adjusting wheel 10.

[0032] A roll forming adjustment wheel 10 is vertically mounted between rectangular blocks 9 via high-precision bearings. This adjustment wheel 10 is made of Cr12MoV mold steel, hardened to HRC58-62, and its surface is precision polished to prevent scratches on the profile surface during roll forming. The roll forming adjustment wheel 10 uses cylinder A8 to adaptively adjust the side roll forming gap, fully meeting the processing requirements of profiles with different widths. The drive shaft at the bottom of the roll forming adjustment wheel 10 is connected to a micro motor 11 via a coupling. The micro motor 11 is a servo motor, and its control terminal is connected to a PLC control system. The PLC can precisely control the speed of the micro motor 11 via pulse signals according to the profile material and roll forming requirements. The speed can be steplessly adjusted within the range of 0-1500 r / min, achieving high-quality roll forming for profiles of different widths. In addition, the synchronous turntable 15 installed on the bottom shaft of the roller pressing composite adjustment wheel 10 has a diameter that matches the size of the side groove of the profile. During the roller pressing process, it can go deep into the groove for roller pressing and positioning, and control the roller pressing composite accuracy of the side surface within a certain error range. The PLC can monitor the positioning status in real time and make dynamic adjustments by receiving the position sensor signal installed at the synchronous turntable 15.

[0033] Three double-sided roller press units 3 are evenly arranged on the surface of the machine base 1, with a spacing of 1500mm between adjacent units, which can form a uniform roller pressing force on the profile. The mounting plate 12 of the double-sided roller press unit 3 uses the same material and processing technology as the fixed plate 7. The surface roller A13 is rotatably mounted in the cavity between the mounting plates 12 via bearings. Its structure is similar to the roller pressing composite adjusting wheel 10. The wheel surface is customized according to the shape of the upper surface of the profile to ensure perfect fit with the profile surface. The drive shaft of the surface roller A13 is connected to the servo motor 14 through a reduction gearbox. The servo motor 14 has a power of 5.5kW, and its control terminal is connected to the PLC control system.

[0034] The PLC can precisely control the speed and direction of the servo motor 14, thereby providing a powerful and stable rolling torque for the surface roller A13. The cylinder B16, mounted on the upper surface of the mounting plate 12, operates at the same pressure as cylinder A8. The control terminal of cylinder B16 is also connected to the PLC control system. The PLC can drive cylinder B16 to adjust the height of the surface roller B19 according to preset profile thickness parameters to accommodate profiles of different thicknesses. The surface roller B19 and surface roller A13 form a synchronous rolling structure for the upper and lower surfaces of the profile. The rolling pressure can be precisely adjusted by the PLC control system, ranging from 5-30 kN, ensuring consistent rolling quality on the upper and lower surfaces of the profile.

[0035] The roller positioning roller group 4, located in the partition cavity of the adjacent double-sided roller press group 3, has the same structure as the side roller press group 2, including a fixed upright plate 7, cylinder A8, rectangular block 9, roller pressing composite adjusting wheel 10, micro motor 11, and synchronous turntable 15. Each driving component of the roller positioning roller group 4 is connected to the PLC control system. During the profile conveying process, the PLC receives signals from the profile position detection sensor and determines in real time whether the profile shows a tendency to deviate. When a deviation is detected, the PLC quickly controls cylinder A8 to adjust the pressure of the roller pressing composite adjusting wheel 10, achieving pneumatic dynamic positioning of the profile and controlling the deviation within a certain range, effectively preventing the profile from deviating and colliding during conveying.

[0036] The conveying support platform 5, connected to the side roller press unit 2 and the roller positioning roller group 4, has a surface made of wear-resistant cast iron. This provides continuous and stable support for the profile while preventing damage from hard contact between the profile and the platform. The height of the conveying support platform 5 is flush with the lowest point of the surface roller A13, ensuring the profile remains horizontal throughout the rolling process. The conveying speed of the conveying support platform 5 is synchronously adjusted by the PLC control system based on the operating speed of each roller press unit, ensuring smooth profile conveying.

[0037] Furthermore, the strip support plate 20, made of high-strength aluminum alloy, is installed between the roller positioning roller group 4 at the end of the machine base 1 and the double-sided roller press group 3. It is mounted on the machine base 1 via an adjustable bracket, and its height adjustment mechanism is connected to the PLC control system. The PLC can automatically adjust the height of the strip support plate 20 according to the profile thickness parameters. The strip support plate 20 provides additional support for long profiles during roller pressing, effectively preventing the profiles from bending downwards due to their own weight, further improving the forming quality of the profiles.

[0038] The PLC control system is also equipped with a touch screen operating interface. Operators can input parameters such as the width and thickness of the profiles through the touch screen, and the system will automatically generate the corresponding processing parameters and control the coordinated work of each unit. At the same time, the touch screen can display the operating status and fault information of each unit in real time, which is convenient for operators to monitor and operate.

[0039] Example 2:

[0040] Please see Figure 4-6 This utility model provides a technical solution that is basically the same as that in embodiment 1, with the slight difference that: a receiving frame 21 is provided between the inner sides of the support legs at the bottom of the machine platform 1. The receiving frame 21 is made of stainless steel plate with a thickness of 2mm and is in the shape of a cuboid. Its length is adapted to the width of the machine platform 1 and is precisely adapted to the distance between the support legs of the machine platform 1 in embodiment 1.

[0041] The surface of the machine base 1 is provided with strip-shaped material drop troughs 22 at equal intervals. The number of material drop troughs 22 corresponds one-to-one with the three double-sided roller press units 3. Each material drop trough 22 is opened on the table surface of the machine base 1 directly below the surface roller A13. Each material drop trough 22 is provided with a cylindrical rod 23 inside. The cylindrical rod 23 is made of steel and has been heat treated. Both ends are fixed to the inner side walls of the two ends of the material drop trough 22 by bearings with seats. The bearings are high-precision deep groove ball bearings to ensure that the cylindrical rod 23 can rotate flexibly.

[0042] The upper end of the cylindrical rod 23 is equipped with a strip-shaped cleaning scraper 24, the length of which perfectly matches the length of the surface roller A13. The cleaning scraper 24 is fixed to the connecting seat at the upper end of the cylindrical rod 23 by countersunk bolts. The connecting seat has an elongated hole adjustment structure, which can be finely adjusted along the axial direction of the cylindrical rod 23 to ensure that the cleaning scraper 24 and the lower surface of the surface roller A13 are fully in contact. The upper edge of the cleaning scraper 24 is CNC machined into an arc shape, which perfectly matches the outer arc of the surface roller A13. The contact gap can be controlled within the range of 0.1 to 0.3 mm, ensuring the scraping effect while avoiding excessive pressure and damage to the roller surface.

[0043] The upper end of the cleaning scraper 24 is in close contact with the lower surface of the surface roller A13. When the surface roller A13 rotates under the drive of the 5.5kW servo motor 14 (the rotation speed is synchronized with that set in Embodiment 1), the cleaning scraper 24 continuously scrapes off the aluminum shavings, oxide scale, and other particulate residues attached to the roller surface. This avoids scratching the precision-polished roller surface. The scraped waste falls into the collection frame 21 through the discharge chute 22 under gravity, achieving centralized collection.

[0044] To further improve the cleaning effect, a small drive motor can be connected to one end of the cylindrical rod 23 via a coupling, according to customer needs. This motor is linked with the PLC control system (Siemens S7-1200) in Example 1. The PLC can adjust the rotation speed of the cylindrical rod 23 according to the real-time rotation speed of the surface roller A13 (obtained through the encoder signal of the servo motor 14) at a transmission ratio of 1:2, so that the cleaning scraper 24 and the wheel surface form a counter-movement, thereby enhancing the scraping force.

[0045] Specifically, during use, the various units work together to achieve efficient and precise processing. The specific process is as follows:

[0046] First, the operator inputs parameters such as the width and thickness of the profile to be processed through the touch screen of the PLC control system, and the system automatically generates the corresponding processing plan. The profile is fed into the device by the conveyor support platform 5. The speed of the conveyor support platform 5 is adjusted by the PLC to keep it synchronized with the operating rhythm of the subsequent roller presses, ensuring smooth conveying of the profile.

[0047] Upon entering the processing area, the side roller pressing unit 2 starts operation first. The PLC controls the extension and retraction of the cylinders A8 on both sides according to the preset width parameters, driving the rectangular block 9 and the roller pressing composite adjusting wheel 10 to move and automatically adjust to the appropriate roller pressing gap. Subsequently, the micro motor 11 drives the roller pressing composite adjusting wheel 10 to rotate, performing roller pressing on the side of the profile; at the same time, the synchronous turntable 15 at the bottom of the roller pressing composite adjusting wheel 10 is embedded in the groove on the side of the profile, achieving precise positioning during the roller pressing process and ensuring the roller pressing accuracy of the side surface. The PLC receives position sensor signals, monitors in real time, and dynamically adjusts the positioning status.

[0048] While being rolled on the side, the profile is conveyed to the double-sided roll forming unit 3. Three evenly distributed double-sided roll forming units 3 sequentially and synchronously process the upper and lower surfaces of the profile: the PLC controls the extension and retraction of cylinder B16 to adjust the height of surface roll forming roller B19 so that it forms a roll forming gap with surface roll forming roller A13 that is suitable for the profile thickness; the servo motor 14 drives surface roll forming roller A13 to rotate, which, together with surface roll forming roller B19, applies a roll forming pressure in the range of 5-30kN to the upper and lower surfaces of the profile. The PLC precisely controls the roll forming pressure and rotation speed to ensure that the roll forming quality of the upper and lower surfaces is consistent.

[0049] The roller positioning roller group 4 between adjacent double-sided roller press units 3 continues to function. Its structure is the same as that of the side roller press unit 2. During the profile conveying process, the PLC monitors the profile position in real time through the position detection sensor. When a deviation trend is detected, the PLC immediately controls the cylinder A8 to adjust the pressure of the roller pressing composite adjusting wheel 10 to form pneumatic dynamic positioning, control the deviation within a reasonable range, and prevent the profile from being damaged by collision.

[0050] For long profiles, the strip support plate 20 at the end of the machine 1 provides crucial assistance. The PLC automatically adjusts the height of the support plate according to the profile thickness parameters, ensuring that it fits against the lower surface of the profile, effectively preventing the profile from bending downwards due to its own weight. The support plate works in conjunction with the conveyor support table 5 to form a continuous and stable support system, ensuring the straightness of the profile during the rolling process.

[0051] Throughout the entire processing, the actions of each unit are controlled in tandem via a PLC system, with the touchscreen displaying real-time operating status and fault information. Once the profile has completed all rolling processes, it is output from the end of the device, completing a one-time forming composite processing step. Through the coordinated operation of all components, this device achieves simultaneous forming of the profile's sides and upper and lower surfaces, balancing processing efficiency and precision to meet the stringent processing requirements of aluminum alloy profiles for rail applications.

[0052] Finally, it should be noted that the above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Although the present utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A composite molding device for aluminum alloy profiles used in railway tracks, characterized in that, include: Machine base (1), the surface of machine base (1) is provided with: Side roll forming unit (2) is symmetrically distributed on both sides of the machine (1) to roll form the side of aluminum profile and adaptively adjust the roll spacing according to the width of aluminum profile. Double-sided roll forming unit (3) is evenly arranged on the surface of machine base (1) for synchronous roll forming of the upper and lower surfaces of aluminum profiles and is adapted to roll forming of aluminum profiles of different thicknesses; The roller positioning roller group (4) is located in the interval cavity of the adjacent double-sided roller press group (3) and is used to achieve dynamic positioning and anti-deviation by pneumatic roller pressing during the conveying of aluminum profiles. The conveying support platform (5) is connected to the side roller press unit (2) and the roller pressing positioning roller group (4) to provide continuous roller pressing conveying support for the profile.

2. The aluminum alloy profile forming composite device for railway tracks according to claim 1, characterized in that: The side roller press unit (2) includes a roller press frame (6). The roller press frame (6) has fixed upright plates (7) on both sides and cylinders A (8) symmetrically arranged on the side plates. The movable end of the cylinder A (8) extends through the fixed upright plate (7) and the other side of the side plate, and is fixed with a rectangular block (9).

3. The aluminum alloy profile forming composite device for railway tracks according to claim 2, characterized in that: The rectangular blocks (9) are vertically rotated with roller pressing adjustment wheel (10), and the roller pressing adjustment wheel (10) adjusts the side roller pressing distance through cylinder A (8); the transmission shaft at the bottom of the roller pressing adjustment wheel (10) is connected to a micro motor (11) to realize roller pressing composite of profiles of different widths.

4. The aluminum alloy profile forming composite device for railway tracks according to claim 3, characterized in that: The bottom shaft of the roller pressing composite adjustment wheel (10) is equipped with a synchronous turntable (15) for roller pressing and positioning in the groove on the side of the profile, so as to ensure the accuracy of roller pressing composite on the side surface.

5. The aluminum alloy profile forming composite device for railway tracks according to claim 1, characterized in that: The double-sided roller press unit (3) includes a mounting plate (12), and a surface roller A (13) is rotatably arranged in the cavity between the mounting plates (12). The drive shaft of the surface roller A (13) is connected to a servo motor (14). A cylinder B (16) is provided on the upper end face of the mounting plate (12). The top of the cylinder B (16) is rotatably arranged with a surface roller B (19) through a rotating shaft seat (18). The height of the surface roller B (19) is adjusted by the cylinder B (16) to adapt to profiles of different thicknesses.

6. The aluminum alloy profile forming composite device for railway tracks according to claim 5, characterized in that: The surface roller B (19) and the surface roller A (13) form a synchronous rolling structure for the upper and lower surfaces of the profile.

7. The aluminum alloy profile forming composite device for railway tracks according to claim 4, characterized in that: The structure of the roller pressing positioning roller group (4) is the same as that of the side roller pressing unit (2), including a fixed vertical plate (7), cylinder A (8), rectangular block (9), roller pressing composite adjustment wheel (10), micro motor (11) and synchronous turntable (15), which is used to position the profile during conveying and prevent offset collision.

8. The aluminum alloy profile forming composite device for railway tracks according to claim 6, characterized in that: A strip support plate (20) is provided between the roller positioning roller group (4) at the end of the machine (1) and the double-sided roller press group (3) to support the profile in the roller pressing and prevent it from bending and deforming downward.

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