Beam manufacturing equipment

Abstract

To provide a beam manufacturing device which can ensure detection of a cutting position of a metal material to prevent occurrence of defects in an entire length and an edge dimension of a product and ensure determination of a type of a product to be produced to prevent wrong production and shipment.SOLUTION: A beam manufacturing device includes a punch press, a cassette type molding machine, and a travel cutting machine. The beam manufacturing device includes cutting position detecting means, type determining means, and feed length measuring means between the cassette type molding machine and the travel cutting machine in a flow direction.SELECTED DRAWING: Figure 2

Description

[[Technical Field]]

[0001] The present invention relates to a beam manufacturing apparatus for manufacturing long plate-shaped products such as guardrails provided, for example, on road shoulders, boundaries between roads and sidewalks, and median strips. [[Background Art]]

[0002] Conventionally, as a roll forming apparatus for forming shaped steel or the like, there has been known a configuration including: an uncoiler for unwinding a coiled metal material such as a thin steel sheet from a coil and supplying the continuous strip-shaped metal material into a forming machine; a leveler for straightening the arcuate curvature imparted to the metal material when it was in the coiled state; a roll forming machine for forming the metal material into a predetermined cross-sectional shape; and a cutting machine for cutting the formed metal material into a predetermined length.

[0003] For example, Patent Document 1 describes a roll forming apparatus for manufacturing long products such as purlins and guardrails, the configuration including an uncoiler, a leveler, a roll forming machine, a press table having a cutting function, and the like. [[Prior Art Documents]] [[Patent Documents]]

[0004] [[Patent Document 1]] Japanese Patent No. 6854651 [[Summary of the Invention]] [[Problem to be Solved by the Invention]]

[0005] In roll forming apparatuses, such as those described in Patent Document 1, a punch press is sometimes provided upstream of the roll forming machine that forms the three-dimensional cross-sectional shape, for drilling holes at predetermined positions in the material. With a roll forming apparatus configured in this way, by drilling holes in advance before forming the cross-sectional shape, it becomes easier to place holes 21 even in the rising portion of a product having a three-dimensional cross-sectional shape, such as as shown in Figure 4, and is therefore preferable because it can handle a wider variety of products.

[0006] Furthermore, for products with such holes, the so-called edge clearance dimension, which is the distance from the center of the hole to the edge of the product, is also an important factor. Therefore, when cutting metal materials that have already been drilled with holes using a cutting machine or the like, it is necessary to cut not only the total length of the product but also the edge clearance dimension without any deviation.

[0007] Furthermore, in roll forming apparatuses such as those described in Patent Document 1, multiple types of products may be manufactured using a single roll forming apparatus. In such cases, it is necessary to verify that the correct product types are being manufactured according to the production instructions.

[0008] Therefore, the present invention has been made in view of the above matters, and aims to provide a beam manufacturing apparatus that can reliably detect the cutting position of a metal material, prevent defects in the overall length and edge clearance dimensions of the product, reliably identify the type of product being manufactured, and prevent misproduction and misshipment. [Means for solving the problem]

[0009] This invention was made to achieve the above-mentioned objectives and is characterized by the following:

[0010] The beam manufacturing apparatus according to the present invention is a beam manufacturing apparatus for continuously forming a strip-shaped metal material, comprising a punch press, a cassette-type forming machine, and a traveling cutting machine, wherein between the cassette-type forming machine and the traveling cutting machine in the flow direction, there is a cutting position detection means, a product type discrimination means, and a feed length measuring means.The cutting position detection means and the product type discrimination means are line-type laser sensors that emit a line-shaped laser beam extending in a direction intersecting the flow direction, and the line-shaped laser beam is used to detect the downstream end of the hole processed in the metal material by the punch press. It is characterized by the following.

[0013] In the beam manufacturing apparatus according to the present invention, the cutting position detection means and the product type discrimination means are preferably installed at an interval in a direction intersecting the feeding direction.

[0014] In the beam manufacturing apparatus according to the present invention, the variety discrimination means is preferably installed downstream of the cutting position detection means in the flow direction.

[0015] The above summary of the invention does not enumerate all the features necessary for the present invention, and subcombinations of these features may also constitute an invention. [Effects of the Invention]

[0016] According to the present invention, the cutting position detection means and the feed length measuring means enable cutting of metal materials at precise positions, thereby preventing defects in the overall length of the product and defects in the edge clearance dimensions. Furthermore, according to the present invention, the product type discrimination means enables reliable identification of the product type to be manufactured, thereby preventing misproduction and misshipment. [Brief explanation of the drawing]

[0017] [Figure 1] A schematic diagram showing a beam manufacturing apparatus according to an embodiment of the present invention. [Figure 2] A perspective view showing the state in which the cutting position detection means according to an embodiment of the present invention is used to detect the feed length measurement reference position, and the state in which the product type is determined using the product type determination means. [Figure 3] (a) is a plan view showing the state in which the feed length measurement reference position is detected using the cutting position detection means according to an embodiment of the present invention, and (b) is a plan view showing the state in which the feed length measurement reference position is detected using a cutting position detection means different from that of the embodiment of the present invention. [Figure 4] A perspective view showing an example of a product with holes in the rising portion of a three-dimensional cross-sectional shape. [Modes for carrying out the invention]

[0018] Preferred embodiments for carrying out the present invention will be described below with reference to the drawings. Note that the following embodiments do not limit the invention according to each claim, and not all combinations of features described in the embodiments are necessarily essential to the solution of the invention.

[0019] The beam manufacturing apparatus according to an embodiment of the present invention can be used as an example for manufacturing guardrails. Hereinafter, a case of manufacturing a guardrail using the beam manufacturing apparatus according to an embodiment of the present invention will be described as an example.

[0020] Figure 1 is a schematic diagram showing a beam manufacturing apparatus according to an embodiment of the present invention; Figure 2 is a perspective view showing a state where a feed length measurement reference position is detected using the cutting position detection means according to an embodiment of the present invention, and a state where a product type is discriminated using the product type discrimination means; Figure 3(a) is a plan view showing a state where a feed length measurement reference position is detected using the cutting position detection means according to an embodiment of the present invention; and Figure 3(b) is a plan view showing a state where a feed length measurement reference position is detected using a cutting position detection means different from that of the embodiment of the present invention. In the present specification, the flow direction, upstream, and downstream are defined as the direction and orientation of the arrows shown in Figures 1 and 2. Also in the present specification, the width direction is defined as the direction of the arrow shown in Figure 2, which is a direction intersecting the flow direction.

[0021] As shown in Figure 1, the beam manufacturing apparatus 1 according to the present embodiment includes, in order from the upstream side in the flow direction, an uncoiler 2, a leveler 3, a punch press 4, a cassette type forming machine 5, a feed length measurement means 6, a cutting position detection means 7, a product type discrimination means 8, a traveling cutting machine 9, and an unloading device 10.

[0022] The uncoiler 2 holds a strip-shaped metal material wound into a coil and unwinds the metal material. Conventionally known devices can be used for the uncoiler 2. For example, devices having a structure that unwinds the metal material by holding the inner diameter of the coiled metal material and rotating the central axis, or a structure that supports the lower part of the coiled metal material with a plurality of rollers and draws out the material by a drawing pinch roll to perform unwinding, and the like can be used. The material unwound by the uncoiler 2 is sent to a leveler 3. In addition, since the metal material unwound from the uncoiler 2 forms a slack loop, a structure in which the floor surface between the uncoiler 2 and the leveler 3 is dug so that the loop does not touch the floor surface may be provided.

[0023] The leveler 3 removes distortion such as curling set remaining from the coiled state of the metal material sent from the uncoiler 2. Conventionally known devices can be used for the leveler 3. For example, devices having a structure in which the metal material is sandwiched between a plurality of rolls arranged vertically along the flow direction, and a load is applied to the metal material from the vertical direction to remove distortion, and the like can be used. The metal material from which distortion has been removed by the leveler 3 is sent to a punch press 4.

[0024] The punch press 4 performs punching and blanking processing into a predetermined shape, at predetermined positions, and in a predetermined number on the metal material sent from the leveler 3 in accordance with production instructions. The punch press 4 performs processing by pressing a punch die against the metal material and punching out a part of the metal material. In the punching processing performed by the punch press 4, slack loops of the strip-shaped metal material are formed on the upstream and downstream sides in the flow direction of the punch press 4, thereby partially stopping the movement of the metal material in the flow direction at the punching position, and the punching processing is performed in the state where the metal material is stopped as described above. Furthermore, the punching processing by the punch press 4 is not limited to this. The punch press 4 itself may have a structure capable of moving along the flow direction, the punch press 4 is moved in accordance with the flow speed of the metal material, and the punching processing may be performed in a state where the punch press 4 and the metal material are relatively stationary. The metal material that has been subjected to predetermined punching processing by the punch press 4 is sent to a cassette type forming machine 5.

[0025] The cassette-type molding machine 5 bends a strip-shaped metal material in the width direction to form it into a uniform cross-sectional shape. The cassette-type molding machine 5 has multiple sets of forming rolls, each set consisting of two rolls positioned vertically, arranged along the flow direction. The strip-shaped metal material sent to the cassette-type molding machine 5 passes between each forming roll in order from the leading edge, and is gradually bent by the load from above and below. After passing through all the forming rolls, it is plastically deformed into a predetermined cross-sectional shape. The metal material processed into a predetermined cross-sectional shape by the cassette-type molding machine 5 passes through the feed length measuring means 6, the cutting position detection means 7, and the product type identification means 8, and is sent to the traveling cutting machine 9.

[0026] The feed length measuring means 6 can, for example, use a roller encoder or the like that can measure the feed length and feed speed by bringing the roller into contact with the surface of a metal material moving in the flow direction.

[0027] As shown in Figure 2, the cutting position detection means 7 includes a photoelectric sensor 71 (line-type laser sensor in the claims) that irradiates a laser beam 72 in a line shape extending in a direction intersecting the flow direction. The photoelectric sensor 71 is positioned so that the line-shaped laser beam 72 is irradiated to match the position in the width direction of the hole 11 which serves as a reference for measuring the feed length of the metal material. The hole 11 which serves as a reference for measuring the feed length can be a hole processed by the punch press 4. The photoelectric sensor 71 of the cutting position detection means 7 may be a transmissive photoelectric sensor in which the light-emitting unit and light-receiving unit are separate, or it may be a mirror-type photoelectric sensor in which the light-emitting unit and light-receiving unit are integrated.

[0028] As shown in Figure 2, the variety discrimination means 8 includes a photoelectric sensor 81 (line-type laser sensor in the claims) that irradiates a laser beam 82 in a line shape extending in a direction intersecting the flow direction. The photoelectric sensor 81 is positioned so that the line-shaped laser beam 82 is irradiated at a distance in the width direction from the laser beam 72 irradiated from the photoelectric sensor 71 of the cutting position detection means 7. Furthermore, the photoelectric sensor 81 of the variety discrimination means 8 is positioned so that the line-shaped laser beam 82 is irradiated downstream in the flow direction from the laser beam 72 irradiated from the photoelectric sensor 71 of the cutting position detection means 7. The photoelectric sensor 81 of the variety discrimination means 8 may be a transmissive photoelectric sensor with a light-emitting unit and a light-receiving unit as separate components, or it may be a mirror-type photoelectric sensor with a light-emitting unit and a light-receiving unit integrated into one unit. Furthermore, the photoelectric sensor 81 of the variety discrimination means 8 may be the same as or different from the photoelectric sensor 71 provided in the cutting position detection means 7.

[0029] The traveling cutting machine 9 cuts the metal material fed from the cassette molding machine 5 to a predetermined length. The traveling cutting machine 9 can move horizontally along the feeding direction of the metal material and cuts the metal material while moving in accordance with the feeding speed of the metal material. The cutting position of the metal material is determined by the feed length measuring means 6 and the cutting position detection means 7 so that it matches the preset product length and edge clearance dimensions. The traveling cutting machine 9 is equipped with a pair of blades, one above the other, and cuts the metal material by shearing it with the pressure applied to the blades. Since the blades of the traveling cutting machine 9 are shaped to correspond to the cross-sectional shape of the metal material formed by the cassette molding machine 5, the cross-sectional shape of the metal material is not deformed during cutting.

[0030] In this way, the metal material, which was in the form of a continuous strip, is cut by the traveling cutting machine 9 to form products of a predetermined length. The finished products are then stacked in a predetermined quantity by the unloading device 10 and unloaded.

[0031] Next, the method for determining the cutting position of the metal material using the feed length measuring means 6 and the cutting position detection means 7 in this embodiment will be described.

[0032] First, the cutting position detection means 7 detects the reference position for measuring the feed length of the metal material. As an example, the reference position can be the end A at the downstream end of the hole 11 made by the punch press 4, as shown in Figure 3(a). Since the laser light 72 irradiated by the photoelectric sensor 71 of the cutting position detection means 7 is in the shape of a line extending in a direction intersecting the flow direction, the position of end A, which is the downstream end of the hole 11, can be reliably detected even if the position of the hole 11 is shifted in the width direction. Note that the positional shift of the hole 11 in the width direction may be caused by the shape remaining in the strip-shaped metal material, processing errors by the punch press 4, molding errors by the cassette-type molding machine 5, etc.

[0033] Next, the feed length measuring means 6 measures the length the metal material is fed along the flow direction from the reference position detected by the cutting position detection means 7. In this embodiment, the beam manufacturing apparatus 1 is programmed in advance with a feed length corresponding to the total length of each product type, and when the metal material has been fed a predetermined length, the cutting position is determined and cut by the traveling cutting machine 9.

[0034] In this way, the cutting position detection means 7 accurately detects the reference position, and the feed length measuring means 6 cuts the metal material at a length measured from the reference position, thereby preventing not only defects in the overall length of the product but also defects in the edge clearance dimension.

[0035] Furthermore, unlike the detection of the reference position by the cutting position detection means 7 in this embodiment, which detects the end A of the hole using a line-shaped laser beam 72 extending in a direction intersecting the flow direction, if detection is performed using a point-shaped laser beam 73, as shown in Figure 3(b), then if the position of the hole 11 is shifted in the width direction, it may not be possible to detect the end A of the downstream tip of the hole 11, and the edge B of the hole may be detected as the reference position. In this case, the reference position will be shifted upstream from its original position, which can cause defects in the overall length and edge clearance dimensions of the product, and will also affect the edge clearance dimensions of subsequent products. In solving these problems, the cutting position detection means 7 in this embodiment is effective because it can accurately detect the reference position.

[0036] Next, we will explain the method for determining product varieties using the variety determination means 8 in this embodiment.

[0037] The types of products manufactured by the beam manufacturing apparatus 1 according to this embodiment include, for example, those in which, in addition to the reference position hole 11, multiple holes 12 are machined at intervals in the width direction, as shown in Figure 3(a).

[0038] The laser beam 82 emitted from the photoelectric sensor 81 of the variety discrimination means 8 is positioned to be emitted at a distance in the width direction relative to the laser beam emitted from the cutting position detection means 7, thereby enabling the detection of the hole 12. Furthermore, since the laser beam 82 is positioned to be emitted downstream in the flow direction relative to the laser beam 72 emitted from the photoelectric sensor 71 of the cutting position detection means 7, the distance between hole 11 and hole 12 in the flow direction can be measured by measuring the time from the detection of the end A of hole 11, which is the reference position, to the detection of hole 12 by the variety discrimination means 8. In addition, since the laser beam 82 emitted from the photoelectric sensor 81 of the variety discrimination means 8 is a line-shaped laser beam extending in a direction intersecting the flow direction, the end of the downstream tip of hole 12 can be detected, and the distance between the end A of hole 11, which is the reference position, and hole 12 in the flow direction can be accurately measured.

[0039] In this way, the product type can be determined by whether or not the product type determination means 8 detects the hole 12, and if so, by detecting the distance between the end A of the hole 11, which is the reference position, and the hole 12.

[0040] Furthermore, unlike the product type discrimination means 8 in this embodiment, which detects the end of the hole 12 using a line-shaped laser beam 82 extending in a direction intersecting the flow direction, if detection is performed using a point-shaped laser beam 83, for example, as shown in Figure 3(b), then if the position of the hole 12 is shifted in the width direction, it may not be possible to detect the downstream end of the hole 12, and there is a risk that the edge of the hole located in an upstream position will be detected. In this case, the distance between the end A of the hole 11 and the hole 12 may be measured incorrectly, and there is a risk that the product type will not be accurately determined. In solving this problem, the product type discrimination means 8 in this embodiment is effective because it can accurately detect the position of the downstream end of the hole 12.

[0041] In this embodiment, the product manufactured using the beam manufacturing apparatus 1 has been described as a guardrail. However, the product manufactured using the beam manufacturing apparatus 1 is not limited to this. It may also be a long plate-shaped product with a three-dimensional cross-sectional shape, such as U-shaped steel for steel decks used in bridges, corrugated steel plates used in civil engineering structural materials and building structural materials, and steel sheet piles. Furthermore, in this embodiment, the product manufactured using the beam manufacturing apparatus 1 has holes drilled at its ends, and the description has focused on the case where these holes at the product ends are used as the reference position. However, the product shape is not limited to this. Multiple holes or punched-out shapes may be made not only at the product ends but also in the middle of the product. In this case, the beam manufacturing apparatus 1 can be programmed in advance to detect the holes at the product ends as the reference position, while not detecting holes in the middle that are not related to the reference position, in accordance with the type of product. Furthermore, while the product type discrimination means 8 has been described as discriminating between product types by detecting the presence or absence of holes 12 or the distance from a reference position to the holes 12, the method of discriminating between product types is not limited to this, and may also be determined by the size of the elongated hole shape extending in the flow direction of the holes 12. It is clear from the description of the claims that such modified or improved forms may also be included in the technical scope of the present invention. [Explanation of Symbols]

[0042] 1. Beam manufacturing equipment 2 Ankoira 3 Level 4. Punch Press 5-cassette molding machine 6. Feed length measuring means 7 Cutting position detection means 8 Type identification means 9. Traveling Cutting Machine 10 Unloading device 11, 12 holes 71, 81 Photoelectric Sensors 72, 82 laser light

Claims

1. A beam manufacturing apparatus for continuously forming strip-shaped metal materials, Equipped with a punch press, a cassette-type molding machine, and a traveling cutting machine, Between the cassette-type molding machine and the traveling cutting machine in the flow direction, there is a cutting position detection means, a product type discrimination means, and a feed length measuring means. The cutting position detection means and the variety discrimination means are line-type laser sensors that emit a line-shaped laser beam extending in a direction intersecting the flow direction, A beam manufacturing apparatus characterized by detecting the downstream end of a hole processed in the metal material by the punch press using the linear laser light.

2. In the beam manufacturing apparatus described in claim 1, The beam manufacturing apparatus is characterized in that the cutting position detection means and the variety discrimination means are arranged at intervals in a direction intersecting the feeding direction.

3. In the beam manufacturing apparatus described in claim 1, The beam manufacturing apparatus is characterized in that the variety discrimination means is arranged downstream of the cutting position detection means in the flow direction.

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