Molding system

Abstract

This molding system in which a metal material is heated comprises an electrical heating unit for heating the metal material by applying electricity, a processing unit for processing the heated metal material, and a roller transportation unit for transporting the heated metal material between the electrical heating unit and the processing unit.

Description

Molding System

[0001] The present disclosure relates to a molding system.

[0002] A conventional apparatus for processing a heated metal material is disclosed in Patent Document 1. This processing apparatus is a forming apparatus that can bring a heated metal pipe material into contact with a forming die to form the material and simultaneously quench it.

[0003] Japanese Patent Application Laid-Open No. 2009-220141

[0004] The processing device described in the aforementioned Patent Document 1 performs electrical heating using electrodes within the forming device. Such electrical heating units may be located outside the processing device. In this case, the metal material is heated by the external electrical heating unit and then transported to the processing device using a robot arm or similar. However, this method requires time to chuck the metal material and a three-dimensional transport trajectory, which results in a time-consuming transport process and a decrease in the temperature of the metal material. Meanwhile, high-speed robot arms are expensive, and chucking still requires a long time.

[0005] The present disclosure has been made to solve such problems, and aims to provide a forming system that can quickly transport electrically heated metal material to a processing section.

[0006] The forming system according to the present disclosure is a forming system for heating a metal material, and includes an electric heating section for electrically heating the metal material, a processing section for processing the heated metal material, and a roller conveying section for conveying the heated metal material between the electric heating section and the processing section.

[0007] The forming system includes an electric heating unit that electrically heats a metal material and a processing unit that processes the heated metal material. Therefore, the metal material electrically heated by the electric heating unit is processed in the processing unit. Here, the forming system includes a roller conveying unit that conveys the heated metal material between the electric heating unit and the processing unit. Therefore, the roller conveying unit can quickly convey the metal material electrically heated in the electric heating unit toward the processing unit using multiple rollers without chucking or the like. As a result, the electrically heated metal material can be quickly conveyed to the processing unit.

[0008] The roller conveying unit may convey the heated metal material in the same orientation as when it is processed in the processing unit, in which case the processing unit can quickly process the conveyed metal material without changing its direction.

[0009] When a reference axis for the metal material is set when the metal material is placed in the processing unit, the roller conveyor may convey the metal material parallel to the reference axis at a position offset from the reference axis. In this case, the roller conveyor can convey the heated metal material while maintaining the same orientation as when the metal material is processed in the processing unit. Therefore, by moving the metal material parallel to the reference axis by the amount of offset from the reference axis, the processing unit can quickly process the conveyed metal material without changing its direction.

[0010] The processing unit may be a forming device that presses and forms a metal material. In this case, the forming device can quickly form the electrically heated metal material while suppressing a temperature drop.

[0011] The processing section may be a high-temperature heating section that heats the metal material to a higher temperature than the electrically heated section. In this case, the high-temperature heating section can quickly heat the electrically heated metal material to a higher temperature while suppressing a temperature drop.

[0012] The molding system may further include a transfer section that transfers the metal material heated by the electrical heating section to the roller transfer section. In this case, the transfer section can quickly transfer the metal material heated by the electrical heating section to the roller transfer section.

[0013] According to the present disclosure, a forming system can be provided that can quickly transport electrically heated metal material to a processing section.

[0014] Fig. 1 is a schematic diagram showing the configuration of a molding system according to the present embodiment; Fig. 2 is a schematic diagram showing the configuration of a molding system according to the present embodiment; Fig. 3 is a schematic diagram showing the operation of the molding system; Fig. 4 is a schematic diagram showing the operation of the molding system; Fig. 5 is a schematic diagram showing the configuration of a molding system according to a modified example; Fig. 6 is a schematic diagram showing the configuration of a molding system according to a modified example.

[0015] Hereinafter, preferred embodiments of the present disclosure will be described with reference to the drawings. In each drawing, the same or corresponding parts are designated by the same reference numerals, and redundant explanations will be omitted.

[0016] 1 and 2 are schematic diagrams showing the configuration of a molding system 100 according to this embodiment. The molding system 100 is a system for molding a metal material. The molding system 100 also functions as a heating system for heating the metal material. As shown in FIGS. 1 and 2, the molding system 100 includes a processing unit 1, an electrical heating unit 2, a roller conveying unit 3, and a transfer unit 4. In this embodiment, a metal pipe material 5 is used as the metal material.

[0017] The processing unit 1 is a device that processes a heated metal pipe material 5. In this embodiment, a forming device 10 that presses and forms the heated metal pipe material 5 is used as the processing unit 1. The forming device 10 is a device that forms the heated metal pipe material 5 using a forming die 11. In this embodiment, a forming device that supplies a fluid to the heated metal pipe material 5 and brings it into contact with the forming surface of the forming die 11, thereby forming and quenching a hollow metal pipe, is used as the forming device 10.

[0018] As shown in FIG. 1 , in this embodiment, the forming apparatus 10 is installed on a horizontal plane. The forming apparatus 10 includes a forming die 11, a holding unit 12, and a fluid supply unit 13. In this specification, the metal pipe material 5 refers to a hollow article before completion of forming in the forming apparatus 10. The metal pipe material 5 is a pipe material made of a hardenable steel. In addition, a reference axis CL1 of the metal pipe material 5 is set when the metal pipe material 5 is placed in the forming apparatus 10. The direction in which the reference axis CL1 extends may be referred to as the "axial direction D1." In addition, among the horizontal directions, a direction perpendicular to the axial direction D1 may be referred to as the "width direction D2."

[0019] The forming die 11 is a die for forming a metal pipe from the metal pipe material 5, and includes a lower die 16 and an upper die 17 that face each other in the vertical direction. The lower die 16 and the upper die 17 are made of steel blocks. Each of the lower die 16 and the upper die 17 has a recess for accommodating the metal pipe material 5. When the lower die 16 and the upper die 17 are in close contact with each other (closed state), each recess forms a space of the target shape for forming the metal pipe material 5. Therefore, the surface of each recess becomes the forming surface of the forming die 11. The lower die 16 is fixed to a base 18 via a die holder or the like. The upper die 17 is fixed to a slide of a drive mechanism via a die holder or the like. The drive mechanism is a mechanism for moving at least one of the lower die 16 and the upper die 17. Each of the dies 16, 17 is provided with a cooling mechanism for cooling the die 16, 17.

[0020] The holding unit 12 is a mechanism for holding the metal pipe material 5 disposed between the lower die 16 and the upper die 17. The holding unit 12 includes a holding member 21A that holds the metal pipe material 5 at one end of the forming die 11 in the axial direction D1, and a holding member 21B that holds the metal pipe material 5 at the other end of the forming die 11 in the axial direction D1. The holding members 21A, 21B on both sides in the axial direction D1 are divided into an upper member and a lower member, respectively, and hold the metal pipe material 5 by sandwiching the vicinity of the end of the metal pipe material 5 from above and below. The holding members 21A, 21B are provided with a drive mechanism (not shown) and are movable in the vertical direction. Note that the holding member does not have to be divided into an upper and lower portion; for example, it may be divided into a left and right portion.

[0021] The fluid supply unit 13 is a mechanism for supplying high-pressure fluid into the metal pipe material 5 held between the lower die 16 and the upper die 17. The fluid supply unit 13 supplies high-pressure fluid to the metal pipe material 5 at a high temperature, causing the metal pipe material 5 to expand. The fluid supply unit 13 is provided on both ends of the molding die 11 in the axial direction D1. The fluid supply unit 13 includes nozzles 22A and 22B that supply fluid from openings at the ends of the metal pipe material 5 to the interior of the metal pipe material 5, and drive mechanisms 23A and 23B that move the nozzles 22A and 22B toward and away from the openings of the metal pipe material 5. The fluid supply unit 13 may supply a gas such as high-pressure air or an inert gas as the fluid. The fluid supply unit 13 may also be included as a single device together with the holding unit 12, which has a mechanism for moving the metal pipe material 5 up and down.

[0022] The electrical heating unit 2 is a device that electrically heats the metal pipe material 5. The electrical heating unit 2 heats the metal pipe material 5 by passing electricity through the metal pipe material 5. The electrical heating units 2 are arranged adjacent to each other at positions spaced apart in the axial direction D1 from the forming device 10. The electrical heating units 2 are provided on a base unit 26. The electrical heating unit 2 includes electrodes 27A and 27B that are arranged spaced apart from each other in the axial direction D1. The electrodes 27A and 27B are each divided into an upper member and a lower member, and hold the metal pipe material 5 by sandwiching the vicinity of the end of the metal pipe material 5 from above and below. The electrodes 27A and 27B are supported by pedestals 28A and 28B provided on the base unit 26. The electrical heating unit 2 passes an electric current from a power source (not shown) through the metal pipe material 5 via the electrodes 27A and 27B while the metal pipe material 5 is held by the electrodes 27A and 27B. The electrodes 27A and 27B are provided with a drive mechanism (not shown) that can move the divided members in the vertical direction. Note that the electrodes 27A and 27B may not be divided into upper and lower parts, but may be divided into left and right parts.

[0023] The roller conveying section 3 conveys the heated metal pipe material 5 between the electrical heating section 2 and the molding device 10. The roller conveying section 3 has a plurality of rollers 31 extending parallel to the width direction D2 (see FIG. 2). The rollers 31 are arranged at equal intervals in the axial direction D1. The height positions of the upper ends of the rollers 31 are set to the same position as the lower end of the metal pipe material 5 held by the electrodes 27A and 27B of the electrical heating section 2. This allows the metal pipe material 5 to be smoothly transferred from the electrical heating section 2 to the roller conveying section 3. The rollers 31 are arranged from a position adjacent to the electrode 27 on the molding device 10 side to the position of the holding member 21A of the molding device 10. The roller conveying section 3 has a driving unit that rotates each roller 31. The rollers 31 are arranged between the molds 16 and 17 when conveying the metal pipe material 5. In response to this, the roller conveyance unit 3 has a mechanism for moving the rollers 31 in the width direction D2 to retract them from the molds 16 and 17 (see FIG. 4(c)).

[0024] The transfer unit 4 is a device that transfers the metal pipe material 5 heated in the electrical heating unit 2 to the roller conveying unit 3. The transfer unit 4 is arranged on the base unit 26 at a position adjacent to the electrical heating unit 2 in the axial direction D1. The transfer unit 4 is arranged on the opposite side of the electrical heating unit 2 from the molding device 10 and the roller conveying unit 3. The transfer unit 4 includes a main body unit 32 arranged on the base unit 26, and an extrusion unit 33. The extrusion unit 33 is supported by the main body unit 32 so as to be able to move back and forth in the axial direction. The extrusion unit 33 extrudes the metal pipe material 5 arranged in the electrical heating unit 2 to the roller conveying unit 3.

[0025] The position of the metal pipe material 5 at each location will be described. The reference axis CL2 of the metal pipe material 5 held by the electrodes 27A and 27B is parallel to the axial direction D1. In the front view shown in FIG. 1, the reference axis CL2 is positioned above the reference axis CL1 of the molding device 10. The center line of the metal pipe material 5 conveyed by the roller conveying unit 3 is parallel to the reference axis CL1 at a position offset upward from the reference axis CL1. In the plan view shown in FIG. 2, the reference axes CL1 and CL2 are parallel to each other and coincide. In the plan view shown in FIG. 2, the center line of the metal pipe material 5 conveyed by the roller conveying unit 3 is parallel to the reference axis CL1 and coincides. The reference axis CL3 of the extrusion unit 33 of the transfer unit 4 coincides with the reference axis CL2 of the electrical heating unit 2. Note that "the reference axes coincide" does not mean that the reference axes do not completely coincide with each other; as long as the problem of the present application can be solved, the reference axes may be slightly misaligned (even if they do not completely coincide with each other).

[0026] Next, the operation of the molding system 100 will be described. First, the metal pipe material 5 is held by the electrodes 27A and 27B of the electrical heating unit 2. The metal pipe material 5 is placed in the electrical heating unit 2 by a robot arm or conveying device (not shown), or manually by an operator. Next, the electrical heating unit 2 electrically heats the metal pipe material 5 via the electrodes 27A and 27B. As a result, a current flows through the metal pipe material 5 in the axial direction D1, and the metal pipe material 5 itself generates heat through Joule heat due to its own electrical resistance. After heating, the electrodes 27A and 27B release the holding.

[0027] The transfer unit 4 extrudes the metal pipe material 5 from the electrical heating unit 2 using the extrusion unit 33 and transfers it to the roller conveying unit 3. As a result, as shown in Figures 3(a) and 4(a), the metal pipe material 5 is conveyed to the molding device 10 by the roller conveying unit 3. When the metal pipe material 5 reaches the position of the dies 16, 17, as shown in Figures 3(b) and 4(b), a positioning member 41 extends from below toward the metal pipe material 5. The positioning member 41 extends above the rollers 31 and restricts movement of the metal pipe material 5 in the width direction (see Figure 4(b)). In this state, the holding members 21A, 21B move upward to hold the metal pipe material 5 on the roller conveying unit 3. Note that movement of the metal pipe material 5 in the conveying direction is restricted by a restricting member 42 (see Figure 4(b)).

[0028] 3(c) and 4(c), the rollers 31 of the roller conveying unit 3 are retracted from the positions of the dies 16 and 17. Also, the positioning member 41 and the holding members 21A and 21B move downward together with the metal pipe material 5. As a result, the metal pipe material 5 is held by the holding members 21A and 21B at the molding position.

[0029] The molding device 10 lowers the upper die 17 and brings it close to the lower die 16, and closes the molding die 11. Meanwhile, the fluid supply unit 13 seals the openings at both ends of the metal pipe material 5 with the nozzles 22A and 22B, and supplies fluid. As a result, the metal pipe material 5, softened by heating, expands and comes into contact with the molding surface of the molding die 11. The metal pipe material 5 is then molded to conform to the shape of the molding surface of the molding die 11. When a metal pipe with a flange is formed, a portion of the metal pipe material 5 is inserted into the gap between the lower die 16 and the upper die 17, and then the mold is closed to crush the inserted portion and form a flange portion. When the metal pipe material 5 comes into contact with the molding surface, it is quenched by the cooled molding die 11, thereby quenching the metal pipe material 5.

[0030] Next, the operation and effects of the molding system 100 according to this embodiment will be described.

[0031] The forming system 100 includes an electric heating unit 2 that electrically heats a metal pipe material 5, and a processing unit 1 that processes the heated metal pipe material 5. Therefore, the metal pipe material 5 that has been electrically heated by the electric heating unit 2 is processed in the processing unit 1. Here, the forming system 100 includes a roller conveying unit 3 that conveys the heated metal pipe material 5 between the electric heating unit 2 and the processing unit 1. Therefore, the roller conveying unit 3 can quickly convey the metal pipe material 5 that has been electrically heated in the electric heating unit 2 toward the processing unit 1 using a plurality of rollers 31 without chucking or the like. As described above, the electrically heated metal pipe material 5 can be quickly conveyed to the processing unit 1.

[0032] The roller conveying unit 3 may convey the heated metal pipe material 5 in the same orientation as when the metal pipe material 5 is processed in the processing unit 1. In this case, the processing unit 1 can quickly process the conveyed metal pipe material 5 without changing the direction of the metal pipe material 5. In the embodiment, if a reference axis CL1 of the metal pipe material 5 is set when the metal pipe material 5 is placed in the processing unit 1, the roller conveying unit 3 conveys the metal pipe material 5 in the axial direction D1 along which the reference axis CL1 extends.

[0033] When a reference axis CL1 of the metal pipe material 5 is set when the metal pipe material 5 is placed in the processing unit 1, the roller conveyor 3 may convey the metal pipe material 5 parallel to the reference axis CL1 at a position offset from the reference axis CL1. In this case, the roller conveyor 3 can convey the heated metal pipe material 5 while maintaining the orientation of the metal pipe material 5 when processed in the processing unit 1. Therefore, the processing unit 1 can quickly process the conveyed metal pipe material 5 by translating the amount of deviation from the reference axis CL1 without changing the direction of the conveyed metal pipe material 5. In this embodiment, when viewed from the front, the roller conveyor 3 conveys the metal pipe material 5 parallel to the reference axis CL1 at a position offset above the reference axis CL1. Therefore, the metal pipe material 5 can be placed in the forming position of the forming device 10 simply by lowering it downward from the roller conveyor 3 while parallel to the reference axis CL1. In addition, in a planar view, the roller conveying section 3 can transport the metal pipe material 5 on the reference axis CL1, so that the metal pipe material 5 can be placed at the forming position of the forming device 10 without parallel movement to eliminate misalignment.

[0034] The processing unit 1 may be a forming device 10 that presses and forms the metal pipe material 5. In this case, the forming device 10 can quickly form the electrically heated metal pipe material 5 while suppressing a temperature drop.

[0035] The molding system 100 may further include a transfer section 4 that transfers the metal pipe material 5 heated in the electrical heating section 2 to the roller conveying section 3. In this case, the transfer section 4 can quickly transfer the electrically heated metal pipe material 5 to the roller conveying section 3.

[0036] The present disclosure is not limited to the above-described embodiments.

[0037] In the above-described embodiment, a forming device 10 is used as the processing unit 1. However, other devices may be used instead of or in addition to this. For example, as shown in Figures 5 and 6, the processing unit 1 may be a high-temperature heating unit 50 that heats the metal pipe material 5 to a higher temperature than the electrically heated unit 2. In this case, the high-temperature heating unit 50 can quickly heat the electrically heated metal material to a higher temperature while suppressing a temperature drop.

[0038] A high-temperature heating section 50 is disposed between the electrical heating section 2 and the molding device 10. The roller conveying section 3 conveys the metal pipe material 5 from the electrical heating section 2 to the high-temperature heating section 50. After heating in the high-temperature heating section 50 is completed, the roller conveying section 3 conveys the metal pipe material 5 to the molding device 10. For example, the electrical heating section 2 heats the metal pipe material 5 from 20°C to 600°C. The high-temperature heating section 50 heats the metal pipe material 5 from 600°C to 1000°C.

[0039] In the above-described embodiment, the transfer section 4 transfers the metal pipe material 5 to the roller conveying section 3 by pushing it out, but the metal pipe material 5 may also be moved to the roller conveying section 3 using a jig that pulls it out of the electrical heating section 2.

[0040] In the above-described embodiment, the center line of the metal pipe material 5 transported by the roller transport section 3 and the reference axis CL2 of the electrical heating section 2 were offset upward from the reference axis CL1 of the molding device 10, but they may also be positioned completely on the reference axis CL1.

[0041] The direction in which the roller conveying section 3 conveys the metal pipe material 5 to the processing section 1 is not particularly limited, and the metal pipe material 5 may be conveyed from the width direction D2.

[0042] The metal material is not limited to a metal pipe material, but may be a metal plate material, in which case a molding device without a fluid supply unit will be employed.

[0043] [Mode 1] A forming system for heating a metal material, comprising: an electric heating unit that electrically heats the metal material; a processing unit that processes the heated metal material; and a roller conveying unit that conveys the heated metal material between the electric heating unit and the processing unit. [Mode 2] The forming system according to Mode 1, wherein the roller conveying unit conveys the heated metal material while maintaining the orientation of the metal material when processed in the processing unit. [Mode 3] The forming system according to Mode 1 or 2, wherein, when a reference axis for the metal material is set when the metal material is placed in the processing unit, the roller conveying unit conveys the metal material parallel to the reference axis at a position offset from the reference axis. [Mode 4] The forming system according to any one of Modes 1 to 3, wherein the processing unit is a forming device that presses and shapes the metal material. [Mode 5] The forming system according to any one of Modes 1 to 4, wherein the processing unit is a high-temperature heating unit that heats the metal material to a temperature higher than that of the electric heating unit. [Mode 6] The molding system according to any one of modes 1 to 5, further comprising a transfer unit that transfers the metal material heated by the electrical heating unit to the roller transfer unit.

[0044] 1... processing section, 2... electrical heating section, 3... roller conveying section, 4... transfer section, 5... metal pipe material (metal material), 10... molding device, 50... high-temperature heating section, 100... molding system.

Claims

1. A forming system for forming a metal material, comprising: an electric heating unit that electrically heats the metal material; a processing unit that processes the heated metal material; a roller conveying unit that conveys the heated metal material between the electrical heating unit and the processing unit, A molding system, wherein the rollers of the roller conveyance section are arranged from the electrical heating section to the inside of the processing section.

2. The molding system according to claim 1 , wherein the roller conveying section conveys the heated metal material in the same orientation as when the metal material is processed in the processing section.

3. When a reference axis of the metal material is set when the metal material is placed in the processing unit, The molding system according to claim 1 , wherein the roller conveying unit conveys the metal material parallel to the reference axis at a position offset from the reference axis.

4. The forming system according to claim 1 , wherein the processing unit is a forming device that presses and forms the metal material.

5. The forming system according to claim 1 , wherein the processing section is a high-temperature heating section that heats the metal material to a higher temperature than the electrical heating section.

6. The molding system according to claim 1 , further comprising a transfer section that transfers the metal material heated by the electrical heating section to the roller transfer section.