Manufacturing method of accessories

Abstract

To provide an accessory allowing suppression of surface waviness at an end part in a width direction.SOLUTION: A production method of a deck accessory 1 for producing the deck accessory 1 for a deck plate 100, in which the deck plate has formed therein surface parts 120 with a plurality of concave groove parts 130 and ribs 110 extending in a length direction L and separated by a specific space in a width direction sequentially and alternately. The production method of a deck accessory includes: a feeding step S1 of feeding a strip-shaped steel plate from a steel plate coil; a forming step S3 of forming surface parts 120 and ribs 110 on the strip-shaped steel plate and a plurality of concave groove parts 130 on the surface parts 120; a length cutting step S4 of cutting the strip-shaped steel plate in a width direction to form the deck plate 100 with a specific length after the forming step S3; and a width cutting step S5 of cutting width end parts of the deck plate 100 along the longitudinal direction L of the deck plate 100.SELECTED DRAWING: Figure 6

Description

[Technical Field]

[0001] The present invention relates to a method for manufacturing accessories, and more particularly to a method for manufacturing accessories for deck plates in which a surface portion having a plurality of grooves and ribs are formed alternately and continuously. [Background technology]

[0002] Deck plates are widely used when constructing floor slabs and ceiling slabs in building structures. Deck plates are installed so as to span between support beams, with both ends of the deck plate fixed to the upper surfaces of the support beams. After the deck plate is fixed, concrete is poured on top of the deck plate, and the floor structure or ceiling structure is constructed as the concrete hardens.

[0003] The deck plate is formed by bending a metal plate by roll forming, etc. Ribs are formed on the deck plate to increase its rigidity (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2017-120014 Summary of the Invention [Problem to be solved by the invention]

[0005] At construction sites where concrete slabs that make up the floors and ceilings of buildings are installed, the width of the deck plates is adjusted to fit the dimensions between the building's support beams using standard width products and accessory products for width adjustment. These standard width products are securely joined by inserting or fitting together.

[0006] On the other hand, in order to allow for flexible width adjustment, accessory products are generally not inserted or fitted together, but rather the flat part of one product is placed on top of the other, and the two products are joined together by welding or screws.

[0007] In accessory products made by cutting standard products, wavy edges may occur on the flat edges in the width direction during the manufacturing process. If such wavy edges occur, gaps may form between the accessory product and other products and supporting beams when concrete is poured, which can lead to slag leakage (seepage of poured concrete) or defects in the slab cross section.

[0008] Therefore, the present invention has been made in consideration of the above-mentioned problems, and aims to provide a technology for manufacturing accessories with reduced waviness at the widthwise ends. [Means for solving the problem]

[0009] In order to solve the above problems, the manufacturing method of a component according to the present invention is a manufacturing method of a component for manufacturing a component for a deck plate in which surface portions and ribs having at least one of a plurality of concave ridge portions and convex ridge portions extending in the longitudinal direction and formed at a predetermined interval in the lateral direction are alternately formed in succession, and is characterized by including a feeding process in which a strip steel plate is fed out from a steel plate coil in which the strip steel plate is wound, a forming process in which the surface portions, the ribs and the concave ridge portions are formed on the surface portions of the strip steel plate, a length cutting process in which the strip steel plate is cut in the width direction after the forming process to form a deck plate of a predetermined length, and a width cutting process in which the width end portions of the deck plate are cut along the length direction.

[0010] In the manufacturing method according to one aspect of the present invention, in the molding step, a folded portion is formed by folding one end of the surface portion in the width direction back toward the rib.

[0011] In the manufacturing method according to one aspect of the present invention, in the width cutting step, the cutting can be performed by cutting a predetermined width variably from the folded portion side. [Effects of the Invention]

[0012] The present invention makes it possible to suppress waviness at the widthwise ends of the accessory. [Brief explanation of the drawings]

[0013] [Figure 1] FIG. 10 is a diagram showing a deck plate installed between support beams and a deck accessory according to the present invention. [Figure 2A] FIG. [Figure 2B] FIG. 2B is a cross-sectional view of the deck plate taken along line BB in FIG. 2A. [Figure 3A] FIG. [Figure 3B] 3B is a cross-sectional view of the deck accessory taken along line BB in FIG. 3A. [Figure 4] 1 is a schematic diagram showing a conventional manufacturing process for a deck accessory. [Figure 5] FIG. 10 is a perspective view of another deck accessory. [Figure 6] 1A to 1C are diagrams showing the manufacturing process of the deck accessory according to the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0014] 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.

[0015] 1 is a diagram showing a deck plate 100 installed between support beams 200 and a deck accessory 1 according to the present invention. The accessory according to the present invention is used when constructing a floor slab or ceiling slab in which the deck plate 100 is used. In the following, the direction in which the deck plate 100 is bridged between support beams 200 of a building is referred to as the longitudinal direction (length direction) L, and the direction in which the deck plate 100 is laid out, intersecting the longitudinal direction L, is referred to as the transverse direction (width direction) W.

[0016] The deck plate 100 is spanned between opposing support beams 200. One end of the deck plate 100 is placed on one of the support beams 200 and fixed to the support beam 200 by welding or the like, and the other end is placed on the other support beam 200 and fixed to the support beam 200 by welding or the like. Specifically, the support beams 200 are made up of, for example, H-shaped steel, and each end of the deck plate 100 is placed on and fixed to the flange portion of the H-shaped steel that makes up the respective support beams 200.

[0017] The accessory 1 according to the present invention is laid to fill the gap in the width direction W between the deck plates 100 and the support beams 200. The accessory 1 is manufactured using the deck plates 100 as described below.

[0018] FIG. 2A is a perspective view of the deck plate 100. FIG. 2B is a cross-sectional view of the deck plate 100 taken along line BB in FIG. 2A. The deck plate 100 is formed from a thin steel strip that has been subjected to a surface treatment such as galvanization. The deck plate 100 is manufactured, for example, by roll-forming a flat steel strip using a roll-forming machine. The deck plate 100 is bent at multiple locations by the roll-forming machine. Note that the deck plate 100 does not necessarily have to be subjected to a surface treatment such as galvanization.

[0019] The deck plate 100 includes, for example, three ribs 110a, 110b, and 110c, a surface portion 120, a groove portion 130, a locking portion (folded portion) 140, and an end-closed portion 150. The ribs 110 are formed to extend along the longitudinal direction L of the deck plate 100. That is, the ribs 110 are formed continuously from one end to the other along the direction in which they are suspended from the support beam 200. The number of ribs 110 is not particularly limited, and may be one or two. In the following description, when the ribs 110a, 110b, and 110c are not to be distinguished from one another, they may be simply referred to as "ribs 110."

[0020] Two ribs 110a, 110b near a locking portion 140 (described later) are formed by bending a steel strip. The ribs 110a, 110b each have a pair of straight portions 111 and a bent portion 112. The straight portion 111 is bent toward one surface of the steel strip, and extends in a direction perpendicular to a surface portion 120 (described later). The bent portion 112 is continuous with the straight portion 111 and is curved and folded back multiple times.

[0021] The pair of straight portions 111 are formed so that their surfaces abut against each other, and are connected to each other by crimping or the like, so that the pair of straight portions 111 do not separate from each other. The bent portion 112 is formed in a generally triangular shape in cross section, and is folded back so that the start point and end point are adjacent to each other so that the straight portions 111 abut against each other.

[0022] Of the three ribs 110a, 110b, and 110c, rib 110c, which is located farthest from a locking portion 140 (see FIG. 2B), which will be described later, has a pair of straight portions 111 and a bent portion 112, similar to the other ribs 110a and 110b. Rib 110c is inclined obliquely toward surface portion 120 in a direction away from one of the pair of straight portions 111 that faces the side opposite ribs 110a and 110b, and a receiving portion 113 is formed between rib 110c and the other straight portion 111. A locking portion 140, which will be described later, is inserted into the receiving portion 113.

[0023] The rib 110c further has an extension 114. The extension 114 is a portion that is folded back by roll forming from one of the pair of straight portions 111 that form the receiving portion 113 so that it extends parallel to the surface portion 120. When connecting deck plates 100, the deck plates 100 are overlapped so that part of the surface portion 120 of another deck plate 100 is placed on the upper surface of the extension 114 of the rib 110c, and the locking portion 140 is inserted into the receiving portion 113.

[0024] The surface portions 120 are primarily portions of the deck plate 100 where the ribs 110 are not formed, and are portions having surfaces that primarily bear the load of the poured concrete. The surface portions 120 are formed between the ribs 110 of the deck plate 100 in the width direction W. In other words, the ribs 110 and the surface portions 120 are formed alternately on the deck plate 100. On the deck plate 100, the surface portions 120 are formed on the same plane.

[0025] The grooves 130 are formed by corresponding roll forming of a strip-shaped steel plate. The grooves 130 are formed on the surface portion 120 so as to protrude concavely toward the side where the ribs 110 are formed. As a result, the surface portion 120 has alternating flat portions and valley portions (ridge portions when viewed from the rib 110 side).

[0026] The grooves 130 extend along the longitudinal direction L, and multiple grooves 130 are formed at predetermined intervals in the width direction W. For example, three grooves 130 are formed per surface portion 120. The number of grooves 130 is not particularly limited and may be one, two, or four or more. The number of grooves 130 may be different for each surface portion 120 of a single deck plate 100, and some surface portions 120 may not have grooves 130. Furthermore, instead of the grooves 130, protruding ridges may be formed on the surface portion 120 that protrude convexly toward the side opposite the side on which the ribs 110 are formed, or both grooves 130 and protruding ridges may be present.

[0027] The locking portion 140 is formed by roll forming at one end of the deck plate 100 in the width direction W. The locking portion 140 is an end portion of steel material that is bent at a substantially right angle from the surface portion 120 and is folded back so as to extend along the extension direction of the rib 110. When connecting deck plates 100, the locking portion 140 of one deck plate 100 is inserted into a receiving portion 113 between a pair of straight portions 111 formed on the rib 110 at the other end of the other deck plate 100. The locking portion 140 is provided on one of both edges of the deck plate 100 in the width direction that is farther from the rib 110.

[0028] The closed-end sections 150 are formed at both ends of the deck plate 100 in the longitudinal direction L. The closed-end sections 150 are formed by crushing both ends of the ribs 110 in a direction perpendicular to the surface 120 of the deck plate 100. As a result, the ribs 110 have a cross section where the closed-end sections 150 at both ends are crushed, and the other parts of the ribs 110 sandwiched between the closed-end sections 150 in the extension direction (longitudinal direction L) are formed into a generally triangular cross section. As a result, the both ends of the ribs 110 are lower in height than the other parts, so they can be placed on the upper surface of the flange portion of the support beam 200. The closed-end sections 150 are formed so that the length along the extension direction of the ribs 110 is longer than the length over which they are placed on the upper surface of the flange portion of the support beam 200.

[0029] Fig. 3A is a perspective view of the deck accessory 1. Fig. 3B is a cross-sectional view of the deck accessory 1 taken along line BB in Fig. 3A. The deck accessory 1 is formed from the above-described deck plate 100. Specifically, it is manufactured by cutting a portion of the deck plate 100 along the longitudinal direction L at a predetermined position in the width direction W from the side of the deck plate 100 where the locking portion 140 is formed. In other words, the deck accessory 1 does not have the locking portion 140 of the deck plate 100.

[0030] The cut edge 10 on the cut side of the deck accessory 1 extends in a straight or substantially straight line along the longitudinal direction L. Here, "substantially straight line" means that even if the cut edge 10 of the deck accessory 1 is wavy, the gap that occurs between the deck accessory 1 and the support beam 200 on the side of the cut edge 10 when the deck accessory 1 is laid between the deck plate 100 and the support beam 200 is small enough to prevent slag leakage when concrete is poured.

[0031] Next, a manufacturing method of the deck accessory 1 will be described. First, a conventional manufacturing method of a deck accessory will be described. FIG. 4 is a diagram showing a conventional manufacturing process of a deck accessory. First, a strip steel plate is unwound from a wound strip steel plate coil (step S101). Next, mark holes and notches are formed in the unwound strip steel plate by press working, and the strip steel plate is cut to a predetermined width in a first press device on one edge side along the length of the strip steel plate to match the width of the deck accessory to be formed (step S102). Here, the mark holes are formed at intervals in the flow direction by the length of the deck accessory 1 to be manufactured. The notches are formed on both edges along the flow direction of the strip steel plate, and are formed in a length from both ends of the deck plate in the longitudinal direction L that ultimately exceeds the end-closed section 150.

[0032] Next, in roll forming equipment downstream in the flow direction from the first press device, the ribs 110, surface portions 120, and groove portions 130 are formed by roll forming (step S103). Also, the straight portions 111 of the ribs 110 are crimped together by a predetermined crimping machine. Since the strip steel sheet has been cut to width in step S102, the strip steel sheet portion where the locking portion 140 is to be formed does not exist in the strip steel sheet sent to the roll forming equipment (step S103), and therefore the locking portion 140 is not formed.

[0033] Next, in a second press machine downstream in the flow direction of the roll forming equipment, the formed workpiece is cut in the width direction based on the mark holes formed in step S102 to form formed workpieces of a predetermined length, and both ends in the length direction are crushed to form end-closed sections 150 (step S104). In this way, the deck plate 100 is manufactured.

[0034] Next, in a slitter downstream of the second press device in the flow direction, the deck plate 100 is cut to width on the other edge of the deck plate 100 opposite the side cut in step S102 (step S105). Note that step S105 is performed as needed based on the width dimension of the deck accessories, and is not performed if not required. In this way, the deck accessories are manufactured, and finally, multiple deck accessories are bundled together and shipped.

[0035] When a deck accessory is manufactured using the above process, waviness occurs along the length of one edge of the deck accessory that was cut to width in step S102 to an unacceptable degree for the product. However, it was found that the problem of waviness is unique to deck accessory 1 that is fitted to deck plate 100, and occurs particularly frequently at cut edge 10 away from rib 110 in the width direction W. Specifically, waviness occurs in the formed workpiece (strip steel plate) processed in the roll forming equipment in step S103.

[0036] In contrast, even when another deck accessory 500 was manufactured using the same manufacturing process, no waviness that was unacceptable for a product occurred along the length of one edge of the deck accessory 500 that was cut to width in step S102.

[0037] 5 is a perspective view of another deck accessory 500. The deck accessory 500 includes a deck plate, for example, a rib 510, a surface portion 520, a convex portion 530, and an end-closed portion 550. The rib 510, the surface portion 520, and the end-closed portion 550 in the deck accessory 500 are the same as the rib 110, the surface portion 120, and the end-closed portion 150 in the deck accessory 1.

[0038] The convex rib portions 530 in the deck accessory 500 are formed by embossing a steel plate. The convex rib portions 530 are formed on the surface portion 520 so as to convex toward the side opposite to the side on which the ribs 510 are formed. The convex rib portions 530 extend along the width direction W, and a plurality of the convex rib portions 530 are formed at predetermined intervals in the length direction L.

[0039] Even after forming in the roll forming equipment in step S103 of the manufacturing process, no waviness occurred in the deck accessory 500. The reason why no waviness occurred is thought to be that the deck accessory 500 is provided with a plurality of protruding ridges 530 extending along the width direction W and spaced at predetermined intervals in the length direction L.

[0040] The load applied to the steel plate during roll forming causes distortion not only in the width direction W but also in the length direction L of the steel plate. However, by providing the convex stripe 530 in the width direction W, which is perpendicular to the length direction L of the steel plate, in a direction that cancels out the waviness of the edge 511, and plastically deforming the steel plate out of the plane, it is possible to reduce residual stress and maintain the shape of the surface portion 120. For this reason, it is believed that waviness does not occur on the edge 511 side. This can be seen from the fact that when the deck plate 100 was manufactured, no waviness occurred near the locking portion 140 and the extension portion 114, which were parts that were plastically deformed by roll forming.

[0041] In contrast, when the deck accessory 1 is manufactured using a conventional manufacturing method, the forming roll comes into contact with the portion 12 (FIG. 3B) between one cut edge 10 in the width direction W of the deck accessory 1 and the nearest grooved rib portion 130 when forming the surface portion 120, but the grooved rib portion 130 and the locking portion 140 are not formed, so distortion remains in the portion 12 and the shape of the surface portion 120 cannot be maintained, which is thought to result in waviness. In other words, it was found that the locking portion 140 suppresses the occurrence of waviness.

[0042] Therefore, the manufacturing method of the present invention was invented for the purpose of manufacturing a deck accessory 1 corresponding to a deck plate 100 so as to prevent waviness from occurring in the deck accessory 1. The manufacturing method of the deck accessory 1 of the present invention is a method for manufacturing a deck accessory 1 for a deck plate 100 in which surface portions 120 and ribs 110, each having a plurality of grooves 130 extending in the length direction L and formed at predetermined intervals in the width direction W, are alternately and continuously formed, and is characterized by including a feeding process S1 in which a strip steel plate is fed from a steel plate coil around which the strip steel plate is wound; a forming process S3 in which the strip steel plate is formed into a formed workpiece having the surface portions 120, the ribs 110, and the grooves 130 on the surface portions 120; a length cutting process S4 in which, after the forming process S3, the formed workpiece is cut in the width direction W to form the deck plate 100 of a predetermined length; and a width cutting process S5 in which the width end portions of the deck plate 100 are cut along the length direction L. The manufacturing method of the deck accessory 1 of the present invention will be specifically described below.

[0043] 6 is a diagram showing the manufacturing process of the deck accessory 1 according to the present invention. In the manufacturing line (not shown) for the deck accessory 1, a steel sheet coil, a first press machine, roll forming equipment, a second press machine, and a slitter are arranged in this order from upstream to downstream.

[0044] First, the strip steel plate is fed out by an uncoiler from a steel plate coil around which the strip steel plate is wound (step S1: feeding process). Next, mark holes and notches are formed in the unwound strip steel plate by pressing in a first press device (step S2: first pressing process). Here, the mark holes are formed at intervals in the flow direction by the length of the deck accessory 1 to be manufactured. The notches are formed on both edges of the strip steel plate along the flow direction, and are formed in the longitudinal direction L for a length that will ultimately exceed the end-closed portion 150.

[0045] Next, downstream in the flow direction from the first press machine, the ribs 110, surface portions 120, grooved streak portions 130, and locking portions 140 are formed by roll forming in roll forming equipment (step S3: roll forming process (forming process)). Also, in the roll forming process S3, the straight portions 111 of the ribs 110 are crimped together using a predetermined crimping machine. Unlike conventional manufacturing processes, the steel plate is not cut to width in the first press process S2, so the locking portions 140 are formed in the formed workpiece in the roll forming process S3.

[0046] Next, downstream in the flow direction of the roll forming equipment, the formed workpiece is cut in the width direction based on the mark holes formed in the first press process S2 in a second press device to form a formed workpiece of a predetermined length, and both ends of the workpiece in the length direction L are crushed to form end-closed portions 150 (step S4: second press process (length cutting process)). The deck plate 100 is manufactured up to the second press process S4.

[0047] Next, downstream of the second press device in the flow direction, the deck plate 100 is cut in width by a predetermined amount in the width direction W to match the width of the deck accessory 1 to be formed in the slitter. Specifically, the deck plate 100 is cut in width on one edge side along the length direction L of the deck plate 100, specifically on the side where the locking portion 140 is formed (step S5: width cutting process). Note that in the width cutting process S5, width cutting may also be performed on the other edge side as necessary based on the width dimension of the deck accessory 1.

[0048] Here, the slitter has a pair of rotary blades. The pair of rotary blades is provided on each side of the end of the deck plate 100 in the width direction W, and cuts the end of the deck plate 100 in the width direction W as it passes. The amount of movement of each rotary blade in the width direction W can be determined by program control. The block that supports the rotary blades moves appropriately in the width direction W based on data input by an operator.

[0049] In this manner, the deck components are manufactured, and finally, a plurality of deck components are bundled together and shipped.

[0050] As described above, in the present invention, the width is cut after the deck plate 100 is manufactured, which has the locking portion 140 formed therein, which suppresses waviness in conventional manufacturing processes, so waviness can be significantly suppressed. As a result, when the deck plate 100 is laid as an accessory to fill the gap between the deck plate 100 and the support beam 200, for example, gaps between the deck plate 100 and the support beam 200 can be suppressed, and concrete slag can be prevented from leaking.

[0051] Furthermore, by adjusting the amount of movement in the width direction W of the block that supports the rotary blade in the slitter, the amount of width cutting of the deck plate 100 can be freely changed.

[0052] <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]

[0053] 1. Deck accessories (accessories) 100···Deck plate 110, 110a, 110b, 110c... Rib, 120... Surface portion, 130... Groove portion, 140... Locking portion (folded portion), 150... End closed portion S1: Delivery process S2: First press process S3: Roll forming process (forming process) S4: Second press process (length cutting process) S5...Width cutting process

Claims

[Claim 1] A method for manufacturing a component for a deck plate in which a surface portion having at least one of a plurality of recessed ridge portions and a plurality of protruding ridge portions extending in the longitudinal direction and formed at predetermined intervals in the lateral direction and a rib are alternately and continuously formed, a feeding step of feeding the strip steel plate from a steel plate coil around which the strip steel plate is wound; a forming step of forming a formed workpiece having the surface portion, the rib, and the groove portion on the surface portion of the strip-shaped steel plate; a length cutting process in which the formed workpiece is cut in the width direction after the forming process to form a deck plate of a predetermined length; a width cutting step of cutting width ends of the deck plate along the length direction; Including, In the molding step, a folded portion is formed by folding one end of the surface portion in the width direction toward the rib, A method for manufacturing a accessory, characterized in that in the width cutting process, a predetermined width including the folded portion is variably cut from the deck plate on the side of the folded portion.

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