Deck plate manufacturing method

Abstract

To provide a technique capable of smoothy inserting the tip of a continuously fed molded workpiece into a cutting mold of a running cutter.SOLUTION: A method for manufacturing a deck plate is for manufacturing a deck plate having a fitting part in which peaks and valleys continuously alternate to form wave shapes via slopes in a width direction and are folded on different sides at the ends in the width direction. This method comprises: an unwinding step S11 of unwinding a strip-like steel plate 10 from a steel plate coil on which the strip-like steel plate has been wound; a first cutting step S12 of cutting off both the corner ends of the strip-like steel plate 10 in a feeding direction F for feeding the strip-like steel plate 10 so as to separate cutting edges from each other upstream in the feeding direction F; a forming step S13 of roll-forming the strip-like steel plate 10 the corner end 13 of which has been cut off and forming a molded workpiece 10A having slopes, peaks, valleys, and a fitting part; and a second cutting step S14 of cutting the molded workpiece 10A with a prescribed length in the feeding direction F.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to a method for manufacturing a deck plate. [Background technology]

[0002] The floors of large buildings such as high-rise buildings are constructed with slabs made of concrete and deck plates. For example, a deck plate is known that has a wave-like shape with alternating peaks and valleys in the width direction via sloped sections, and has fitting sections at the ends in the width direction that are folded back to opposite sides.

[0003] Deck plates are manufactured, for example, by continuously feeding strip steel sheet that has been slit to a specified width and wound into a coil into a roll forming machine using an uncoiler, then bending it using forming rolls to form a formed workpiece with the desired cross-sectional shape, and then inserting (threading) the formed workpiece into the cutting die of a flying cut-off machine and cutting it to a specified length (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2013-132667 Summary of the Invention [Problem to be solved by the invention]

[0005] When a steel coil is replaced, the leading edge of the strip steel sheet being fed must be inserted into the cutting die of the flying cut-off machine. The formed workpiece sent from the roll forming machine to the flying cut-off machine has a complex cross-sectional shape with inclined sections, peaks, bottoms, and fitting sections, and it can be difficult to insert it into the cutting die in the correct position and orientation.

[0006] To insert a formed workpiece into a cutting die, manual work was sometimes required, such as supporting the formed workpiece by a person and adjusting the position and orientation of the tip of the formed workpiece relative to the entrance of the cutting die.

[0007] Therefore, the present invention has been made in consideration of the above-mentioned problems, and aims to provide a technology that enables the tip of a continuously fed formed workpiece to be smoothly inserted into the cutting die of a flying cut-off machine. [Means for solving the problem]

[0008] In order to solve the above problem, the manufacturing method of the present invention is a manufacturing method for manufacturing a deck plate in which peaks and valleys are alternately and continuously arranged in a wave shape in the width direction via inclined portions, and which has folded portions folded back to different sides at the ends in the width direction, and is characterized by including: an unwinding process in which a strip steel plate is fed from a steel plate coil in which the strip steel plate is wound; a first cutting process in which both corner ends of the strip steel plate are cut off in the feed direction in which the strip steel plate is fed so that the cut edges move away from each other upstream in the feed direction; a forming process in which the strip steel plate from which the corner ends have been cut off is roll-formed to form a formed work having the inclined portions, the peaks, the valleys, and the folded portions; and a second cutting process in which the formed work is cut to a predetermined length in the feed direction.

[0009] In a manufacturing method according to one embodiment of the present invention, the folded portion may be formed by folding the strip steel plate between a tip corner of the cutting edge and a side edge corner of the cutting edge on the side of the side edge of the strip steel plate extending along the feed direction.

[0010] In a manufacturing method according to one aspect of the present invention, the angle formed between the inclined portion and the peak portion in the portion where the folded portion is not formed in the width direction may be smaller than the angle formed between the inclined portion where the folded portion is formed in the width direction and the peak portion, and the peak portion where the folded portion is not formed in the width direction may be formed higher in the width direction than the peak portion where the folded portion is formed.

[0011] In a manufacturing method according to one aspect of the present invention, the molded workpiece may be inserted into a cutting die used to cut the molded workpiece from the top portion, and then the folded portion may be inserted.

[0012] Furthermore, in order to solve the above-mentioned problems, the manufacturing method of the present invention is a manufacturing method for manufacturing a deck plate in which peaks and valley bottoms are alternately and continuously arranged in a wave shape in the width direction via inclined portions, and which has folded portions folded back to different sides at the ends in the width direction, and is characterized by including: an unwinding process in which the strip steel plate is fed from a steel plate coil in which the strip steel plate is wound; a forming process in which the strip steel plate is roll-formed to form a formed work having the inclined portions, the peaks, the valley bottoms, and the folded portions; a first cutting process in which the formed work is cut in a V shape in the feed direction of the strip steel plate at the transition portion between the inclined portions and the valley bottoms, which are continuous in the width direction, at the tip of the formed work, and corners are cut off at the folded portions so that the cut edges move away from each other upstream in the feed direction; and a second cutting process in which the formed work is cut to a predetermined length in the feed direction.

[0013] In the manufacturing method according to one aspect of the present invention, the corner may be cut off, including a transition portion between the valley bottom portion and the inclined portion, which is continuous with the folded portion. [Effects of the Invention]

[0014] According to the present invention, the leading ends of continuously fed formed workpieces can be smoothly inserted into the cutting die of a flying cut-off machine. [Brief explanation of the drawings]

[0015] [Figure 1A] 1 is a perspective view of a deck plate manufactured by a manufacturing method according to a first embodiment. FIG. [Figure 1B] FIG. 2 is a cross-sectional view of the deck plate taken along line BB in FIG. 1. [Figure 2] 1 is a diagram schematically showing a production line for producing a deck plate in a production method according to a first embodiment. [Figure 3] FIG. 2 is a schematic front view of a cutting die in a flying cut-off machine. [Figure 4] FIG. 1 is a schematic diagram showing the state of a formed workpiece in front of a flying cut-off machine in a conventional manufacturing method. [Figure 5] FIG. 10 is a diagram showing a state in which the fitting portion is derailed in the cutting die. [Figure 6] FIG. 2 is a plan view showing the tip of the processed steel strip. [Figure 7A] FIG. 2 is a perspective view showing a formed workpiece having a deformed portion after roll forming. [Figure 7B] FIG. 7B is a side view of the formed workpiece shown in FIG. 7A. [Figure 7C] 7C are cross-sectional views showing cross sections taken along lines CI-CI and CII-CII in FIG. 7B. [Figure 7D] FIG. 10 is an enlarged perspective view showing one of the fitting portions on the leading end side of the formed workpiece in the feed direction. [Figure 7E] FIG. 10 is an enlarged plan view showing one of the fitting portions on the leading end side of the formed workpiece in the feed direction. [Figure 8] 3 is a schematic view showing the state of a formed workpiece in front of a flying cut-off machine in the manufacturing method according to the first embodiment. FIG. [Figure 9] FIG. 10 is a diagram schematically showing a production line for producing a deck plate in a production method according to a second embodiment. [Figure 10] FIG. 2 is a perspective view showing a machined formed workpiece. DETAILED DESCRIPTION OF THE INVENTION

[0016] Hereinafter, embodiments of the present invention will be described with reference to the drawings. Note that in the following description, the drawings are schematic, and the dimensional relationships and ratios of elements may differ from the actual ones. The dimensional relationships and ratios may differ between the drawings.

[0017] First Embodiment FIG. 1A is a perspective view of a deck plate 100 manufactured by a manufacturing method according to a first embodiment. FIG. 1B is a cross-sectional view of the deck plate 100 taken along line BB in FIG. 1. The deck plate 100 is a corrugated steel plate formed by roll forming. The deck plate 100 has a peak portion 110, valley bottom portions 120 and 130, an inclined portion 140, and mating portions (folded portions) 150 and 160. The deck plate 100 has a length direction L and a width direction W that intersects with the length direction L.

[0018] The peaks 110 and valley bottoms 120, 130 are continuous with each other in the width direction W via inclined portions 140 extending in the length direction L, and the deck plate 100 has a corrugated shape. Each deck plate 100 is made up of two peaks 110, three valley bottoms 120, 130, and two pairs of inclined portions 140, and is formed into a corrugated shape in cross section along the width direction W. The deck plate 100 may also be end-closed at both ends in the length direction L.

[0019] The peak portion 110 is a flat portion located above and spaced apart from the support beam when the slab is spanned between support beams, for example, and is a plate-like portion extending in the longitudinal direction L. The peak portion 110 has a groove 111. The groove 111 is formed in a concave shape facing the valley bottom 120. The groove 111 extends in the longitudinal direction L, and when there is only one groove 111, it is located near the center in the width direction W.

[0020] The valley bottoms 120, 130 are parallel or approximately parallel to the peak 110 and are flat portions that are placed on the support beams when the support beams are bridged between them. The valley bottoms 120, 130 are flat, plate-like portions that extend in the length direction L. The valley bottoms 120, 130 do not overlap with the peak 110 in the width direction W.

[0021] Of the three valley bottoms 120, 130, the valley bottom 120 is sandwiched between the valley bottoms 130 in the width direction W and is located in the center of the deck plate 100. Inclined portions 140, described below, are continuous with both sides of the valley bottom 120 in the width direction W. The valley bottom 120 is wider in the width direction W than the valley bottom 130. The valley bottom 120 has multiple embossed portions 121 located in the center or approximately the center in the width direction W. The embossed portions 121 are equally spaced along the length direction L and are formed convexly toward the peak portions 110. The embossed portions 121 may also be formed as grooves that extend along the length direction L and are formed convexly toward the peak portions 110. The embossed portions 121 and grooves increase the rigidity of the deck plate 100 and stabilize its shape.

[0022] Valley bottoms 130 are provided at both ends in the width direction W of deck plate 100. A sloping portion 140, which will be described later, is continuous with each valley bottom 130 on the side of valley bottom 120 in the width direction W. Fitting portions 150, 160, which will be described later, are provided at the end of valley bottom 130 opposite the side where sloping portion 140 is continuous.

[0023] The inclined portions 140 are portions that connect the peak portion 110 and the valley bottoms 120, 130, and are flat, plate-like portions that extend in the longitudinal direction L. The inclined portions 140 extend obliquely from both end sides of the peak portion 110 toward the valley bottoms 120, 130 in the width direction W. The inclined portions 140 that are adjacent to each other in the width direction W extend in different directions from the peak portion 110 so as to be spaced apart from each other. The inclined portions 140 are inclined to form a predetermined angle, for example, an obtuse angle, with respect to the peak portion 110 and the valley bottoms 120, 130.

[0024] A plurality of embossed portions 141 are formed on the inclined portion 140. The embossed portions 141 are provided at predetermined intervals along the longitudinal direction L. The embossed portions 141 are formed to protrude toward the valley bottoms 120, 130 where the inclined portions 140 are continuous. The embossed portions 141 increase the rigidity of the deck plate 100 and stabilize its shape.

[0025] Bulging portions 142 are formed at the transitions between the valley bottoms 120, 130 and the slopes 140. The bulging portions 142 are portions that protrude in opposite directions on a pair of slopes 140 in one peak 110. On a pair of slopes 140 that face each other across the valley bottom 120, the bulging portions 142 are formed to face each other and bulge in directions that approach each other. Furthermore, the bulging portions 142 formed on each side of the valley bottom 130 bulge in the direction opposite the valley bottom 120.

[0026] A dovetail groove 143 extending along the length direction L is formed between the bulge portion 142 and the valley bottoms 120, 130. The cross section of the dovetail groove 143 along the width direction W is formed to be curved. In a pair of inclined portions 140 facing each other across the valley bottom 120, the dovetail grooves 143 are formed to face each other and curve in directions away from each other, that is, toward the valley bottom 130. Furthermore, the dovetail grooves 143 formed on each side of the valley bottom 130 are curved toward the valley bottom 120.

[0027] The mating portions 150, 160 are provided contiguous to each valley bottom 130. The mating portions 150, 160 are used to connect adjacent deck plates 100 in the width direction W when constructing a slab. Specifically, the mating portion 150 of one deck plate 100 and the mating portion 160 of the other deck plate 100 are mated with each other, thereby connecting the two deck plates 100 in the width direction W. The mating portions 150, 160 are folded back to different sides.

[0028] The fitting portion 150 is provided on one of the valley bottoms 130 and is folded back to the side opposite the peak portion 110. The fitting portion 150 has an upright portion 151 and a hook portion 152. The upright portion 151 extends obliquely from the valley bottom 130 so as to move away from the inclined portion 140. The hook portion 152 is located on the tip side of the upright portion 151 and extends from the upright portion 151 parallel or approximately parallel to the valley bottom 130 to the side opposite the inclined portion 140. The tip of the hook portion 152 is folded back to the side opposite the peak portion 110 and toward the upright portion 151.

[0029] The fitting portion 160 is provided on the other valley bottom 130 and is folded back toward the peak 110. The fitting portion 160 has an upright portion 161 and a hook portion 162. The upright portion 161 extends obliquely from the valley bottom 130 so as to be away from the inclined portion 140. The hook portion 162 is located on the tip side of the upright portion 151 and is folded back from the upright portion 161 toward the inclined portion 140.

[0030] Next, a manufacturing line 200 for manufacturing the deck plate 100 will be described with reference to Figure 2. Figure 2 is a diagram schematically illustrating a manufacturing line for manufacturing the deck plate 100 using the manufacturing method according to the first embodiment. The manufacturing line 200 includes an uncoiler 210, a processing unit 215, roll forming equipment (roll forming machine) 220, a flying cut-off machine 230, and a feed roller table 240. A steel sheet coil around which a strip-shaped steel sheet that has been slit to a predetermined width is wound is set in the uncoiler 210. By operating the manufacturing line, the uncoiler 210 feeds the strip-shaped steel sheet toward the roll forming equipment 220.

[0031] The processing section 215 is provided between the uncoiler 210 and the roll forming equipment 220. In the processing section 215, the corners 13 (see FIG. 6) of the steel strip 10 are cut off. It is assumed that the cutting process is performed by a hand shear, a grinder, or a gas torch in the processing section 215, but processing may also be performed by a press device. Each method is optional and may be selected according to the scale and specifications of the line.

[0032] The roll forming equipment 220 has a plurality of roll stands 221. Each roll stand 221 supports a predetermined number of rolls, and the steel strip 10 fed to the roll forming equipment 220 is sequentially bent at each roll stand 221. In the roll forming equipment 220, the steel strip 10 is bent in multiple stages, and the peak portions 110, valley bottom portions 120, 130, inclined portions 140, and mating portions 150, 160 are formed from the steel strip 10, thereby forming a formed workpiece 10A having a predetermined cross-sectional shape. Here, the "formed workpiece 10A" refers to an intermediate product that is continuous with the steel strip 10 and has not yet been cut into the deck plate 100.

[0033] The flying cut-off machine 230 cuts the formed workpiece 10A, which has a predetermined cross-sectional shape in the roll forming equipment 220, in the width direction W to separate the formed workpiece 10A into deck plates 100 having a predetermined length. The flying cut-off machine 230 has a cutting die 231. Figure 3 is a schematic front view of the cutting die 231 in the flying cut-off machine 230. The cutting die 231 is provided with blade (lower blade) blocks 232, 233, and 234 that correspond to the shape of the deck plate 100 to be produced, and is formed with a plate passing opening 235 through which the formed workpiece 10A passes.

[0034] When cutting the continuously fed molded workpieces in the traveling cut-off machine 230, the cutting die 231 cuts the molded workpiece 10A to a predetermined length while traveling together with the molded workpiece 10A along a traveling rail (not shown) in the feed direction F of the molded workpiece 10A. The deck plate 100 cut to the predetermined length is sent downstream via a feed roller table 240 to an area where work such as bundling and shipping is performed.

[0035] For example, when the steel plate coil is replaced, the leading end of the formed workpiece 10A that has been sent through the production line 200 and processed must be inserted into the cutting die 231 of the flying cut-off machine 230. The cutting die 231 has a plurality of lower blade blocks 232, 233, 234 and a plate passing opening 235. Note that the upper blade is not shown.

[0036] The lower blade block 232 corresponds to the mountain-shaped space defined by the peak portion 110 and the slope portion 140 of the deck plate 100. The lower blade block 233 corresponds to the fitting portion 150 of the deck plate 100, and the lower blade block 234 corresponds to the fitting portion 160 of the deck plate 100.

[0037] The position at which the lower blade block 232 is provided in the feed direction F is, for example, upstream of the other lower blade blocks 233, 234, and the molded workpiece 10A to be inserted into the cutting die 231 is first supported by the lower blade block 232 at the crest portion 110 and fed into the cutting die 231. The position of the lower blade block 232 may be the same as the other lower blade blocks 233, 234 in the feed direction F.

[0038] The roll forming equipment 220 and the flying cut-off machine 230 are provided at a predetermined distance from each other. The leading end of the formed workpiece 10A continuously formed in the roll forming equipment 220 may sag due to its own weight while being fed from the final roll stand 221 of the roll forming equipment 220 to the flying cut-off machine 230. Figure 4 is a schematic diagram showing the state of the formed workpiece 20A located just before the flying cut-off machine 230 in a conventional manufacturing method. Note that the formed workpiece 20A, like the formed workpiece 10A, is an intermediate product used to manufacture the deck plate 100, and for ease of explanation, parts corresponding to the components of the deck plate 100 are designated by the same reference numerals.

[0039] For example, in the conventional manufacturing method, the strip steel sheet 10 is not processed on the upstream side of the roll forming equipment 220, and the leading end of the formed workpiece 20A is located below the plate passing opening 235 in the cutting die 231. Specifically, the position where the peak portion 110 is formed on the formed workpiece 20A does not reach position H corresponding to the lower blade block 232 that guides the peak portion 110. Therefore, it was necessary to manually lift the lower blade block 232 so that the peak portion 110 reached the height position H of the lower blade block 232.

[0040] The operation of lifting the molded workpiece 20A and inserting it into the cutting die 231 requires simultaneous work to align the peak portion 110 with the block 232 and, in particular, the work to align the fitting portions 150, 160 with the lower blade blocks 233, 234, since the peak portion 110 of the molded workpiece 20A and the fitting portions 150, 160 are in the same position in the feed direction F. Furthermore, since the plate passage opening 235 is narrow, this is a difficult operation.

[0041] In particular, the task of properly installing the fitting portion 150 in the lower blade block 233 is time-consuming, and preventing derailment of the fitting portion 150 within the cutting die 231 is extremely important during the plate threading operation. Figure 5 is a diagram showing a state in which the fitting portion 150 has derailed within the cutting die 231. For example, if the fitting portion 150 is not positioned correctly relative to the block 233 and derails, specifically, if the fitting portion 150 is placed on the block 233 and the molded workpiece 20A is inserted into the cutting die 231 and cut, the fitting portion 150 will become a crushed deck plate 100, and it is also expected that the molded workpiece 20A will become stuck in the cutting die 231.

[0042] Therefore, as a result of intensive research, the inventors have invented the manufacturing method of the present invention. The manufacturing method of the present invention for a deck plate 100 is a manufacturing method for manufacturing a deck plate 100 having peaks 110 and valleys 120, 130 alternately and continuously in a width direction W via an inclined portion 140, and having fitting portions (folded portions) 150, 160 folded back to each other on the ends in the width direction W, the method comprising the steps of: unwinding step S11 in which the strip steel plate 10 is unwound from a steel plate coil; The method includes a first cutting step S12 in which both corner ends 13 of the steel strip 10 are cut off so that the cutting edges 14 move away from each other upstream in the feed direction F, a forming step S13 in which the steel strip 10 from which the corner ends 13 have been cut off is roll-formed to form a formed workpiece 10A having an inclined portion 140, a crest portion 110, bottom portions 120, 130, and fitting portions 150, 160, and a second cutting step S14 in which the formed workpiece 10A is cut to a predetermined length in the feed direction F. A manufacturing method according to the first embodiment of the deck plate 100 will now be described in detail.

[0043] First, the uncoiler 210, on which a new steel sheet coil is set, sends out the strip steel sheet 10 from its starting end (tip) (unwinding process S11). Next, the strip steel sheet 10 is sent to a processing section (processing zone) 215, which is provided between the uncoiler 210 and the roll forming equipment 220 and processes the tip end of the strip steel sheet 10. In the processing section 215, the tip end of the strip steel sheet 10 is processed (first cutting process S12).

[0044] 6 is a plan view showing the tip of the processed steel strip 10. The tip of the steel strip 10 fed from the uncoiler has a tip edge 11 facing the feeding direction F and side edges 12 of the steel strip 10 extending in the feeding direction F, and further has a corner 13 defined by the tip edge 11 and the side edges 12.

[0045] The steel strip 10 that has been fed with the corners 13 is cut diagonally and linearly at the leading edge 11 and the side edges 12, removing the two corners 13. The two cut edges 14 of the steel strip 10 from which the corners 13 have been cut approach each other in the feed direction F from the starting ends (corners) 12a of the side edges 12 toward the leading edge 11. The corners 13 are cut so that the leading edge 11 remains in the steel strip 10 after processing. The leading edge of the steel strip 10 is formed into a trapezoidal shape by an imaginary line V that connects the leading edge 11 and the corners 12a, which are also the starting ends in the width direction W.

[0046] The corner portion 13 of the strip steel plate 10 is cut off at a position (corner portion) 11a at the leading edge 11, which is a distance (mm) L1 from the side edge 12 in the width direction W, and at a position (corner portion) 12a at the side edge 12, which is a distance (mm) L2 from the leading edge 11 in the feed direction F. L1:L2=1.5:1.0 In the processing section 215, the tip end of the strip steel plate 10 is processed so as to satisfy the relationship shown above.

[0047] The strip steel plate 10, from which the corners 13 at the leading end have been cut off, is then sent to roll forming equipment 220 and passed through the installed roll stands 221 in order to form a formed workpiece 10A in which the peaks 110, valley bottoms 120, 130, inclined portions 140, and mating portions 150, 160 of the deck plate 100 have been formed (roll forming step S13). Note that the order in which the peaks 110, valley bottoms 120, 130, inclined portions 140, and mating portions 150, 160 are formed is not particularly limited here.

[0048] In the first cutting process S12, the corners 13 at the leading end of the strip steel plate 10 are removed, resulting in a deformed portion 110A at the leading end of the formed workpiece 10A formed in the roll forming equipment 220, which has a deformed portion 110A that differs from the desired shape. FIG. 7A is a perspective view showing the formed workpiece 10A having the deformed portion 110A after roll forming. FIG. 7B is a side view of the formed workpiece 10A shown in FIG. 7A. FIG. 7C is a cross-sectional view showing cross sections taken along lines CI-CI and CII-CII in FIG. 7B. FIG. 7D is an enlarged perspective view showing one fitting portion 160 at the leading end side of the formed workpiece 10A in the feed direction F. FIG. 7E is an enlarged plan view showing one fitting portion 160 at the leading end side of the formed workpiece in the feed direction F.

[0049] The leading end of the strip steel sheet 10 (formed workpiece 10A) formed in the roll forming equipment 220 extends obliquely along the feed direction F from the portion where the cut edge 14 at the valley bottom 130 continues to the inclined portion 140 toward each of the fitting portions 150, 160. Furthermore, at the leading end of the formed workpiece 10A, the strip steel sheet 10 rolled in the roll forming equipment 220 is partially missing in the width direction W (the corner portion 13 is cut off), so that the formed workpiece 10A formed in the roll forming equipment 220 has an intentionally formed deformed portion 110A.

[0050] The deformed portion 110A is generated at the position of the peak 110 on the tip end side. Because the steel plate portion where the valley bottom 130 is formed in the roll forming process S13 is partially absent at the tip end of the strip steel plate 10, the forming force applied from the width direction W acts excessively on the inclined portion 140 continuing from the valley bottom 130. As a result, the position of the peak 110 as the deformed portion 110A is formed at a higher position than the position of the normal peak 110 (see FIG. 7B). In other words, the peak 110 of the formed workpiece 10A extends in a downward inclined manner from the tip end side toward the upstream side in the feed direction F.

[0051] The angle θ1 formed between the peak 110 and the inclined portion 140 in the deformed portion 110A is smaller than the angle θ2 (θ1<θ2) of the inclined portion 140, where the fitting portions 150, 160 are formed in the width direction W, relative to the peak 110. In other words, the inclination of the inclined portion 140 in the deformed portion 110A is closer to vertical than the inclination of a normal inclined portion 140.

[0052] Furthermore, for example, the fitting portion 160 on the tip end side of the formed workpiece 10A is formed by folding back between the corner 11a on the tip edge 11 side of the strip steel plate 10 and the corner 12a on the side edge 12 side. In this state, both side edges 12 in the width direction W face the inclined portion 140 side. Furthermore, the cutting edge 14 extends from the tip end side of the formed workpiece 10A obliquely outward (away from the inclined portion 140) to the upstream side in the feed direction F, then obliquely upward (toward the peak portion 110) to the upstream side in the feed direction F, and then obliquely inward (toward the inclined portion 140) to the upstream side in the feed direction F to the side edge 12.

[0053] Finally, the formed workpiece 10A thus formed is sent to the flying cutter 230, where it is cut into individual deck plates 100 of a predetermined length (second cutting step S14).

[0054] FIG. 8 is a schematic diagram showing the state of the formed workpiece 10A just before the flying cut-off machine 230 in the manufacturing method according to the first embodiment. When the formed workpiece 10A is sent from the rearmost roll stand 221 of the roll forming equipment 220 to the flying cut-off machine 230, the leading edge of the formed workpiece 10A may drop due to its own weight. However, due to the deformed portion 110A, the position of the crest 110 is higher than the normal position of the crest 110. Therefore, when the formed workpiece 10A is inserted into the cutting die 231 of the flying cut-off machine 230, the deformed portion 110A of the crest 110 first rests on the block 232 of the cutting die 231. As a result, the formed workpiece 10A is sent upward into the plate-passing opening 235 of the cutting die 231, and then the fitting portions 150, 160 approach the plate-passing opening 235.

[0055] In the formed workpiece 10A, the cutting edge 14 extends obliquely from the tip toward the fitting portions 150, 160 in the feed direction F, and this cutting edge 14 provides a distance until the blocks 233, 234 first come into contact with the fitting portions 150, 160. In addition, the cutting edge 14 has a portion that extends obliquely upward from the side of the valley bottom 130 toward the side of the crest 110. This allows smooth guidance of the workpiece 10A into the plate-passing opening 235 in the fitting portions 150, 160, and allows stable plate passing through the fitting portions 150, 160.

[0056] The formed workpiece 10A is cut by a flying cutter 230 to produce deck plates 100 of a predetermined length. Note that deck plates 100 produced from the portion of the formed workpiece 10A that includes the deformed portion 110A do not meet product eligibility and are therefore rejected after being cut from the formed workpiece 10A.

[0057] According to the manufacturing method described above, the leading ends of the successively formed workpieces 10A fed from the roll forming equipment 220 and guided into the flying cut-off machine 230 are tapered in the feed direction F. As a result, the peaks 110 of the formed workpieces 10A are guided into the cutting die 231 first, followed by the cutting edge 14 inclined in the feed direction F and in the height direction, and finally the mating portions 150, 160 are guided into the cutting die 231. By guiding the peaks 110 first, the formed workpieces 10A are ensured to be in the correct position and orientation within the cutting die 231. Therefore, the subsequently inserted mating portions 150, 160 can also be ensured to be in the correct position and orientation relative to the lower blade blocks 233, 234, and the leading ends of the continuously fed formed workpieces 10A can be smoothly inserted into the cutting die 231 of the flying cut-off machine 230.

[0058] Furthermore, by cutting off the corners 13 of the strip steel sheet 10 before roll forming, the fitting portions 150, 160 are not formed at the leading end side of the strip steel sheet 10 during roll forming, and a greater force is applied to the inclined portion 140 than usual (when the fitting portions 150, 160 are formed). As a result, the rise of the inclined portion 140 formed at the leading end side of the formed workpiece 10A is closer to vertical and steeper in the width direction W than the rise of the inclined portion 140 where the fitting portions 150, 160 are formed. As a result, the peak 110 continuing from the inclined portion 140 at the leading end side is located higher in the height direction than the subsequent peak 110.

[0059] Therefore, even if the tip of the formed workpiece sags due to its own weight between the roll forming equipment 220 and the flying cutting machine 230, the peak 110 on the tip side of the formed workpiece, which is located higher than the peak 110 of the deck plate 100 that meets the product standards, will compensate for the sagging amount, and the workpiece can be fed smoothly into the plate passage opening 235 of the cutting die 231, for example, without human intervention.

[0060] In the manufacturing method of the present invention, the corner portions 13 of the strip steel plate 10 before roll forming are cut off, thereby preventing the fitting portions 150, 160 from being formed at the tip of the strip steel plate 10 in the roll forming equipment 220, and intentionally changing the pressure distribution at the tip from the pressure distribution in the part where the fitting portions 150, 160 are formed.

[0061] <Second embodiment> Next, a description will be given of a manufacturing method according to a second embodiment of the deck plate 100. The manufacturing method of the deck plate 100 according to the second embodiment is a manufacturing method for manufacturing a deck plate 100 having a wave shape in which peaks 110 and valley bottoms 120, 130 are alternately and continuously arranged in the width direction W via inclined portions 140, and having fitting portions 150, 160 folded back to different sides at the ends in the width direction W, and includes an unwinding process S21 in which the strip steel plate 10 is unwound from a steel plate coil in which the strip steel plate 10 is wound, and a roll-forming process S22 in which the strip steel plate 10 from which the corner ends 13 have been cut off is performed to form the inclined portions 140, the peaks 110, the valley bottoms 120, 130, and the fitting portions 150, 160. The method includes a roll-forming process S22 for forming a formed workpiece 10B having a slope 140 and fitting portions 150, 160; a first cutting process S23 for cutting the formed workpiece 10B in a V-shape in the feed direction F of the steel strip 10 at the transition portion between the slope 140 and the valley bottom 120, which are continuous in the width direction W, at the leading end of the formed workpiece 10B, and for diagonally cutting the fitting portions 150, 160 so that the cut edges 14 move away from each other upstream in the feed direction F; and a second cutting process S24 for cutting the formed workpiece 10B to a predetermined length in the feed direction F. A specific description of a manufacturing method for a deck plate 100 according to a second embodiment will be given below. Note that, in the following, the same components as those in the first embodiment will be designated by the same reference numerals and will not be described again.

[0062] FIG. 9 is a schematic diagram of a production line 200A that produces a deck plate 100 using a production method according to a second embodiment. The production line 200A includes an uncoiler 210, a roll forming facility 220, a processing unit 225, a flying cut-off machine 230, and a feed roller table 240. In the second embodiment, the processing unit 225 is provided between the roll forming facility 220 and the flying cut-off machine 230. In the processing unit 225, corners 170 (see FIG. 1A) are cut off at the fitting portions 150, 160 of the formed workpiece 10B. While cutting is assumed to be performed using a gas torch in the processing unit 225, a hand shear, grinder, or press may also be used. Each method is optional and may be selected according to the scale and specifications of the line.

[0063] First, a strip steel sheet is fed from its starting end (tip) from an uncoiler on which a new steel sheet coil is set (unwinding process S21). Next, the strip steel sheet 10 is sent to roll forming equipment 220 and passed through the installed roll stands 221 in order to form a formed workpiece 10B in which the peak portion 110, the valley bottom portions 120, 130, the inclined portion 140, and the fitting portions 150, 160 of the deck plate 100 are each formed (roll forming process S22).

[0064] The formed workpiece 10B sent out from the rearmost roll stand 221 in the roll forming equipment 220 is then sent to the processing section 225. FIG. 10 is a perspective view showing the processed formed workpiece 10B. Unlike the manufacturing method according to the first embodiment, the leading end of the formed workpiece 10B has fitting portions 150, 160 formed at both ends in the width direction W. In the processing section 225, the leading end of the formed workpiece 10B is partially processed (first cutting step S23).

[0065] The formed workpiece 10B is cut away at the transition between the valley bottom 120 and the inclined portion 140 that continues in the width direction W, to form a notch 144. Specifically, the notch 144 is a V-shaped portion of the formed workpiece 10B cut away at the bulge 142 and dovetail groove 143 that continue to the valley bottom 120, toward the upstream side in the feed direction F.

[0066] Furthermore, in the processing section 225, the corner portion 170 of the formed workpiece 10B is cut off obliquely, including the fitting portions 150 and 160. Specifically, the formed workpiece 10B is cut off from the middle of the inclined portion 140 continuing to the valley bottom portion 130, including the dovetail groove 143, toward the upstream side in the feed direction F and toward the fitting portions 150 and 160.

[0067] Next, the formed workpiece 10B thus formed is sent to the flying cutter 230, where it is cut into individual deck plates 100 of a predetermined length (second cutting step S24).

[0068] When the above-described shaped workpiece 10B is passed through the flying cut-off machine 230, the portion of the shaped workpiece 10B that is first inserted into the cutting die 231 has curved portions such as the dovetail groove 143 and the fitting portions 150, 160 cut away, leaving a flat portion such as the valley bottom 120 and the inclined portion 140 that continues to the valley bottom 120. This allows the shaped workpiece 10B to be smoothly guided into the passing opening 235 of the cutting die 231.

[0069] <Other> Although the preferred embodiments of the present invention have been described above, the present invention is not limited to the above embodiments and includes all aspects encompassed by the concept of the present invention and the scope of the claims. Furthermore, each configuration may be appropriately and selectively combined to achieve at least some of the above-described problems and effects. Furthermore, for example, the shape, material, arrangement, size, etc. of each component in the above embodiments may be appropriately modified depending on the specific use of the present invention. [Explanation of symbols]

[0070] 10: Strip steel plate; 10A, 10B: Formed workpiece; 11: Leading edge; 12: Side edge; 13: Corner portion; 14: Cutting edge 100···Deck plate, 110···Crest portion, 110A···Deformed portion, 120···Bottom portion, 130···Bottom portion, 140···Sloped portion, 150, 160···Fitting portion (folded portion) 200, 200A··· production line, 210··· uncoiler, 215··· processing section (processing section), 220··· roll forming equipment, 225··· processing section, 230··· flying cut-off machine, 231··· cutting die

Claims

1. A manufacturing method for manufacturing a deck plate having a wave shape in which peaks and valleys are alternately and continuously formed in a width direction via inclined portions, and having folded portions folded back to different sides at the ends in the width direction, an unwinding step of unwinding the strip steel plate from a steel plate coil around which the strip steel plate is wound; a first cutting step of cutting off both corner end portions of the strip steel plate in a feeding direction in which the strip steel plate is fed so that cutting edges are spaced apart from each other toward the upstream side in the feeding direction; a forming step of roll-forming the strip steel plate from which the corner ends have been cut off to form a formed workpiece having the inclined portion, the peak portion, the valley bottom portion, and the folded-back portion; a second cutting step of cutting the formed workpiece into a predetermined length in the feed direction; Including, A method for manufacturing a deck plate, characterized in that in the forming process, the folded portion is not formed in the portion where the corner end is cut off, throughout the entire feed direction.

2. 2. A method for manufacturing a deck plate according to claim 1, characterized in that the folded portion is formed by folding back the strip steel plate between a tip corner of the cutting edge and a side edge corner of the cutting edge on the side of the side edge of the strip steel plate extending along the feed direction.

3. A manufacturing method for manufacturing a deck plate having a wave shape in which peaks and valleys alternately and continuously in the width direction via inclined portions, and having folded portions folded back to different sides at the ends in the width direction, an unwinding step of unwinding the strip steel plate from a steel plate coil around which the strip steel plate is wound; a first cutting step of cutting off both corner end portions of the strip steel plate in a feeding direction in which the strip steel plate is fed so that cutting edges are spaced apart from each other toward the upstream side in the feeding direction; a forming step of roll-forming the strip steel plate from which the corner ends have been cut off to form a formed workpiece having the inclined portion, the peak portion, the valley bottom portion, and the folded-back portion; a second cutting step of cutting the formed workpiece into a predetermined length in the feed direction; Including, A method for manufacturing a deck plate, characterized in that a formed workpiece is formed so that the angle formed between the inclined portion and the peak portion in the part where the folded portion is not formed in the width direction is smaller than the angle formed between the inclined portion where the folded portion is formed in the width direction and the peak portion, and the peak portion where the folded portion is not formed in the width direction is higher in the width direction than the peak portion where the folded portion is formed.

4. A manufacturing method for manufacturing a deck plate having a wave shape in which peaks and valleys alternately and continuously in the width direction via inclined portions, and having folded portions folded back to different sides at the ends in the width direction, an unwinding step of unwinding the strip steel plate from a steel plate coil around which the strip steel plate is wound; a first cutting step of cutting off both corner end portions of the strip steel plate in a feeding direction in which the strip steel plate is fed so that cutting edges are spaced apart from each other toward the upstream side in the feeding direction; a forming step of roll-forming the strip steel plate from which the corner ends have been cut off to form a formed workpiece having the inclined portion, the peak portion, the valley bottom portion, and the folded-back portion; a second cutting step of cutting the formed workpiece into a predetermined length in the feed direction; Including, A method for manufacturing a deck plate, characterized in that the formed workpiece is inserted into a cutting die used to cut the formed workpiece from the top portion, and then the folded portion is inserted.

5. A manufacturing method for manufacturing a deck plate having a wave shape in which peaks and valleys are alternately and continuously formed in a width direction via inclined portions, and having folded portions folded back to different sides at the ends in the width direction, an unwinding step of unwinding the strip steel plate from a steel plate coil around which the strip steel plate is wound; a forming step of roll-forming the strip steel plate to form a formed workpiece having the inclined portion, the peak portion, the valley bottom portion, and the folded-back portion; a first cutting step of cutting off the formed workpiece in a V-shape at the tip end of the formed workpiece at a transition portion between the inclined portion and the valley bottom portion, which are continuous in the width direction, in the feed direction of the strip steel plate, and cutting off corners at the folded portion so that the cut edges move away from each other upstream in the feed direction; a second cutting step of cutting the formed workpiece into a predetermined length in the feed direction; A method for manufacturing a deck plate, comprising:

6. The method for manufacturing a deck plate according to claim 5, characterized in that the corners are cut off, including the transitional portion between the valley bottom and the inclined portion, which are continuous with the folded portion.

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