Bending Roll

Abstract

To prevent an end shape defect of a molding in a bending roll in which a metal plate fan-shaped in a plan view is bent to be a truncated-cone molding.SOLUTION: A bending roll body 10 for bending a metal plate 1, a carrying-in device 20 that carriers-in the metal plate 1 toward the bending body 10, and alignment devices 30 that position the metal plate 1 at a position in a prescribed roll shaft direction are associated. In a state where the metal plate 1 is stopped before start of the bending and during the bending, guide rollers 31 on both sides of each alignment device 30 are brought into contact with a width end of the metal plate 1 to position the metal plate 1. During the bending, the guide rollers 31 are retreated to positions not in contact with the metal plate 1. Thus, an end shape defect of the molding can be surely prevented.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a bending roll for bending a metal plate having a sector shape in plan view between an upper roll and a plurality of lower rolls to form a truncated cone-shaped product. [Background technology]

[0002] A bending roll is a device that bends a metal sheet by clamping the metal sheet between an upper roll and multiple lower rolls and rotating the lower rolls.

[0003] Among the bending rolls described above, those that bend and shape a metal plate that is sector-shaped when viewed from above into a truncated cone-shaped product are usually equipped with a positioning mechanism that positions the metal plate so that it passes through a predetermined position in the roll axial direction between the upper and lower rolls (see, for example, Patent Documents 1 and 2).

[0004] The positioning mechanism generally has positioning members such as vertical guide rollers arranged on both sides of the axial direction of the upper and lower rolls, with at least one of the positioning members being movable in the roll axial direction, and the metal plate being clamped between the positioning members on both sides to position the metal plate in the roll axial direction. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] JP 2000-280029 A [Patent Document 2] JP 2012-236207 A Summary of the Invention [Problem to be solved by the invention]

[0006] The bending roll equipped with the above-mentioned positioning mechanism performs forming while the metal plate, which is sector-shaped in plan view, is positioned in the roll axis direction, i.e., while the movement of the metal plate in the roll axis direction is restricted by the positioning member abutting the width direction end of the metal plate. Therefore, the width direction end of the metal plate is strongly pressed against the positioning member during forming, and shape defects may occur at the large diameter side end and the small diameter side end (hereinafter collectively referred to as "ends") of the truncated cone-shaped formed product.

[0007] In particular, when forming large truncated cone-shaped structures used in large facilities (for example, those used in the tower body of a wind power generation plant or the seabed foundation of an offshore wind power generation plant), the thickness of the metal plate used as the material becomes thick, which increases the contact force between the widthwise end of the metal plate and the positioning member, making it easy for defects to occur, such as the welding grooves pre-formed on the widthwise end of the metal plate being crushed.

[0008] Therefore, an object of the present invention is to prevent defects in the end shape of a formed product in a bending roll that bends a metal plate that is sector-shaped when viewed from above into a truncated cone-shaped product. [Means for solving the problem]

[0009] In order to solve the above problems, the present invention provides a bending roll comprising an upper roll, a number of lower rolls arranged below the upper roll, and a positioning mechanism for positioning a metal plate that is sector-shaped in plan view so that it passes through a predetermined roll axial position between the upper roll and the number of lower rolls, and which bends and shapes the metal plate into a truncated cone-shaped product by rotating and driving the lower rolls or the upper roll or the upper and lower rolls while the metal plate is clamped between the upper roll and each lower roll.The positioning mechanism has a positioning member that abuts against the widthwise end of the metal plate when positioning the metal plate and retracts to a position where it does not come into contact with the metal plate during bending.

[0010] According to the above-mentioned configuration, since the width direction end portion of the metal plate is not pressed against the positioning member of the positioning mechanism during bending, defects in the shape of the end portion of the truncated cone-shaped molded product can be reliably prevented.

[0011] In the above configuration, it is desirable to position the metal sheet by the positioning mechanism before the start of bending the metal sheet and in the middle of bending the metal sheet while the metal sheet is stopped. In this way, even if the passing position of the metal sheet between the upper and lower rolls displaces in the roll axial direction during bending, the metal sheet can be returned to a predetermined roll axial position before the displacement amount becomes large, thereby preventing the occurrence of defects due to the displacement of the metal sheet in the roll axial direction.

[0012] Furthermore, if the positioning mechanism is separated from the bending roll body including the upper roll and each lower roll, and is configured to be provided on the side of the bending roll body where the metal plate is transported, the structure of the bending roll body is simplified, and replacement work for each roll of the bending roll body and the positioning members of the positioning mechanism can be easily performed. Effect of the Invention

[0013] As described above, the bending roll of the present invention is configured so that the positioning member of the positioning mechanism, which positions the metal plate that is fan-shaped in plan view at a predetermined position in the roll axial direction, is retracted to a position that does not contact the widthwise end portion of the metal plate during bending, thereby reliably preventing poor end shape of the truncated cone-shaped product. [Brief description of the drawings]

[0014] [Figure 1] FIG. 3 is a plan view of the bending roll according to the embodiment; [Diagram 2] Side view of Figure 1 [Diagram 3] Front view of the bending roll body of Figure 1 [Figure 4] FIG. 2(a) is an enlarged plan view of the loading device in FIG. 1, and FIG. 2(b) is a front view of FIG. [Diagram 5]FIG. 2(a) is an enlarged plan view of the alignment device in FIG. 1, and FIG. 2(b) is a front view of FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0015] Hereinafter, an embodiment of the present invention will be described with reference to the drawings. As shown in Fig. 1 and Fig. 2, this bending roll is composed of a bending roll body 10 that bends a metal sheet 1 that is a fan-shaped material in plan view, a plurality of feed devices 20 that feed the metal sheet 1 before bending toward the bending roll body 10, and a plurality of alignment devices 30 as a positioning mechanism that positions the metal sheet 1 at a predetermined position in the roll axis direction. The bending roll body 10 is installed on the bottom of a pit 3 that is dug to a predetermined depth from a floor surface 2 of a factory, and the feed devices 20 and the alignment devices 30 are installed on the floor surface 2, respectively. The metal sheet 1 transported by the feed devices 20 is passed through the bending roll body 10 while maintaining a constant height from the floor surface 2.

[0016] 1 to 3, the bending roll body 10 includes an upper roll 11, a pair of lower rolls 12 arranged on both the front and rear sides below the upper roll 11, a backup roll 13 supporting the axial center of each of the lower rolls 12 from both the front and rear sides below, left and right substantially gate-shaped upper frames 14 and 15 supporting both ends of the upper roll 11, a lower frame 16 supporting both ends of each of the lower rolls 12 and the legs of each of the upper frames 14 and 15, and a drive mechanism 17 for rotating each of the lower rolls 12. With the metal sheet 1 sandwiched between the upper roll 11 and each of the lower rolls 12, each of the lower rolls 12 is rotated to bend the metal sheet 1 into a truncated cone-shaped formed product 1'.

[0017] Of the two upper frames 14, 15, the upper frame 14 on the lower side in Fig. 1 (left side in Fig. 3) is a tipping frame that moves away from one end of the upper roll 11 and rotates (tip-overs) toward the lower side in Fig. 1 (left side in Fig. 3) when the truncated-cone shaped molded product 1' is removed. On the other hand, the upper frame 15 on the upper side in Fig. 1 (right side in Fig. 3) is an upright frame that is held in an untoppable state because the other end of the upper roll 11 extends axially outward.

[0018] A hydraulic cylinder 18 is attached to the upper end of each of the upper frames 14, 15, and by operating each hydraulic cylinder 18, the upper roll 11 can be tilted by a predetermined angle or raised and lowered.

[0019] In addition, a hydraulic cylinder 19 is attached between the lower part of one end face of the lower frame 16 and the upper frame 14, and when removing the molded product 1', this hydraulic cylinder 19 is operated to cause the upper frame 14 to tip over and return to its original position.

[0020] On the other hand, six loading devices 20 are arranged on the side (left side in Figures 1 and 2) where the metal sheet 1 before bending is loaded onto the bending roll body 10, so as to follow the fan-shaped planar shape of the metal sheet 1 (only two of which are shown close to the bending roll body 10).

[0021] As shown in Figures 4(a) and (b), this loading device 20 comprises three conveying rollers 21 arranged parallel to each other at a predetermined interval in the conveying direction, a chain 22 and sprockets 23 connecting adjacent conveying rollers 21, and a servo motor 24 that drives and rotates the most downstream conveying roller 21.The servo motor 24 drives each conveying roller 21 to rotate synchronously, and the metal plate 1 placed on each conveying roller 21 is sent to the bending roll body 10.

[0022] The alignment devices 30 are disposed one each before and after (on the upstream side and downstream side) the most downstream carry-in device 20.

[0023] As shown in Fig. 5(a) and (b), the alignment device 30 includes vertical guide rollers 31 as positioning members arranged on both the left and right sides (in the roll axial direction of the bending roll body 10), roller support bases 32 that rotatably support the lower ends of the guide rollers 31, ball screws 33 that extend in the left and right direction and are screw-coupled to the roller support bases 32, and a motor 34 with a cycloid reducer that rotates and drives the ball screw 33. The ball screw 33 is formed by connecting two screw shafts arranged concentrically in opposite directions to each other so that they rotate together, and the roller support bases 32 and guide rollers 31 on both sides are moved in opposite directions by the drive of the motor 34. The ball screw 33 can also be configured so that the left and right screw shafts are driven independently by separate motors. In this way, the left and right roller support bases 32 and guide rollers 31 can be moved independently of each other.

[0024] Next, a procedure for bending the metal sheet 1 using the bending rolls will be described.

[0025] When bending the metal sheet 1, the hydraulic cylinders 18 attached to the upper frames 14, 15 of the bending roll body 10 are operated in advance to set the upper roll 11 at a predetermined height while tilting it at a predetermined angle according to the shape of the formed product 1'. In addition, both guide rollers 31 of each alignment device 30 are retracted to a position where the distance between them is wider than the width of the metal sheet 1.

[0026] At the start of the forming operation, first, the servo motors 24 of each carrying device 20 are driven to transport the metal sheet 1 toward the bending roll body 10, and the metal sheet 1 is stopped once the leading end of the metal sheet 1 reaches in front of the bending roll body 10. Then, the motors 34 of each alignment device 30 are driven to bring the guide rollers 31 on both sides into contact with the width direction ends of the metal sheet 1 (the metal sheet 1 is sandwiched between both guide rollers 31), thereby positioning the metal sheet 1 so that it passes through a predetermined position in the roll axis direction between the upper and lower rolls 11, 12.

[0027] Thereafter, the motors 34 of each alignment device 30 are reversed to move the guide rollers 31 on both sides to positions where they do not come into contact with the metal plate 1, and then the transportation of the metal plate 1 by each loading device 20 is resumed, and the metal plate 1 is sent between the upper and lower rolls 11, 12 of the bending roll body 10 to begin bending.

[0028] After bending starts, the bending roll body 10, each loading device 20, and each alignment device 30 are linked to repeat the following operation: forming the metal sheet 1 to a predetermined length → stopping the metal sheet 1 (the loading device 20 and the lower roll 12 stop) → lifting the upper roll 11 → positioning the metal sheet 1 by the guide roller 31 → retracting the guide roller 31 → lowering the upper roll 11, and this operation ends when the rear end of the metal sheet 1 has been formed. Note that the operations up to this point are performed automatically based on data on the dimensions and shape of the metal sheet 1 and its formed product 1'.

[0029] After the bending is completed, the hydraulic cylinder 19 of the bending roll body 10 is operated to turn over the upper frame 14, and after the formed product 1' is removed from the bending roll body 10, the hydraulic cylinder 19 is operated again to return the upper frame 14 to its original upright position.

[0030] As described above, before the start of bending the metal sheet 1 and while the metal sheet 1 is stopped during bending, this bending roll positions the metal sheet 1 in the roll axial direction by abutting the guide rollers 31 on both sides of each alignment device 30 against the widthwise ends of the metal sheet 1, and during bending, the guide rollers 31 are retracted to positions where they do not come into contact with the metal sheet 1 so that the widthwise ends of the metal sheet 1 are not pressed against the guide rollers 31, thereby reliably preventing poor shape of the ends of the molded product 1'.

[0031] In addition, the forming operation of the metal sheet 1 is performed by repeatedly forming the metal sheet 1 to a predetermined length, stopping the forming, positioning the metal sheet 1, and then resuming forming, so that even if the passing position of the metal sheet 1 between the upper and lower rolls 11, 12 displaces in the roll axial direction during bending, the metal sheet 1 is returned to a predetermined position in the roll axial direction before the amount of displacement becomes large. Therefore, the forming operation can be performed while preventing the occurrence of problems due to the displacement of the metal sheet 1 in the roll axial direction.

[0032] Furthermore, the alignment device 30 that positions the metal plate 1 is separated from the bending roll body 10 and is provided on the side where the metal plate 1 is transported into the bending roll body 10. Therefore, compared to the case where a positioning mechanism is provided within the bending roll body, the structure of the entire bending roll is simpler, and replacement work for the upper and lower rolls 11, 12 of the bending roll body 10 and the guide roller 31 of the alignment device 30 is also easier to perform.

[0033] The embodiments disclosed herein should be considered to be illustrative and not restrictive in all respects. The scope of the present invention is defined by the claims, not by the above meaning, and is intended to include all modifications within the scope and meaning equivalent to the claims.

[0034] For example, in the above-described embodiment, cylindrical upper rolls and lower rolls are used, but tapered rolls may also be used.

[0035] Furthermore, the positioning mechanism for positioning the metal plate is not limited to an alignment device equipped with guide rollers as in the embodiment, but may be any mechanism having a positioning member that abuts against the widthwise end of the metal plate when positioning the metal plate and retracts to a position not in contact with the metal plate during bending. [Explanation of symbols]

[0036] 1 metal plate 1' molding 10 Bending roll body 11 Upper roll 12 Lower roll 13 Backup Role 14, 15 Upper frame 16 Lower Frame 17 Drive mechanism 18, 19 Hydraulic cylinder 20 Loading device 21 Transport roller 24 Servo motor 30 Alignment device (positioning mechanism) 31 Guide roller 34 Motor

Claims

1. The present invention is provided with an upper roll, a plurality of lower rolls disposed below the upper roll, and a positioning mechanism for positioning the metal sheet so that the metal sheet passes through a predetermined position in the roll axis direction between the upper roll and the plurality of lower rolls, and the metal sheet is moved between the upper roll and each lower roll. In the bending roll, the metal plate is bent into a truncated cone-shaped product by rotating the lower roll or the upper roll or the upper and lower rolls while the metal plate is sandwiched between the lower roll and the upper roll, the positioning mechanism has a positioning member that comes into contact with a width direction end of the metal plate when positioning the metal plate and retreats to a position not in contact with the metal plate during bending, A bending roll characterized in that the positioning mechanism is separated from a bending roll body including the upper roll and each lower roll, and is provided on the side where the metal plate is brought into the bending roll body.

2. The bending roll according to claim 1, characterized in that the positioning mechanism positions the metal plate before the start of bending the metal plate and in the middle of bending the metal plate while the metal plate is stopped.

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