DEVICE AND METHOD FOR FLEXIBLE ROLL FORMING OF A SEMI-PRODUCT

Description

BACKGROUND OF THE INVENTION 1. Field of the invention

[0001] The invention relates to a device and a method for the flexible roll forming of a semi-finished product, in particular a rolled sheet, into a profile with a cross-section varying along its longitudinal axis and / or with a varying longitudinal axis. 2. Description of the state of the art

[0002] Devices of the type mentioned above have been used in profiling technology for many years when rolled sheet metal, usually wound as a continuous strip on spindles, is to be used to produce profiles with a cross-section that varies along its length and / or with a varying longitudinal axis. In a profile with a varying longitudinal axis, this axis does not run along a straight line, but is curved in at least one plane.

[0003] Such systems meet the demand for increasingly unusual and freely designed profile shapes, particularly in facade and roofing technology. These so-called free-form profiles are primarily used as covering elements for exterior facades and roofs, which must meet high design requirements. Free-form profiles are frequently used, especially in construction projects with a certain prestigious character. Depending on the complexity of the free-form shape of the facade or roof, each individual profile used may have a unique shape.

[0004] In order to produce the required profiles as efficiently as possible, such flexible roll forming devices are usually brought directly to the construction site and sometimes even operated directly on the roof or facade in question.

[0005] These mobile and flexible roll forming devices are subjected to great stress during daily operation on the construction site and due to frequent transport, and the maintenance and repair costs are correspondingly high.

[0006] In stationary roll-forming devices, which cannot be moved from their fixed location without significant structural effort, as well as in mobile roll-forming devices, the transport and profiling of a rolled sheet is carried out in a conventional manner by driven profiling rollers. The profiling rollers, which are positioned very closely together, transfer the forming forces required for forming and transport to the rolled sheet through frictional engagement. The rolled sheet is conveyed through a roll gap formed between the profiling rollers, in which the forming forces required for forming are transferred to the rolled sheet.

[0007] DE 100 11 755 A1 discloses a device for roll forming longitudinally oriented components, comprising a frame with several support devices carried by the frame. Each support device is designed as a carriage and can be moved translationally relative to the frame by means of threaded spindles. A profiling unit, referred to as a stand half, is arranged on each support device. Each profiling unit has a pair of rotatably mounted rollers between which a roll gap remains. This known device can produce relatively small radii of curvature for the outer edges of profiles with cross-sections that vary along the longitudinal axis. A disadvantage of this design is that the profiling units are occasionally subjected to strong vibrations during operation due to the high forming forces required.This not only increases noise generation and susceptibility to material fatigue, but in the worst case can also have a negative impact on machining accuracy.

[0008] EP 1 676 654 A1, on which the preamble of claim 1 is based, discloses a roll forming system in which several support devices, referred to as forming station supports, each carry three profiling units. In one embodiment, the support devices, together with the profiling units carried thereon, are each translationally movable and rotatable about a vertical axis of rotation.

[0009] By arranging three profiling units, each on a support device, the system is more stable overall than the device described in DE 100 11 755 A1. A disadvantage of this known roll forming system is that only relatively large radii of curvature of the profile outer edges can be achieved in the profiling plane containing the longitudinal direction. This also applies if the profiling units are individually adjustable, as proposed in EP 1 676 654 A1, since even then, three profiling units are always mounted together on a support device.

[0010] Furthermore, EP 2 134 484 B1, WO 2012 / 091650 A1 and WO 2018 / 147773 A1 disclose roll forming systems which each have independently rotatable profiling units which are each individually attached to a separate frame part.

[0011] SE 135 00 12 A1 describes a roll forming system with pairs of profiling units. Two profiling units are directly connected to each other and can be moved relative to each other perpendicular to the conveying direction. The two profiling units can rotate together around a central axis located between the profiling units.

[0012] These designs can also be subject to increased vibrations during operation due to the high forming forces required, which can have a negative impact on machining accuracy in addition to increased noise and susceptibility to material fatigue. SUMMARY OF THE INVENTION

[0013] The object of the invention is therefore to provide a device and a method for the flexible roll forming of a semi-finished product, which counteracts the disadvantages of the prior art explained above and enables the production of free-form profiles with very small radii of curvature with low-vibration operation.

[0014] This object is achieved according to the invention with a device for the flexible roll forming of a semi-finished product, in particular a rolled sheet, of the type mentioned above, which device has a frame. Several support devices are carried by the frame, wherein the support devices are each mounted so as to be translationally movable relative to the frame and rotatably mounted. The device further has several profiling units, each of which has a pair of rotatably mounted rollers, between which a roll gap remains, which is dimensioned such that a semi-finished product, in particular a rolled sheet, can be conveyed along a conveying direction and simultaneously roll-formed by frictional engagement of the rollers.

[0015] While in the devices known from the aforementioned EP 1 676 654 A1, three profiling units are each supported by a common support device, in the device according to the invention, exactly two profiling units are arranged on each support device, mounted rotatably relative to the support device. As a result, the device according to the invention can produce profiles whose outer edges can have smaller radii of curvature than in the known device. In this case, the third profiling unit considerably limits the possible radii of curvature.

[0016] Compared to the device known from DE 100 11 755 A1, the device according to the invention has the advantage that two profiling units are connected to each other via a support device, thus forming an inherently rigid assembly despite the individual rotatability of the profiling units. The support device, which supports two profiling units compared to the known device and is therefore necessarily larger, can in turn be supported on the frame at opposite ends, reducing the risk of tilting vibrations due to the forming forces. This results in a more rigid overall structure for the device according to the invention, enabling low-vibration operation.

[0017] The device according to the invention therefore represents an optimal compromise as regards the achievable radii of curvature for the profile outer edges on the one hand and a low-vibration structure on the other.

[0018] If only one side of the semi-finished product is to be profiled, arranging the supports along a straight or curved line is sufficient. However, especially in facade and roofing technology, profiles are required that are profiled on both long sides by roll forming.

[0019] During the two-sided roll forming of a profile, the support devices and the profiling units mounted on them are preferably arranged in two rows running essentially parallel to each other and essentially parallel to a profiling plane when the device is at rest. Alternatively, the two rows of support devices can diverge, converge, or be arranged irregularly in the conveying direction. It is also possible to arrange the support devices offset from each other at a certain height in the conveying direction.

[0020] The profiling plane is defined by the orientation of the semi-finished product entering the fixture. While the longitudinal axis and cross-section of a semi-finished product to be roll-formed can change over the conveying and forming time, the profiling plane, once defined upon entry of the semi-finished product into the fixture, remains constant even if the height of the support fixtures changes.

[0021] In order to achieve maximum flexibility in the design of profiles with cross-sections varying along the longitudinal axis and / or with varying longitudinal axes, the inventor recognized that it is advantageous for the support devices and the profiling units they support to have several independent translational and rotational degrees of freedom. Independent degrees of freedom are understood to be rotational and translational axes around or along which at least one element of the support devices, the profiling units, or the frame can be rotated or moved translationally.

[0022] Preferably, at least one support device is rotatably mounted about a first axis of rotation arranged parallel to a first direction of rotation. At least one profiling unit is rotatably mounted about a second axis of rotation arranged parallel to a second direction of rotation. The support device is translationally movable parallel to a translation direction, wherein the first direction of rotation forms a first angle, preferably 90°, with the translation direction, and the second direction of rotation forms a second angle with the translation direction. The second axis of rotation runs through a processing point in the roll gap between the pair of rotatably mounted rollers of the at least one profiling unit.

[0023] This position of the second rotation axis allows the pair of rollers in each profiling unit to be aligned so that the machining point is optimally positioned relative to the outer profile edge of the semi-finished product being roll-formed. This, in turn, enables particularly precise machining accuracy.

[0024] In one embodiment, the pairs of rotatably mounted rollers each comprise a first roller and a second roller different from the first roller, wherein the first and second rollers each have at least one first forming section extending in the circumferential direction and a second forming section arranged offset in the axial direction and extending in the circumferential direction. The processing point is then located at the transition from the first forming section to the second forming section. The transition itself can be designed, for example, as a conical third forming section.

[0025] To keep the design of the device as simple as possible, it is advantageous if the first and second axes of rotation each run essentially parallel to one another and the direction of rotation of the axes of rotation is essentially orthogonal to the direction of translation of the translation axes. However, it is also possible for the first and second axes of rotation and the translation axes to be aligned entirely differently, thus resulting in multiple directions of rotation and multiple directions of translation for the support devices and the profiling units. The resulting asymmetrical rotation and travel behavior and / or the skewed rotation and translation axes of the support devices and profiling units can be compensated for, for example, by inclined components of the frame and / or varying basic geometric shapes of the support devices and / or another axis of rotation.Such an additional rotation axis can, for example, be a horizontal rotation axis for tilting the profiling units toward or away from the semi-finished product to be profiled. Compensation here means that the same profile shapes can be achieved.

[0026] It is advantageous if the first and second axes of rotation are each arranged eccentrically to the respective geometric center axis, since on the one hand the support devices can thus pivot further and on the other hand the angular positions of the profiling units can be adapted more precisely to the moving profile outer edge of the semi-finished product.

[0027] Preferably, the eccentricity is so large that, when the support devices each have an elongated basic shape with at least two shorter opposite sides, the first axis of rotation runs through a point on the support devices whose distance from one of the two shorter sides is at least twice as great as from the other side. Accordingly, when the profiling units each have an elongated basic shape with at least two shorter opposite sides, the second axis of rotation runs through a point on the profiling units whose distance from one of the two shorter sides is at least twice as great as from the other side.

[0028] With respect to both the first axes of rotation and the second axes of rotation, the ratio of the distances from the axes of rotation to the respective sides is preferably in a range from 2:1 to 25:1, but particularly preferably in a range from 5:1 to 15:1.

[0029] In order to make the device generally more stable so that it does not undergo undesirable vibration due to forming forces caused by compressive, tensile and shear forces at the forming points, the support devices in one embodiment are each supported on at least two support device bearing points.

[0030] In a further development, the support devices can have three support device bearing points instead of two. To efficiently utilize the available installation space, the support devices can each have two first support elements, wherein the two first support elements provide a first support device bearing point and a second support device bearing point. Furthermore, the support devices each have a first rotary element that defines the first axis of rotation and provides a third support device bearing point.

[0031] To further increase stability against forming forces, it is also possible to support the profiling units at at least two profiling unit bearing points.

[0032] Here, too, it is possible for the profiling units to have three profiling unit support points instead of two. The profiling units can each have two second support elements, with the two second support elements providing a first profiling unit support point and a second profiling unit support point. Each profiling unit has a second rotary element that defines the second rotation axis and provides a third profiling unit support point.

[0033] For example, the second pivot drives can each have a first transmission element, e.g., a curved rack, which engages with a second transmission element, in particular a gear. The two transmission elements can be arranged at a greater distance from the second axis of rotation.

[0034] The semi-finished products to be roll-formed in the plant, in particular rolled sheets, can preferably comprise ductile materials such as aluminum (Al), manganese (Mn), zinc (Zn), titanium (Ti), iron (Fe), or alloys of these materials. Particularly preferably, the semi-finished products to be roll-formed comprise aluminum (Al) and aluminum alloys. Elemental aluminum and aluminum alloys with a high aluminum content (e.g., over 75 atomic percent) have the special property of forming a passivating protective layer of aluminum oxide (AlO) or boehmite (AlO(OH)) upon contact with oxygen, which is impermeable to air, water, and a broad spectrum of light. This passivating protective layer thus protects the underlying aluminum or aluminum alloy from corrosion. Since this is a naturally occurring process, these materials are particularly suitable for further processing into profiles that are later used outdoors.

[0035] In the method according to the invention for the flexible roll forming of a semi-finished product, in particular a rolled sheet, into a profile with a cross-section varying along its longitudinal axis and / or a profile with a varying longitudinal axis, the above-mentioned object is achieved by the following steps: a) Providing a frame and a plurality of support devices carried thereby, wherein the support devices each carry exactly two profiling units, each having a pair of rotatably mounted rollers between which a roll gap remains; b) Translating and rotating the support devices relative to the frame and rotating the exactly two profiling units relative to the respective support device, while the semi-finished product is guided along a conveying direction through the roll gap.

[0036] The advantages mentioned for the device apply accordingly to the process.

[0037] In a preferred development of the method, a device is used which comprises some or all of the above-mentioned features. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] In the following, exemplary embodiments of the invention are explained in more detail with reference to the drawings. In these drawings: Figure 1 shows the device according to the invention in a perspective view; Figure 2 shows a perspective view of a combination of a support device and two profiling units carried by the same, each having a pair of corresponding profiling rollers; Figure 3 shows a reduced perspective view of an embodiment of a first pivot drive for pivoting the support devices; Figure 4 shows a longitudinal sectional view of a profiling unit according to the invention with a part of an upper support region of a support device, by which the profiling unit is carried; Figure 5a shows a reduced perspective view of an embodiment of a second pivot drive for pivoting the profiling units; Figure 5b shows a top view of the embodiment of the second pivot drive;Figures 6a and 6b show exemplary embodiments for a profile with a cross-section varying along the longitudinal axis and a profile with a varying longitudinal axis; Figure 7 shows an exemplary embodiment of a profile flower required to create a profile; Figure 8 shows a simplified representation of a profiling method known from the prior art with a desirable profile outer edge; Figure 9 shows the device according to the invention in a simplified plan view with a desirable profile outer edge. DESCRIPTION OF PREFERRED EMBODIMENTS

[0039] The Figure 1shows a device, designated overall by 10, for the flexible roll forming of a semi-finished product 12, which in the illustrated embodiment is a rolled sheet. Through roll forming, the semi-finished product 12 is transformed into a profile having a cross-section and / or a varying longitudinal axis that varies along its longitudinal axis. An example of a profile with a varying longitudinal axis is shown in the device explained below. Figure 6a shown and labeled 12'. The Figure 6b shows a 12" profile with a cross-section varying along its longitudinal axis.

[0040] In the illustrated embodiment, a frame 14 extends along a conveying direction F, carrying several support devices in the form of plate-shaped swivel tables 16. Each swivel table, in turn, carries exactly two profiling units 18. A pair 20 of rollers 20', 20" is rotatably mounted on each of the profiling units 18, which serve to profile the semi-finished product 12 in a manner known per se.

[0041] The swivel tables 16 and the profiling units 18 carried by them are arranged in two rows essentially parallel to each other and parallel to the conveying direction F. As best seen in the enlarged section of the Figure 2 can be removed, the profiling units 18 are aligned such that end faces 22 of the profiling rollers 20', 20" are aligned orthogonally to the conveying direction F and face each other in pairs.

[0042] In embodiments not specifically shown, the pivoting tables 16 and thus also the profiling units 18 carried by them are arranged alternately with one another, for example, in a zigzag pattern. Furthermore, it is not essential for the feasibility of the invention that the profiling units 18 are arranged in two substantially parallel rows, in rows parallel to the conveying direction F, or with the end faces 22 of the profiling rollers 20', 20" orthogonal to the conveying direction. Furthermore, it is conceivable to arrange the profiling units 18 at different heights or inclined to the vertical. Depending on the specific application area, location, or profile shape, the profiling units 18 can be arranged and / or tilted in almost any three-dimensional orientation, whereby the orientation and / or position can be individual for each profiling unit 18.

[0043] The profiling device 10 is intended and configured to convey a semi-finished product 12 along the conveying direction F and to profile it in order to obtain the profile 12', 12''. Profiling in this context is understood to mean any type of change in shape of the semi-finished product 12, in particular a rolled sheet, with a thickness of up to 5 mm, which is flat at the time of clamping in the device 10.

[0044] For this purpose, each combination of swivel table 16 and profiling units 18 is movable in at least two degrees of freedom, namely translationally movable and pivotable.

[0045] How best in the Figure 2As can be seen, in the illustrated embodiment, the swivel tables 16 carried by the frame 14 can each be moved along a translation axis T n , which here runs perpendicular to the conveying direction F. In addition, the swivel tables 16 can be pivoted about a first axis of rotation D1 n , where n ≥ 2 stands for the n-th combination of a swivel table 16 and two profiling units 18.

[0046] Each swivel table 16 can be moved along the translational axis T n by means of a translational drive 24. In the present embodiment, the swivel table 16 is moved along the translational axis T n by means of a ball screw 26 that runs parallel to the translational axis T n. For this purpose, the ball screw 26 is rotated by an electric motor 28. This causes a translational movement of the swivel table 16 along the ball screw 26 in a manner known per se.

[0047] To generate a motorized linear movement along the translation axes T n, it is also possible to use a roller screw drive, a hydraulic or pneumatic cylinder, a linear motor or another electromechanical linear drive.

[0048] The swivel tables 16 are each mounted for translational movement on two lateral rail elements 30 formed on the frame 14. For example, the two rail elements 30 here have an I-shaped profile, which is surrounded by rail guides 32 and forms a plain bearing with them. Alternatively, guides with roller bearings can of course also be used.

[0049] In the present exemplary embodiment, each assembly comprising the support device 16 and the two profiling units 18 is arranged on a support element arranged between the frame 12 and the support device 16, which in this case is designed as a plate-shaped support table 34. The rail guides 32 are formed on the underside of the support tables 34, whereby each support table 34, together with the pivoting table 16 carried thereby, can be moved translationally along the translation axis T n relative to the frame 14. A support element, which does not necessarily have to be designed as a support table, is required to make the respective pivoting table 16 translationally movable and pivotable independently of one another.

[0050] How best in the Figure 2As can be seen, each swivel table 16 has a first rotating element in the form of a first axial rotary shaft 36, which is rotatably received in a rotary bearing 38 of the support table 34. The rotary shaft and the rotary bearing 38 together define the first axis of rotation D1 n of the swivel table 16, which in turn runs parallel to a first direction of rotation.

[0051] By means of a first pivot drive 40, the pivot table 16 can be pivoted relative to the support table 34 and thus also relative to the frame 14 about the first axis of rotation D1 n. The pivoting movement is generated by the pivot drive 40. In the Figure 2 The swivel drive 40 is only indicated schematically. The swivel drive can, for example, comprise a hydraulically controlled lever that connects the support table 34 to the swivel table 16. A drive using a recirculating ball screw can also be considered for generating the swivel movement.

[0052] The first axis of rotation D1 n passes through a point 42 of the elongated swivel table 16, the distance AD ​​of which to one side 44 of two shorter opposite sides 44, 44' is at least twice as large as the distance AD ​​' to the other side 44'.

[0053] In the present embodiment, the two profiling units 18 can also be pivoted about second axes of rotation D2 n by means of a second pivot drive 45, each of which is defined by second rotary elements in the form of second axial rotary shafts 46. Similar to the first axes of rotation D1 n, the second axes of rotation D2 n each pass through a point 48 of the profiling units 18, the distance AP of which to one side 50 of two shorter opposite sides 50, 50' is more than twice as large as the distance AP ' to the other side 50'.

[0054] This eccentric arrangement of the second rotation axes D2 n results in different rotational pivoting paths of the two sides 50, 50'. An actuator arranged on the side 50 with the longer pivoting path can therefore adjust the pivoting angle of the profiling unit 18 and thus of the rollers 20', 20'' particularly precisely due to the longer lever.

[0055] In Figure 3 an area 56 is shown between the swivel table 16 and the support table 34. To increase the mechanical load-bearing capacity and reduce vibrations, each swivel table 16 has, according to the invention, at least two, in the present embodiment, three support device bearing points L1 D , L2 D , and L3 D , at which the swivel table 16 is supported and which are provided by three support elements 52, 52'; 54.

[0056] In the Figure 3Furthermore, a parallelogram pivoting device 58 is visible, which is arranged between the pivoting table 16 and the support table 34 and provides the first two support device bearing points L1 D , L2 D. For dual bearing, the parallelogram pivoting device 58 has a first guide element designed as a transverse rail element 60, which is fastened to the support table 34 and runs transversely to the conveying direction F, as well as two second guide elements designed as longitudinal rail elements 62, which are fastened to the pivoting table 36 and run along the conveying direction F. Alternatively, the transverse rail element 60 can also be formed by the rail elements 30 provided by the frame 14.

[0057] The transverse rail element 60 and the longitudinal rail elements 62 are slidably connected to one another via two pivoting elements designed as guide carriages 64, wherein the guide carriages 64 are each arranged to be movable along the rail elements 60, 62. For this purpose, the guide carriages 64 have first connecting means designed as transverse grippers 66 that engage around the longitudinal rail elements 62, and second connecting means designed as longitudinal grippers 68 that engage around the transverse rail elements 60. These grippers 66, 68 ensure that the guide carriages 64 cannot be detached from the rail elements 60, 62 by a tensile force that acts essentially in the opposite direction to the direction of the gravitational force or at an angle α < 90° to this direction. For this purpose, it would be necessary to move the guide carriages 64 out of the rail elements 60, 62 in the respective travel direction.

[0058] As a result, the swivel table 16 is connected to the support table 34 in a form-fitting and particularly stable manner, which counteracts the formation of vibrations.

[0059] To enable the swivel table 16 to perform a rotating or pivoting movement, the guide carriages 64 have rotating structures 70, which in the present embodiment are designed as a pair of axial rotary cylinders 70a, 70b, with each rotary cylinder 70a projecting into the other rotary cylinder 70b in such a way that rotation of the rotary cylinders 70a, 70b relative to one another is enabled. When the swivel table 16 is pivoted counterclockwise, both guide carriages 64 move away from the viewer, with the rotary movement of the swivel table 16 being effected by a combination of a rotational twist of the rotary cylinders 70a, 70b relative to one another and a translational movement of the guide carriages 64 along the longitudinal rail elements 62. Clockwise pivoting requires correspondingly reversed movement sequences of the elements of the parallelogram pivoting device 58.

[0060] How best to see in the side view of the Figure 4As can be seen, the second pivot drive 45 in the present embodiment is arranged below the profiling unit 18. In the perspective view of the Figure 5a and the top view of the Figure 5b It can be seen that the second pivot drive 45 has a first and a second drive element, which here is designed as a gear 72 or as a curved rack 74, which is meshed by the gear 72. The curved rack 74 is attached to a support foot 86 of the profiling unit 18 by fastening means 82 and via axial bores 84.

[0061] A gear wheel 72 is attached to the swivel table 16, which is driven by a Figure 4 shown motor 47 is driven via a gear axle pin 76. Rotation of the gear 72 causes the profiling unit 18 to pivot about the second axis of rotation D2 n .

[0062] During a pivoting movement of the profiling unit 18 generated by the gear 72, the curved rack 74 runs on swivel rollers 78, 78', which form second support elements and are fastened to the swivel table 16 below the curved rack 74. The directions of rotation of the axes of rotation 80, 80' of the swivel rollers 78, 78' essentially run through the second axis of rotation D2 n . Compared to a parallel alignment of the axes of rotation 80, 80' to one another, this means that the curved rack 74 can roll on the swivel rollers 78, 78' with less frictional resistance.

[0063] In addition to reducing friction, the swivel rollers 78, 78' in the present embodiment have another function: they provide a first profiling unit bearing point L1 F and a second profiling unit bearing point L2 F for the profiling unit 18. The second axial rotary shaft 46, which is connected to both the swivel table 16 and the profiling unit 18, forms a third support element 79 of the second support elements 78, 78'; 79 and thus provides a third profiling unit bearing point L3 F.

[0064] The three relatively widely spaced profiling unit bearing points L1 F , L2 F and L3 F absorb the static and dynamic forces and contribute to the stability of the device 10.

[0065] How to Figure 4As can be seen, the profiling units 18 each have a framework element in the form of an angle 92, to which two second swivel rollers 94 are fastened, which provide two abutment points 96. Together with the above-mentioned swivel rollers 78, 78' on the underside of the rack 74, the two further swivel rollers 94 prevent the profiling unit 18 from tilting about a tilt axis arranged perpendicular to the paper plane when forming forces in a vertical direction act on the rollers 20', 20''. This measure also reduces the tendency towards unwanted vibrations.

[0066] As in the Figure 2 and 4 As can be seen, the axis of rotation D2 n , about which the profiling units 18 can be pivoted, runs through a processing point 98, 100 which is located in a roll gap 102 formed between the pair 20 of rollers 20', 20" of the profiling units 18.

[0067] The rollers 20', 20" each have a plurality of sections: a first circumferentially rotating forming section 104 and a second circumferentially rotating forming section 106 different from the first circumferentially rotating forming section. A third circumferentially rotating forming section 108 different from the forming sections 104, 106 can also be formed at the transition from the first forming section 104 to the second forming section 106.

[0068] At the transition from the first forming section 104 to the second forming section 106, a first forming edge 110 can be formed, which transfers a large portion of the forming forces required for profiling to the semi-finished product 12 to be profiled. In the present embodiment, the transition forms the third forming section 108. Accordingly, an additional second forming edge 112 is formed at the transition from the third forming section 108 to the second forming section 106.

[0069] At the in the in Figure 4 In the illustrated and particularly preferred embodiment, the rotation axis D2 n runs through a processing point 98, 100 located at one of the forming edges 110, 112. Thus, the angle of the profiling units 18 can be optimally adapted to a progressive and changing profile outer edge 114 to be profiled, because the profiling units 18 can always be pivoted precisely around one of the forming points 98, 100 as the curvature of the profile outer edge 114 changes.

[0070] In Figure 6In each case, a profile 12' made from a semi-finished product 12 with a cross-section varying along its longitudinal axis LK and a profile 12" with a varying longitudinal axis XV are shown by way of example. Profiles which have both a varying longitudinal axis XV and a cross-section varying across the varying longitudinal axis XV are not specifically shown, although the device 10 is also suitable for producing such profiles.

[0071] In this context, changing longitudinal axes XV are understood to mean continuous longitudinal axes XV with curvature. The longitudinal axes XV can have curvatures not only in two dimensions, but also in three dimensions.

[0072] In Figure 7A possible profile flower is shown as an example, designated 116, which illustrates in a simplified representation different profiling steps for profiling a profile 12', 12". For each of the profiling steps, a separate pair 20 of corresponding profiling rollers 20', 20'' is required, each of which forms a roll gap 102, the shape of which in longitudinal section corresponds to that of the profile 12', 12" in the respective profiling step.

[0073] In Figure 8is a plan view of a prior art assembly comprising a support device 16 and three profiling units 18 carried by it. It can be seen that due to the rotatability of the support device 16, only one profiling unit 18 can be optimally aligned to the profile outer edge 114 at a time. However, if the curvature of the profile outer edge 114 is large (i.e., small radii of curvature r K ), not all profiling units can be aligned to the profile outer edge 114 at the same time in such a way that optimal forming (or any forming at all) is possible.

[0074] In comparison, Figure 9a section of the device 10 according to the invention in a plan view. Since each swivel table 16 carries only two profiling units 18, which are also individually pivotable, the device 10 overall - with the same number of profiling units - has significantly more degrees of freedom compared to conventional devices of this type, which can be used to adapt the profiling units 18 to the profile outer edge 114. Assuming that the profiling units can be pivoted through any desired pivot angle, two profiling units 18 on a swivel table 16 can be adapted to almost any desired small radii of curvature. If, however, as in the prior art, three profiling units are mounted on a rotary table, this does not apply even if the profiling units could also be pivoted through any desired angle on the rotary table.

[0075] To the Figure 9To achieve the adjustment of the position of the profiling units to the profile outer edge 114 shown, several individual movements are carried out one after the other or simultaneously. Figure 9 The combination of swivel table 16 and profiling units 18 shown above performs, for example, the following movements: 1. a translational movement of the swivel table 16 in the direction of the profile outer edge 114 to be profiled; 2. a clockwise swivel movement of the swivel table 16; 3. a clockwise swivel movement of the upper of the two profiling units 18; and 4. a counterclockwise swivel movement of the lower of the two profiling units 18.

[0076] The one in the Figure 9 The combination of swivel table 16 and profiling units 18 shown below, for example, performs the following related movements: 1. a translational movement of the swivel table 16 in the direction of the profile outer edge 114 to be profiled; 2. a counterclockwise swivel movement of the swivel table 16; 3. a counterclockwise swivel movement of the lower of the two profiling units 18.

[0077] This movement sequence causes the Figure 9 Adaptation of the profiling units 18 to the curvature of the profile outer edge 114, shown as an example.

[0078] In an embodiment not specifically illustrated, it is possible to move the swivel tables 16 along additional translation directions. It is also possible to configure the swivel tables 16 such that they are also rotatable about a rotation axis running parallel to the profiling plane EP and in the direction of the conveying direction F. This allows the swivel tables 16 and the profiling units 18 supported by them to be tilted toward the profiling plane EP or away from it.

Claims

1. Device (10) for flexibly roll forming a semi-finished product (12), in particular a rolled sheet, into a profile (12', 12") having a cross-section varying along the longitudinal axis thereof and / or having a varying longitudinal axis, the device comprising a frame (14), a plurality of support devices (16) carried by the frame (14), the support devices (16) each being translationally movable relative to the frame (14) and rotatably mounted, a plurality of profiling units (18), each having a pair (20) of rotatably mounted rollers (20', 20"), between which a roller gap (102) remains, characterized in that on each support device (16) exactly two profiling units (18) are arranged so as to be rotatably mounted relative to the support device (16).

2. Device (10) according to claim 1, characterized in that at least one support device (16) is rotatably mounted about a first axis of rotation (D1n)which is in parallel with a first direction of rotation, at least one profiling unit (18) is rotatably mounted about a second axis of rotation (D2n) which is in parallel with a second direction of rotation, the support device (16) is translationally movable in parallel with a direction of translation, the first direction of rotation forms a first angle with the direction of translation and the second direction of rotation forms a second angle with the direction of translation, and in that the second axis of rotation (D2n) extends in each case through a processing point (98, 100) in the roller gap (102) between the pair (20) of rotatably mounted rollers (20', 20") of the at least one profiling unit (18).

3. Device (10) according to claim 2, characterized in that the pairs (20) of rotatably mounted rollers (20', 20") each comprise a first roller (20') and a second roller (20") different from the first roller, in that the first and second rollers (20', 20") each have at least one first forming portion (104) rotating in the circumferential direction and a second forming portion (106) arranged offset from the first in the axial direction and rotating in the circumferential direction, and in that the processing point (98, 100) is arranged at the transition from the first forming portion (104) to the second forming portion (106).

4. Device (10) according to any of the preceding claims, characterized in that the support devices (16) are each supportingly mounted at at least two support device bearing points (L1D, L2D, L3D).

5. Device (10) according to claim 4, characterized in that the support devices (16) each have two first support elements (52, 52'), the two first support elements (52, 52') providing a first support device bearing point (L1D) and a second support device bearing point (L2D) and in that the support devices (16) each have a first rotation element (36) which defines the first axis of rotation (D1n) and provides a third support device bearing point (L3D).

6. Device (10) according to any of the preceding claims, characterized in that the profiling units (18) are each supportingly mounted at at least two profiling unit bearing points (L1P, L2P, L3P).

7. Device (10) according to claim 6, characterized in that the profiling units (18) each have two second support elements (78, 78'), the two second support elements (78, 78') providing a first profiling unit bearing point (L1P) and a second profiling unit bearing point (L2P), and in that each profiling unit (18) has a second rotation element (46) which defines the second axis of rotation (D2n) and provides a third profiling unit bearing point (L3P).

8. Device (10) according to any of claims 4 to 7, characterized in that exactly two stand elements (92) are arranged on the support device (16), each of which stand elements provides at least two abutment points (96) for the profiling units that are different from the bearing points (L1D, L2D, L3D; L1P, L2P, L3P).

9. Method for flexibly roll forming a semi-finished product (12), in particular a rolled sheet, into a profile (12', 12") having a cross-section varying along the longitudinal axis thereof and / or having a varying longitudinal axis, the method comprising the following steps: a) providing a frame (14) and a plurality of support devices (16) carried thereby, wherein the support devices (16) each carry exactly two profiling units (18), each having a pair (20) of rotatably mounted rollers (20', 20"), between which a roller gap (102) remains; b) translationally moving and rotating the support devices (16) relative to the frame (14) and rotating the exactly two profiling units (18) relative to the corresponding support device (16), while the semi-finished product (12) is guided in a conveying direction (F) through the roller gap (102).

10. Method according to claim 9, characterized in that a device (10) according to any of claims 1 to 8 is used.