Strength member manufacturing equipment

Abstract

To provide a manufacturing apparatus of a strength member capable of reducing a manufacturing cost of the strength member of a honeycomb structure.SOLUTION: A manufacturing apparatus (10) of a strength member includes: a slit formation part (30) which forms a slit (2) on a position suitable to a shape of the strength member (9) of a honeycomb structure of a manufacturing target, with respect to a plate material (1); a wave-form processing part (40) which processes the plate material (1) into a wave form along a conveyance direction of the plate material (1) formed of the slit (2); and bending parts (50, 60) which push the plate material (1) by means of bending members (51a, 52b) from thickness directions of the plate material (1) along folding line parts (4,6) of the wave-form processed plate material (1), bend the plate material (1), and form a strength member (7) of the honeycomb structure.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] The present invention relates to a manufacturing method and apparatus for strength members that can be used as reinforcing materials, building materials, wall materials, etc. Place In particular, manufacturing equipment for honeycomb structural members that are lightweight and have high strength properties. Place Regarding. [Background technology]

[0002] A honeycomb-structured strength member, which is a structure in which hexagonal cylindrical parts are packed together, is known. The honeycomb-structured strength member is known to be a lightweight, high-strength strength member, and is a promising building material for use as a reinforcing material or wall material for automobiles, a building material for buildings, and an exterior or interior wall material for trains and aircraft. As a method for manufacturing a reinforcing member having a honeycomb structure, the technique described in Patent Document 1 is conventionally known. Patent Document 1 (JP 2018-167286 A) describes a technology for producing a honeycomb panel by processing a flat plate into a corrugated plate, forming slits, folding the plate at the slits, and crimping the plate to secure the plate in place. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2018-167286 A (Figs. 1 and 4) Summary of the Invention [Problem to be solved by the invention]

[0004] (Problems with the Prior Art) In the manufacturing method described in Patent Document 1, a base material that has been processed into a corrugated shape is prepared in advance, and then slits are formed in the corrugated base material and it is folded. In the manufacturing method described in Patent Document 1, it is necessary to manufacture the corrugated sheet separately, and the entire process of manufacturing the honeycomb core panel from the flat sheet material cannot be automated. Therefore, there is a problem that mass production or continuous production is difficult, and cost reduction is difficult.

[0005] An object of the present invention is to reduce the manufacturing costs of strength members having a honeycomb structure. [Means for solving the problem]

[0006] In order to solve the above technical problem, the manufacturing apparatus for a strength member of the invention described in claim 1 comprises: A conveying unit that conveys unprocessed plate materials; a slit forming section for forming slits in the plate material conveyed by the conveying section at positions corresponding to the shape of a strength member of a honeycomb structure to be manufactured; a corrugation processing section that is disposed downstream of the slit forming section in the conveying direction of the plate material and processes the plate material into a corrugated shape along the conveying direction of the plate material by forming alternate concaves and convexes in the thickness direction of the plate material while conveying the plate material with the slits formed therein without cutting the plate material; a bending section that is disposed downstream of the corrugation section in the conveying direction of the plate material, and that conveys the corrugated plate material without cutting it, and presses the plate material with a bending member in the thickness direction of the plate material along the folding line on the extension of the slit to bend the plate material, thereby creating a strength member of a honeycomb structure; The present invention is characterized by comprising:

[0007] In order to solve the above technical problem, the manufacturing apparatus for a strength member of the invention described in claim 2 comprises: A conveying unit that conveys unprocessed plate materials; a slit forming section for forming slits in the plate material conveyed by the conveying section at positions corresponding to the shape of a strength member of a honeycomb structure to be manufactured; a corrugation processing unit that processes the plate material into a corrugated shape along a conveying direction of the plate material by alternately forming concaves and convexes in a thickness direction of the plate material on the plate material having the slits formed therein; a bending section which bends the corrugated plate material by pressing the plate material in the thickness direction along the folding line on the extension of the slit with a folding member, and which completely folds the plate material by narrowing the width direction of the plate material toward the downstream side in the conveying direction while pressing the plate material in the thickness direction bent by the folding member to create a strength member of a honeycomb structure; The present invention is characterized by comprising:

[0008] The invention as set forth in claim 3 is the manufacturing apparatus for a strength member as set forth in claim 1 or 2, The corrugation processing unit has a pair of forming rolls arranged at a position sandwiching the plate material along the thickness direction of the plate material; Equipped with At least one of the pair of forming rolls is relatively movable along a thickness direction of the plate material, The distance between the pair of forming rolls in the thickness direction is set according to the strength members of the honeycomb structure to be manufactured. It is characterized by:

[0009] The invention as set forth in claim 4 is the manufacturing apparatus for a strength member as set forth in claim 1 or 2, A pair of bending shafts arranged opposite to each other across the plate material in the thickness direction of the plate material; A bending member supported on the bending shaft and contacting and pushing the passing plate material from a thickness direction, the bending member supported movably along a width direction of the plate material; The present invention is characterized by comprising: Effect of the Invention

[0010] Claim 1, 2 to According to the described invention, the plate material is sequentially slit-formed, corrugated, cut, and bent, which reduces the manufacturing costs of honeycomb-structured strength members compared to conventional techniques that require the preparation of corrugated plate material in advance. In addition, claims 1 toAccording to the described invention, slitting, corrugation and bending can be performed continuously without cutting the sheet material. Furthermore, claims 2 to According to the described invention, while holding down the thickness direction of the plate material, the width direction of the plate material is narrowed as it moves downstream in the conveying direction, and the plate material can be folded by pushing the plate material from the thickness direction along the fold line with a bending member, and a strength member can be created from the plate material as it is sent downstream. According to the invention as recited in claim 3, the distance between the forming rolls can be adjusted to allow fine adjustment according to the position of the slit. According to the invention as recited in claim 4, folding can be performed reliably at the folding line position, compared to a configuration in which the folding member cannot move in the axial direction. [Brief description of the drawings]

[0011] [Figure 1] FIG. 1 is an explanatory diagram of the manufacturing process of the honeycomb-structured strength member of Example 1, in which FIG. 1A is an explanatory diagram of the plate material before processing, FIG. 1B is an explanatory diagram of the plate material after slits are formed, FIG. 1C is an explanatory diagram of the plate material after corrugation processing, and FIG. 1D is an explanatory diagram of the honeycomb core after bending along the slits. [Diagram 2] FIG. 2 is an overall explanatory view of a manufacturing apparatus for a strength member according to the present invention. [Diagram 3] 3A is an explanatory diagram of the slit forming portion of the first embodiment, FIG. 3B is an explanatory diagram of a first modified example of the first embodiment, and FIG. 3C is an explanatory diagram of a second modified example of the first embodiment. [Figure 4] FIG. 4 is an explanatory diagram of the corrugation forming unit of Example 1, in which FIG. 4A is a schematic diagram of the corrugation forming roll of Example 1, and FIG. 4B is a side view. [Diagram 5] FIG. 5 is an explanatory diagram of the bending device of the first embodiment. [Figure 6] 6A and 6B are explanatory views of the folding process of the first embodiment, in which FIG. 6A is an explanatory view of the state before folding, FIG. 6B is an explanatory view of the state after folding, and FIG. 6C is a side view. [Figure 7] FIG. 7 is an explanatory diagram of the finishing device of the first embodiment, FIG. 7A being a perspective view and FIG. 7B being a top view. [Figure 8] FIG. 8 is a functional block diagram of the control unit according to the first embodiment. [Figure 9] 9A and 9B are explanatory views of the corrugation process in the first embodiment, where FIG. 9A is an explanatory view when the center distance is long, and FIG. 9B is an explanatory view when the center distance is short. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] Next, specific examples of the present invention will be described with reference to the drawings. However, the present invention is not limited to the following examples. In the following description using the drawings, illustrations of components other than those necessary for the description are omitted as appropriate to facilitate understanding. EXAMPLES

[0013] FIG. 1 is an explanatory diagram of the manufacturing process of the honeycomb-structured strength member of Example 1, in which FIG. 1A is an explanatory diagram of the plate material before processing, FIG. 1B is an explanatory diagram of the plate material after slits are formed, FIG. 1C is an explanatory diagram of the plate material after corrugation processing, and FIG. 1D is an explanatory diagram of the honeycomb core after bending along the slits. In FIG. 1, when a honeycomb core is produced as an example of a strength member of Example 1, first, in a slit forming step, a plurality of slits (notches) 2 are formed in a flat plate 1 shown in FIG. 1A as shown in FIG. 1B. The slits 2 are formed, for example, by a roller having a cutting blade or It can be formed by cutting with a mold or a laser cutter.

[0014] 1B, the slits 2 of Example 1 are formed by alternately forming first slits 2a and second slits 2b at intervals in the width direction of the flat plate 1 intersecting with the conveying direction Ya of the flat plate 1. The first slits 2a are arranged at intervals along the conveying direction Ya of the flat plate 1. The second slits 2b are arranged at intervals along the conveying direction Ya of the flat plate 1 and are formed at positions shifted from the first slits 2a in the conveying direction Ya. The first slit 2a and the second slit 2b are not limited to the shape illustrated in FIG. 1, and may be shaped as described in Patent Document 1, for example.

[0015] In FIG. 1B and FIG. 1C, after the slit forming step, in the corrugation process, the flat plate 1 with the slits 2 formed therein is processed into a corrugated shape along the conveying direction Ya of the flat plate 1 as shown in FIG. 1C by forming concaves and convexes alternately in the thickness direction of the flat plate 1. The corrugated plate can be processed by, for example, sandwiching the plate between rolls having a gear-like cross section or by using a press machine. In the corrugation process of the first embodiment, the plate is folded along the valley fold lines shown by the dashed lines and the mountain fold lines shown by the dashed lines in FIG. 1B to be corrugated. Thus, the corrugated flat plate 1 has a top wall 3a as an example of a first wall portion, a bottom wall 3b as an example of a second wall portion disposed below the top wall 3a in the thickness direction, and an inclined wall 3c as an example of an inclined portion connecting the top wall 3a and the bottom wall 3b. Each of the walls 3a to 3c extends in the width direction of the flat plate 1. Also, as shown in FIG. 1C, in Example 1, a mountain fold line 4 (see the dotted line in FIG. 1C) as an example of a fold line is set on the bottom wall 3b on the extension of the first slit 2a, and a valley fold line 6 (see the dashed line in FIG. 1C) as an example of a fold line is set on the top wall 3a on the extension of the second slit 2b.

[0016] The flat plate 1 that has been continuously processed into a corrugated shape is folded along the mountain fold lines 4 and the valley fold lines 6 in a folding process to produce a honeycomb core 7 as an example of a strength member of a honeycomb structure. Then, in the dividing step, the honeycomb core 7 is divided at positions according to the size of the honeycomb core 7 to be manufactured. In the first embodiment, the flat plate 1 is folded and then divided after the corrugation process, but the present invention is not limited to this. For example, the flat plate 1 may be divided after the corrugation process, and then the divided corrugated flat plate 1 may be folded along the slits 2, the mountain fold lines 4, and the valley fold lines 6 to produce a honeycomb core 7 in which cylindrical parts having a hexagonal cross section are filled in a plane.

[0017] A honeycomb core panel can be produced by joining face plates to both end faces of the produced honeycomb core 7. The corrugated plate 1 in the folding process is folded using a folding device 50 and a finishing device 60 described below, but is not limited thereto and can be folded by various conventionally known methods, such as the device described in Patent Document 1. The face plates can be joined by any conventionally known method, such as hot melt technology, spot welding, or applying an adhesive to the end face of the honeycomb core 7 and then bonding the face plates.

[0018] FIG. 2 is an overall explanatory view of a manufacturing apparatus for a strength member according to the present invention. 3A is an explanatory diagram of the slit forming portion of the first embodiment, FIG. 3B is an explanatory diagram of a first modified example of the first embodiment, and FIG. 3C is an explanatory diagram of a second modified example of the first embodiment. FIG. 4 is an explanatory diagram of the corrugation forming unit of Example 1, in which FIG. 4A is a schematic diagram of the corrugation forming roll of Example 1, and FIG. 4B is a side view.

[0019] In FIG. 2, a honeycomb core manufacturing apparatus 10 is shown as an example of a manufacturing apparatus for a strength member of the present invention. has a supply device 20 as an example of a conveying section. The supply device 20 has a delivery roller 21 and a conveying roller 22 that sandwiches and conveys the flat plate 1. The delivery roller 21 supports a supply roll 11 on which the flat plate 1 as an example of a plate material is wound in a roll shape. A drive is transmitted to the conveying roller 22 from a conveying motor (not shown), and the conveying roller 22 conveys the flat plate 1 downstream when the drive is transmitted. Note that the conveying roller 22 in the first embodiment is driven intermittently to convey the flat plate 1 in order to stop the flat plate 1 every time it is cut at a cutting section described later, but if it is not necessary to stop it when cutting, it may be driven continuously. In the first embodiment, the thickness and material of the flat plate 1 can be changed as desired depending on the strength, weight, etc. of the honeycomb core to be manufactured. Therefore, it is possible to use a thick and hard plate material such as a stainless steel plate, or a thin and soft plate material such as an aluminum foil.

[0020] 2 and 3, a slit forming device 30 as an example of a slit forming section is disposed downstream of the conveying roller 22. The slit forming device 30 has a pair of a first cut roll 31 and a second cut roll 32 disposed opposite to each other in the thickness direction with the flat plate 1 sandwiched therebetween. The surface of the first cut roll 31 has a first cut blade 31a for forming a first slit 2a and a second cut blade 31b for forming a second slit 2b according to the honeycomb core to be manufactured. Therefore, when the flat plate 1 passes through the first cut roll 31, each of the slits 2a and 2b is formed by each of the cut blades 31a and 31b.

[0021] As shown in Fig. 3A, both of the cutting blades 31a and 31b may be provided on the first cut roll 31, but this is not limiting. As shown in Fig. 3B, the second cutting blade 31b may be provided on the second cut roll 32, or both cutting blades may be provided on the second cut roll 32. Alternatively, as shown in Fig. 3C, it is also possible to form the slits 2a and 2b using a laser processing device 33 without using the cutting blades 31a and 31b.

[0022] In FIG. 2 and FIG. 4, a corrugation device 40 as an example of a corrugation section is disposed downstream of the slit forming device 30. The corrugation device 40 has a first corrugated roll 41 and a second corrugated roll 42 disposed opposite to each other in the thickness direction with the flat plate 1 sandwiched therebetween. The first corrugated roll 41 and the second corrugated roll 42 have a gear-shaped cross section, and are disposed so that the teeth of the first corrugated roll 41 and the teeth of the second corrugated roll 42 mesh with each other. In FIG. 4, in the first embodiment, the rotating shafts 41a, 42a of the corrugated rolls 41, 42 are rotatably supported by bearings 43, 44. The bearing 43 of the first corrugated roll 41 is supported by a shaft support section 45 so as to be movable in a direction in which the distance between the rotating shafts 41a, 42a approaches or moves away from the second corrugated roll 42. Moreover, the bearing 43 in the first embodiment is biased in a direction away from the first corrugated roll 41 by a coil spring 46 as an example of a biasing member. The bearing 43 is configured to be movable in the direction toward and away from the first corrugated roll 41 by an eccentric cam 47 as an example of an operating member. Therefore, the corrugation device 40 in the first embodiment is configured to adjust the distance between the first corrugated roll 41 and the second corrugated roll 42 in accordance with the operation of the eccentric cam 47, that is, to be relatively movable. In Example 1, a configuration in which the first corrugated roll 41 is moved is exemplified, but this is not limited to this, and it is also possible to have a configuration in which the second corrugated roll 42 is moved, or a configuration in which both the corrugated rolls 41 and 42 are movable.

[0023] FIG. 5 is an explanatory diagram of the bending device of the first embodiment. In Fig. 2, a bending device 50 is disposed downstream of the corrugation device 40. In Figs. 2 and 5, the bending device 50 has a first bending shaft 51 and a second bending shaft 52 disposed opposite to each other in the thickness direction with the corrugated flat plate 1 in between. The first bending shaft 51 and the second bending shaft 52 are formed in the shape of a shaft extending along the width direction of the flat plate 1. A first folding plate 51a as an example of a first folding member is supported on the upper first folding shaft 51. A plurality of first folding plates 51a of the first embodiment are arranged at intervals along the first folding shaft 51. The first folding plates 51a are supported on the first folding shaft 51 at intervals similar to the intervals in the width direction between the valley fold lines 6 in correspondence with the valley fold lines 6 of the top wall 3a. The first folding plate 51a of the first embodiment is formed in a disk shape. Furthermore, the first folding plate 51a of the first embodiment is made of elastically deformable rubber. A second folding plate 52a as an example of a second folding member is supported on the second folding shaft 52. The second folding plate 52a is different from the first folding plate 51a in that it is disposed at a position corresponding to the position of the mountain fold line portion 4 of the bottom wall 3b, and is otherwise configured in the same manner.

[0024] 6A and 6B are explanatory views of the folding process of the first embodiment, in which FIG. 6A is an explanatory view of the state before folding, FIG. 6B is an explanatory view of the state after folding, and FIG. 6C is a side view. 6, when the flat plate 1 enters the bending device 50, when the valley fold line 6 comes into contact with the first bending plate 51a, the flat plate 1 is pushed in the thickness direction by the first bending plate 51a and is folded along the valley fold line 6. In the first embodiment, in the folding along the valley fold line 6 at this time, the flat plate 1 is not folded until the adjacent top walls 3a come into close contact with each other (i.e., it is not folded completely), and the top walls 3a are deformed from being on the same plane to being inclined, as shown in FIG.

[0025] At this time, the widthwise spacing between the valley fold lines 6 changes as the valley fold lines 6 are folded (it temporarily gets longer and then gets shorter), but the rubber first folding plate 51a elastically deforms to follow the position of the valley fold line 6. Therefore, if the first folding plate 51a does not move in the widthwise direction, as the position of the valley fold line 6 changes, the pressing position may shift from the position of the valley fold line 6, and the paper may be folded at a location other than the valley fold line 6. However, in the first embodiment, it is possible to continue pressing the valley fold line 6 even if the position of the valley fold line 6 changes. Therefore, it is possible to reliably fold the paper at the position of the valley fold line 6.

[0026] When the first folding plate 51a passes the position of the valley fold line 6 during the transportation of the flat plate 1 and the second slit 2b reaches the first folding plate 51a, the first folding plate 51a elastically restores its original shape. Furthermore, when the mountain fold line 4 reaches the second folding plate 52a, the corrugated flat plate 1 is folded along the mountain fold line 4 by the second folding plate 52a, as in the case of the valley fold line 6 and the first folding plate 51a described above.

[0027] FIG. 7 is an explanatory diagram of the finishing device of the first embodiment, FIG. 7A is a perspective view, and FIG. 7B is a plan view. In FIG. 1, a finishing device 60 is disposed downstream of the bending device 50. In FIG. 7, the finishing device 60 has a base portion 61 and a restricting portion 62 disposed opposite to the base portion 61. The base portion 61 is formed in a plate shape that supports the lower side of the flat plate 1 bent by the bending device 50. The restricting portion 62 is formed in a top plate shape that is disposed at a distance from the base portion 61 in the vertical direction. The restricting portion 62 is disposed to restrict the flat plate 1 from moving upward (i.e., the flat plate 1 from escaping upward) when the flat plate 1 is completely bent. In the first embodiment, the distance between the base portion 61 and the restricting portion 62 is set to a length that is a design height of the honeycomb core 7 plus a margin based on the height of the completed honeycomb core 7.

[0028] Between the base portion 61 and the restricting portion 62, as an example of a finishing member, A first side wall 63 and a second side wall 64 are disposed opposite each other. The first side wall 63 and the second side wall 64 are formed in an inclined shape such that the distance between them (the distance in the width direction of the flat plate 1) becomes narrower toward the downstream side in the feed direction of the flat plate 1. In the first embodiment, the distance between the first side wall 63 and the second side wall 64 is set to a length based on the width of the completed honeycomb core 7 at the downstream end in the feed direction of the flat plate 1. It is also possible to configure the distance between the base portion 61 and the restricting portion 62 to become narrower toward the downstream side in the feed direction of the flat plate 1.

[0029] Therefore, as the flat plate 1 sent to the finishing device 60 moves downstream, it is pushed inward in the width direction by the side walls 63, 64. At this time, the flat plate 1 has already been folded partway along the mountain fold lines 4 and the valley fold lines 6 by the folding device 50, and is pushed by the side walls 63, 64 to be further folded at the mountain fold lines 4 and the valley fold lines 6. At this time, even if the flat plate 1 tries to escape upward or downward, the upward or downward movement is prevented by the base portion 61 and the restricting portion 62, and the flat plate 1 is folded at the mountain fold lines 4 and the valley fold lines 6. Then, when the flat plate 1 reaches the downstream end of the finishing device 60, it is bent until the adjacent top walls 3a are in close contact with each other and the adjacent bottom walls 3b are in close contact with each other (i.e., completely bent). Thus, a honeycomb core 7 is formed from the flat plate 1. The folding device 50 and the finishing device 60 constitute a folding section (50+60) of the first embodiment.

[0030] A dividing device (dividing cutter) 70, which is an example of a dividing section, is disposed downstream of the finishing device 60. The dividing cutter 70 divides the formed honeycomb core 7 at a position according to the size of a honeycomb core panel, which is a strength member of the honeycomb structure to be manufactured. The dividing cutter 70 of the first embodiment divides the honeycomb core 7 based on the distance the honeycomb core 7 has been fed in the feed direction.

[0031] In addition, when dividing the honeycomb core 7, the honeycomb core 7 is divided at a dividing position based on the distance the honeycomb core 7 has been fed, but this is not limited thereto, and it is also possible to determine the dividing position based on the rotation speed of the cut rolls 31, 32 and the rotation speed of the corrugated rolls 41, 42, etc. However, if the length to divide the honeycomb core 7 becomes long, errors such as deviations during the formation of the slits 2 and the processing of the corrugations accumulate, and there is a risk that the position at the time of division may be shifted. Therefore, it is desirable to detect and confirm the position of the honeycomb core 7 by a sensor or the like upstream of the dividing device 70, and when it is detected by a sensor or the like, even if deviations occur, it is possible to divide the honeycomb core 7 at the target position according to the deviations.

[0032] In addition, in the first embodiment, the configuration in which the cutting device 70 is disposed downstream of the finishing device 60 is exemplified, but the present invention is not limited to this. For example, the cutting device 70 may be disposed between the corrugation device 40 and the bending device 50, and the cut flat plate 1 may be sent to the bending device 50. In other words, the plate can be cut at any position according to the design and specifications. In an assembly process, the cut flat plate 1 has face plates 8 joined thereto, and a honeycomb core panel 9, which is a strength member to be manufactured, is produced.

[0033] (Explanation of the control unit) FIG. 8 is a functional block diagram of the control unit according to the first embodiment. In the honeycomb core manufacturing apparatus 10 of the first embodiment, the supply device 20, the slit forming device 30, the corrugation device 40, the bending device 50, and the cutting device 70 are controlled by a control unit C. The control unit C of the first embodiment has an input / output interface I / O for inputting and outputting signals from and to the outside. The control unit C also has a ROM (read-only memory) in which programs and information for performing necessary processing are stored. The control unit C also has a RAM (random access memory) for temporarily storing necessary data. The control unit C also has a ROM The control unit C of the first embodiment has a central processing unit (CPU) that performs processing according to a program stored in a ROM or the like. Therefore, the control unit C of the first embodiment is configured with a small information processing device, a so-called microcomputer. Therefore, the control unit C can realize various functions by executing a program stored in a ROM or the like. The control unit C of the first embodiment realizes various functions in response to inputs from an operation panel, a sensor (not shown), etc. The control unit C of the first embodiment has the following functions (program modules).

[0034] The supply control means C1 controls the driving of the transport rollers 22 of the supply device 20 to transport the flat plate 1. The supply control means C1 of the first embodiment controls the rotation speed of the transport rollers 22 to a predetermined rotation speed to control the transport speed of the flat plate 1.

[0035] The slit formation control means C2 controls the driving of the cut rolls 31, 32 of the slit forming device 30 to form the slits 2 in the flat plate 1. The slit formation control means C2 of the first embodiment controls the rotation speed of the cut rolls 31, 32 according to the size of each honeycomb (hexagonal) of the honeycomb core panel 9 to be manufactured. That is, when the size of the honeycomb is to be reduced, the rotation speed of the cut rolls 31, 32 is made faster relative to the conveying speed of the flat plate 1 to reduce the length of the slits 2 in the conveying direction that are formed. Conversely, when the size of the honeycomb is to be increased, the rotation speed of the cut rolls 31, 32 is made slower relative to the conveying speed of the flat plate 1 to increase the length of the slits 2 in the conveying direction that are formed.

[0036] 9A and 9B are explanatory views of the corrugation process in the first embodiment, where FIG. 9A is an explanatory view when the center distance is long, and FIG. 9B is an explanatory view when the center distance is short. The corrugation control means C3 has an axis distance control means C3A and a rotation speed control means C3B, and controls the driving of the corrugated rolls 41, 42 of the corrugation device 40 to corrugate the flat plate 1. The center distance control means C3A controls the eccentric cam 47 to control the center distance between the corrugated rolls 41, 42. The center distance control means C3A of the first embodiment controls the center distance between the corrugated rolls 41, 42 according to the size of each honeycomb (hexagonal) of the honeycomb core panel 9 to be manufactured. That is, when the size of the honeycomb is to be reduced, the center distance between the corrugated rolls 41, 42 is increased to reduce the height of the unevenness formed on the flat plate 1 (see FIG. 9A). Conversely, when the size of the honeycomb is to be increased, the center distance between the corrugated rolls 41, 42 is decreased to increase the height of the unevenness formed on the flat plate 1 (see FIG. 9B).

[0037] The rotation speed control means C3B controls the rotation speed of the corrugated rolls 41, 42. In the first embodiment, when the size of the honeycomb (hexagon) of the honeycomb core panel 9 to be manufactured becomes smaller, the slits 2 become shorter and the unevenness becomes lower. In response to this, the rotation speed control means C3B also speeds up the rotation speed of the corrugated rolls 41, 42 relative to the flat plate 1 to form unevenness (corrugation) that matches the size of the hexagon. Conversely, when the size of the hexagon becomes larger, the slits 2 become longer and the unevenness becomes higher. In response to this, the rotation speed control means C3B also slows down the rotation speed of the corrugated rolls 41, 42 relative to the flat plate 1 to form unevenness (corrugation) that matches the size of the hexagon.

[0038] The folding control means C4 controls the folding device 50 to fold the corrugated flat plate 1. The folding control means C4 of the first embodiment controls the rotation of a motor (not shown) that drives the folding shafts 51 and 52, and rotates the folding shafts 51 and 52 so as to send the flat plate 1 between the folding shafts 51 and 52 downstream. During this rotation, the flat plate 1 is folded by the folding plates 51a and 52a supported by the folding shafts 51 and 52.

[0039] The cutting control means C5 controls the cutting device 70 to cut the honeycomb core 7. Cutting control The means C5 operates the cutting device 70 at a position corresponding to the size of the honeycomb core panel 9 to be manufactured, to cut (cut) the honeycomb core 7.

[0040] (Function of Example 1) In the honeycomb core manufacturing apparatus 10 of Example 1 having the above-mentioned configuration, the flat plate 1 sent out from the supply device 20 has slits 2 formed in the slit forming device 30, is corrugated in the corrugation device 40, is folded into honeycomb cores 7 in the folding device 50 and the finishing device 60, and is cut in the cutting device 70. The cut honeycomb cores 7 are face-plate-bonded in an assembly process to produce honeycomb core panels 9. Thus, the processes from forming the slits 2 to corrugation, bending, and cutting are carried out continuously and automatically. This enables mass production in a short time, and reduces manufacturing costs.

[0041] In addition, in the first embodiment, the size of the honeycomb (hexagonal) of the honeycomb core panel 9 to be manufactured can be changed to a desired size by adjusting the rotation speed of the cut rolls 31 and 32 and the axis distance and rotation speed of the corrugated rolls 41 and 42. Therefore, the honeycomb core manufacturing apparatus 10 of the first embodiment can also handle various sizes according to the purpose. In particular, the size and required strength of the honeycomb core panel 9 differ depending on the object, such as an automobile or a building, and the required strength and size of the same object differ depending on the place where it is used. Therefore, the technology described in Patent Document 1 has a problem that it is difficult to handle strength members of honeycomb structures of various sizes and shapes. In contrast, in the first embodiment, the rotation speed of the cut rolls 31 and 32 and the like can be adjusted to handle the honeycomb core panel 9 of the desired size and shape.

[0042] It is also possible to replace the cut rolls 31, 32 and the corrugated rolls 41, 42, or to replace the bending plates 51a, 51b with ones having a different interval, depending on the size of the honeycomb core panel 9 to be manufactured. When the cut rolls 31, 32 are replaced, the interval of the slits 2 in the width direction of the flat plate 1 can also be changed, and not only the size of the hexagon of the honeycomb core panel 9 to be manufactured but also its height can be changed.

[0043] (Example of change) Although the embodiments of the present invention have been described above in detail, the present invention is not limited to the above embodiments, and various modifications can be made within the scope of the gist of the present invention described in the claims. Modifications (H01) to (H03) of the present invention are illustrated below. (H01) In the above embodiment, the coil spring 46 and the eccentric cam 47 are used as an example of a method for adjusting the center distance, but the present invention is not limited to this. Any structure capable of adjusting the center distance may be used, such as a structure that combines a motor and a gear, or a structure that uses hydraulic pressure.

[0044] (H02) In the above embodiment, the bending plates 51a, 52a are made of an elastic material to be movable in the width direction, but the present invention is not limited to this. For example, the bending plates 51a, 52a may be supported so as to be slidable along the axial direction of the bending shafts 51, 52, to be movable in the width direction.

[0045] (H03) In the above embodiment, when bending the corrugated flat plate 1 into the honeycomb core 7, a configuration in which bending is performed in two stages by the bending device 50 and the finishing device 60 has been exemplified, but the present invention is not limited to this. For example, it is possible to configure the bending to be performed almost completely by the bending device 50 alone by thinning the thickness of the bending plates 51a, 52a to the limit. [Explanation of symbols]

[0046] 1...Plate material, 2…slit, 4,6…Folding line portion, 7...Honeycomb structured strength member, 10...Strength member manufacturing equipment, 20...Transport unit, 30...slit forming portion, 40...Wave processing section, 41, 42...forming roll, 50+60…Bending part, 51a, 52a... bending members, 70...Divided part.

Claims

1. A conveying unit that conveys unprocessed plate materials; a slit forming section for forming slits in the plate material conveyed by the conveying section at positions corresponding to the shape of a strength member of a honeycomb structure to be manufactured; a corrugation processing section that is disposed downstream of the slit forming section in the conveying direction of the plate material and processes the plate material into a corrugated shape along the conveying direction of the plate material by forming alternate concaves and convexes in the thickness direction of the plate material while conveying the plate material with the slits formed therein without cutting the plate material; a bending section that is disposed downstream of the corrugation section in the conveying direction of the plate material, and that conveys the corrugated plate material without cutting it, and presses the plate material with a bending member in the thickness direction of the plate material along the folding line on the extension of the slit to bend the plate material, thereby creating a strength member of a honeycomb structure; A strength member manufacturing apparatus comprising:

2. A conveying unit that conveys unprocessed plate materials; a slit forming section for forming slits in the plate material conveyed by the conveying section at positions corresponding to the shape of a strength member of a honeycomb structure to be manufactured; a corrugation processing unit that processes the plate material into a corrugated shape along a conveying direction of the plate material by alternately forming concaves and convexes in a thickness direction of the plate material on the plate material having the slits formed therein; a bending section which bends the corrugated plate material by pressing the plate material in the thickness direction along the folding line on the extension of the slit with a folding member, and which completely folds the plate material by narrowing the width direction of the plate material toward the downstream side in the conveying direction while pressing the plate material in the thickness direction bent by the folding member to create a strength member of a honeycomb structure; A strength member manufacturing apparatus comprising:

3. The corrugation processing unit has a pair of forming rolls arranged at a position sandwiching the plate material along the thickness direction of the plate material; Equipped with At least one of the pair of forming rolls is relatively movable along a thickness direction of the plate material, The distance between the pair of forming rolls in the thickness direction is set according to the strength members of the honeycomb structure to be manufactured.

3. The apparatus for manufacturing a strength member according to claim 1 or 2.

4. A pair of bending shafts arranged opposite to each other across the plate material in the thickness direction of the plate material; A bending member supported on the bending shaft and contacting and pushing the passing plate material from a thickness direction, the bending member supported movably along a width direction of the plate material; 3. The apparatus for manufacturing a strength member according to claim 1, further comprising:

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