MODULAR AND INTERCHANGEABLE ROLLER FORMING MECHANISM

Abstract

The invention relates to forming rollers used in coil forming machines to form sheet metal profiles and the mechanisms for mounting these rollers onto shafts. The invention relates specifically to a modular forming device used in coil sheet forming lines, consisting of a fixed inner core and a replaceable outer roller that can be attached and detached from this core.

Description

1 TARIFF MODULAR AND INTERCHANGEABLE ROLLER FORMING SYSTEM ARRANGEMENT Technical Field to Which the Invention Relates The invention is for forming sheet metal profiles in coil forming machines. with the forming rollers used and the mechanisms for mounting these rollers to the shafts It is related. The invention specifically uses a fixed inner core with this type of coil sheet forming lines. Modular design consisting of a removable and replaceable external roller that can be attached and detached from the hub. It relates to the shaping device. 10 State of the Art In coil sheet forming lines, the desired profile geometry is applied to the sheet metal material. forming rollers mounted on machine shafts for the purpose of providing are used. In current applications, these forming rollers are used. It is generally produced in the form of a single-piece, solid, and monoblock steel body / hub. 15 The forming process involves the roller making direct contact with the sheet metal. Although the part that performs the action is the outer surface, the pulley is mounted on the shaft. The core section that enables the connection is also made of the same steel mass as the outer forming surface. It is being created as part of it. In the production of monoblock rollers, large-diameter solid steel material is used according to the shaft diameter and 20 a significant amount of material is required to adapt it to the desired reel geometry. It must be removed by machining. It should not come into contact with the sheet metal. A large portion of the high-quality steel material in the core area is reduced to chips. importing it leads to raw material waste and the material cost per reel. This leads to an increase. Also, rough turning, fine turning, 25 for large and heavy parts. Processes such as milling, hard turning, and grinding extend manufacturing times. This leads to faster wear of cutting tools and increased machine tool operating costs. It opens. Wear resistance of the outer surfaces of forming rollers in contact with the sheet metal. Heat treatment is applied to increase its strength. However, in existing monoblock structures, 30 2 Although it is sufficient to harden only the outer surface, the entire roller The steel mass is subjected to heat treatment. The desired hardness is achieved for large mass parts. Keeping it in the oven for a long time to reach its value results in high energy consumption and thermal... This leads to increased processing costs. In addition, the outer surface of the part... Different heating and cooling rates between the inner core region and the outer core region result in non-homogeneous stiffness. 5 This leads to disruption, internal stresses, deformations, and a risk of crack formation. It can open. During the roll forming process, the sheet metal is continuously moved around the outside of the coil. Due to contact with the surface, over time, the outer circumference of the reel Wear, crushing, and deformations can occur. The current monoblock 10 Even if only the outer surface of the structure is damaged, the entire pulley can be damaged. removal from the machine spindle, regrinding, or decommissioning It is necessary to reduce the outer diameter when the roller is re-ground. the shaping geometry of the pulley and its compatibility with other pulleys This can have a negative impact. However, completely replacing the reel is possible. 15 This also leads to the discarding of the umbilical region in this situation. In addition, different rollers with different surface geometries for producing profile geometries It is necessary to use them. Each pulley in the monoblock structure has its own hub. The inclusion of this region allows the same shaft connection structure to be reproduced for each pulley, and This leads to numerous heavy pulleys being stored as spare parts or molds. 20 It opens. Removal and installation of heavy monoblock rollers, maintenance and profile change. This complicates operations, increases production line downtime, and reduces spare parts costs. It increases inventory costs. Monoblock forming rollers, as used in the known state of the art, have high... the use of a large amount of high-quality steel, excessive machining, long manufacturing and heat treatment 25 due to their duration, high energy consumption, heat treatment-related deformation risks, and maintenance costs associated with replacing the entire reel in case of wear This is the reason. Therefore, in the production of forming rollers... reducing the amount of raw materials used and processing requirements, and reducing wear and tear. easier renewal of sections and shorter maintenance times 30 A structure is needed that will enable its realization. 3 Brief Description and Objectives of the Invention The primary purpose of the invention is to provide forming capabilities for use in coil sheet forming machines. its pulley, with an inner hub connected to the machine shaft, and on that inner hub Modular in the form of an external roller that can be detached and reattached. The goal is to structure it so that the hub 5 does not come into direct contact with the sheet metal. In this section, the use of unnecessary amounts of high-quality steel is prevented by reducing the raw materials. The goal is to reduce consumption and material waste. Another purpose of the invention is to protect materials that come into contact only with sheet metal and are subject to abrasion. The aim is to ensure that the remaining outer roller is subjected to heat treatment. This allows for the processing of the large mass. The need to bake the entire monoblock rollers is reduced by heat treatment 10 reducing the processing time and energy consumption; also a more homogeneous hardness distribution. by obtaining and heat-treating the results, the risks of internal stress, deformation, and crack formation are reduced. This helps to reduce [the problem]. Another purpose of the invention is to improve performance during the production of the forming roller. The goal is to reduce rough and fine machining operations. This allows for the processing of large volumes of steel. 15 By reducing the need to remove large amounts of material from the masses, the machine tool... shortening service life, limiting cutting tool wear and production The goal is to reduce costs. Another purpose of the invention is to replace the outer roller, which wears out or is damaged during operation, with the inner roller. 20 The aim is to ensure that the usable inner core can be reused, not only. Replacing the worn outer roller and disassembling the entire roller or The goal is to reduce maintenance and spare parts costs associated with discarding the product. Another objective of the invention is to attach the outer roller to the inner hub quickly and reliably. The goal is to create a connecting structure that allows for assembly. This enables the inner hub and the outer 25... Preventing relative rotation between the pulleys, transferring the torque from the machine shaft to the outside. transfer of the roller to the forming surface and the operation of the outer roller during operation The goal is to ensure the preservation of its axial position. Another purpose of the invention is to create external shapes for different sheet metal profile geometries. The aim is to enable the use of the rollers with a common inner hub. This allows for the use of 30 different rollers. External rollers with shaping surfaces can be optionally mounted on the same internal hub. 4 the ability to install, simplifying reel change operations and meeting needs on the production line The goal is to reduce the variety of molds and apparatus used. Another purpose of the invention is to improve production processes that rely on the disassembly and assembly of heavy monoblock rollers. The goal is to reduce downtime. This is achieved through a lighter and replaceable outer pulley. With this structure, profile changes and maintenance operations can be carried out in a shorter time and 5 The goal is to increase the production efficiency of the roll forming line. Explanation of the Figures Figure 1: A representative isometric view of the forming device that is the subject of the invention. It is the appearance. Figure 2: A representative image of the exploded view of the forming device that is the subject of the invention. It is the appearance. Figure 3: General view of the forming device, subject to the invention, mounted on the shaft. It is a representative view. Figure 4: Isometric view of the forming device, subject to the invention, mounted on the shaft. This is a representative view. 15 Figure 5: Representative cross-sectional view of the forming device subject to the invention. It is the appearance. Explanation of References in Figures To better understand the invention, the numbers in the figures correspond to the following: Given: 20 1. Pulley 2. Navel 3. Shaft Key 4. Fastener 25 5. Connector Housing 6. Wedge Channel 7. Mile Keyway 8. Outer Wall 9. Kama 30 Detailed Description of the Invention Examples of arrangements can be further elaborated by referring to the accompanying explanations below. This is described in detail. However, the regulations take different forms. It can be created and should not be interpreted as being limited to the regulations stated herein. Instead, these sample arrangements are intended to ensure that this statement is complete and its scope is 5 It has been provided to ensure that it is fully communicated to experts in the field. The terminology used in this specification is intended only to describe a specific example arrangement. It is not intended to be restrictive or limiting. As used here, "one" means "most". The forms "few" and "preferably" are plural forms unless the context explicitly indicates otherwise. It is also intended to include. 10 The invention is designed to form sheet metal profiles in coil forming machines. with the forming rollers used and the mechanisms for mounting these rollers to the shafts It is related. The invention specifically uses a fixed inner core with this type of coil sheet forming lines. Modular 15 consisting of a removable and replaceable external roller that can be attached and detached from the hub. It relates to the shaping device. The invention describes a modular design with interchangeable outer walls for roll forming lines. It is a roller forming device and is functionally divided into two instead of a single hub. It has a structural feature. This structural feature is important during the production, assembly and maintenance of the reel. It provides maximum flexibility. The intermediate bushing, the center hub (2), is connected to the shaft (M) in the system by 20 fixed hub that makes direct contact, receives torque from the shaft (M) and carries the outer roller (1) (2) element. Preferably has an outer diameter of 120-150 mm. Replaceable outer forming roller (1), forming sheet metal directly, exposed to wear It is an external element in the shape of a ring. It preferably has an outer diameter of 300-400 mm. The invention also... 25 where the shaft key (3) is inserted to ensure that the hub (2) is fixed to the shaft (M). The shaft keyway (7) located on the hub (2) is fitted onto the shaft keyway (7). The shaft wedge (3) which enables the hub (2) to be fixed to the shaft (M), bending forces and torques from the shaft (M) to the outermost roller (1) surface without loss and without gap by fixing the pulley (1) axially on the hub (2) which enables the transfer. It includes an interlocking mechanism to prevent slipping. 30 6 The interlocking mechanism is located inside the pulley (1) and outside the hub (2). When attached to the pulley (1) and hub (2) located in the part, the wedge (9) creating the opening in which it can be placed, ensuring the fixation of the hub (2) and the pulley (1). at least one wedge channel (6) into which the wedge (9) is inserted, by inserting it into the wedge channel (6) At least one wedge (9) which locks the pulley (1) to the hub (2), connection 5 At least one element that is inserted into the slot (5) and secures the wedge (9). fastener (4), at least one fastener where the fasteners (4) are mounted It contains element housing (5). In a preferred application of the invention, at least three wedge channels (6) and at least three There are several wedges (9). However, there are at least three fixing elements (4) and 10 There are at least three fixing element slots (5). High bending forces and high torques generated in roll forming lines transfer from the shaft (M) to the outermost roller (1) surface without loss and without gap It features a snap-and-lock mechanism that provides precise torque transmission. It does not take. This mechanism includes outer wall wedge channels (6), wedge (9), fixing 15 It consists of the element housing (5) and the fixing elements (4). The inner pulley (1) wedge channels (6) extending along the axis are located on the surface and on the outer surface of the hub (2). It takes. The wedges (9) are the inner circular of the replaceable outer shaping roller (1). The surface is in perfect harmony with the wedge channels (6) which are the female sockets located on the navel (2). These are the elements that provide. The outer roller (1) is axially 20° on the hub (2). When driven, the wedge channels (6) and wedges (9) lock together perfectly. This prevents circular misalignments and ensures that parts align properly under high torque loads. This prevents slipping (spinning freely) and ensures 100% mechanical power. Transfer is provided. In addition, thanks to the conical structure of the wedge channel (6), the hub (2) and pulley (1) are aligned. Preferably the keyway (6) is at an angle of 1 degree 25 It has a certain taper. The invention features selective hardening and heat treatment capabilities. Hardening only. The required part is hardened and heat treated. The navel (2) any Because it is not subject to wear, it does not require high hardness, only the load It is sufficient for it to have sufficient load-bearing strength (toughness). Therefore, heat-treated 30 It is not retained. Only the roller (1) that is in direct contact with the sheet metal is functional. The outer edge (8) is hardened. The part to be heat treated is only the roller. 7 (1) outer wall (8) and the thickness of the part to be heat treated is largely Because it is reduced, a homogeneous hardness depth is obtained in heat treatment furnaces, and The baking time is kept to a minimum. In the invention, the inner hub (2) is used as a standardized infrastructure element. The sheet metal forming molds with different geometries developed within the scope of this invention are these 5 It is attached to the navel (2). In this way, the outer perimeter (8) can be in different forms (e.g. U profile, C profile, corner profile (designed for bending in different geometries) or 300- Different outer rollers (1) with an outer diameter of 400 mm can be easily mounted on the same hub (2) It can be disassembled. This situation reduces the variety of tools and mold inventory costs in the factory. It lowers. 10 The outer pulley (1) mounted by passing it over the hub (2) during operation To prevent axial (right-left) displacement, the system is fitted with a wedge channel (6) Mounted into the fastener housing (5) with a wedge (9) that is positioned conically and angularly. It is supported by the connecting element (4). In this way, it can withstand high lateral loads. The position of the pulley (1) on the shaft (M) is secured by maintaining it precisely in millimeters. 15 Axial fixation is provided. Application of the invention in coil sheet forming lines, - The invention's mounting and centering principle on the shafts (M); The system For it to function, the carrier and torque transmission infrastructure must first be established. It is necessary. First, the main drive of the core (2) roll forming machine is 20 It is passed through the shaft (M). The shaft wedge channel is located inside the hub (2). (7) The shaft wedge (3) is mounted and locked together. In this way The rotational movement of the shaft (M) is transmitted directly to the hub (2). The shaft of the hub (2) (M) must also be fixed axially so that it does not shift left or right. is provided. 25 - Axial mounting and locking principle of the replaceable roller (1); Wear resistance The roller (1) which will be exposed to and bend the sheet metal is mechanically mounted on the hub (2). It is locked in place. Selected according to the form of the profile to be produced. Replaceable outer shaping roller (1), fixed on the shaft (M) It is driven axially (by pushing) onto the hub (2). Assembly 30 during this time, some of it is on the inner circular surface of the pulley (1) and other parts of it are The wedge channels (6) located on the navel (2) will complement each other, complete 8 The transition is made in a way that will be compatible. Here, the locking logic is a wedge. This is achieved by mounting wedges (9) into the channels (6). Also, to eliminate all gaps in the circular (radial) direction, on the hub. The connecting element is mounted into the connecting element slot (5) located there. This In this way, the pulley (1) and the hub (2) lock together as one whole. Axial 5 To prevent (right-left) sliding, the connector housing (5) and the connector The element (4) is fixed longitudinally to the hub (2) and pulley (1). - Principle of force and torque transmission (during operation); When the machine is started and the sheet metal When it starts moving along the track, the transmission of torque is based on the following chain principle: is happening; 10 Power Transmission: ▪ The main motor shaft (M) is rotating, ▪ The rotational movement is transferred to the hub via the wedge (3) on the shaft (M). (2) is being transferred, ▪ Keyways (6) and keys between hub (2) and pulley (1) 15 (9) applies physical pressure to the outer roller (1), ▪ With this pressure, the torque is transferred without loss to the outermost functional outer wall (8) It reaches. o Shaping: functional outer shell (8), from the line at high speed and pressure By applying pressure to the sheet metal, the bending process was completed in 20 seconds. It is carrying out. - Wear and maintenance principle (sustainability); Sheet metal while the system is operating Due to friction, only the outermost layer wears down over time. In this case... The system's operational and maintenance advantages come into play. The pulley (1) It needs to be changed. Here, 25 ▪ The disassembly process involves removing all parts of the shaft (M) when wear occurs. There is no need to disassemble the mechanism. Only the fastening is required. element (4) is loosened and the worn outer roller (1) axial It is easily removed by pulling it out from the navel (2). ▪ Change: during these operations the hub (2) is fixed on the shaft (M) and 30 It remains firmly in place. The worn pulley (1) instead of a new roller (1) or the form corrected by grinding The pulley (1) is slid back onto the hub (2) It is locked. 9 This makes it extremely expensive to produce, process, and heat treat on a mass scale. The umbilical cord (2) is used for life. It is only cheap, lightweight and easy The machineable reel (1) is being replaced. A sample application of the invention includes the following steps: - The forming spindle on the production line is attached to the hub (2) 5 by the personnel. installation, - The hub is inserted by personnel through the shaft wedge channel (7) inside the hub (2). (2) By locking the mile (M) it becomes a standard carrier hub (2), - The pulley (1) with the geometry suitable for the profile form to be produced, the belly (2) of the personnel Install by sliding it onto the surface in the axial direction, 10 - Three pieces for assembling the pulley (1) and the hub (2) to form a single unit. Installation of wedges (9) and three fixing elements (4), - By tightening the fixing element (4) of the locking pulley (1) and its hub (2) completion of assembly, - The staff operating the roll forming machine, 15 - The rotational movement from the motor is transferred to the shaft (M), and the movement is located on the shaft (M). It is also transferred to the navel (2) by means of a wedge, - The rotational movement of the hub (2) to the pulley (1) without loss and slippage. transfer, - The functional outer edge (8) of the rotating pulley (1) has a high 20° to the sheet metal passing through the line. shaping by pressure, - Wear occurs on the outer edge (8) during the shaping process, - By loosening the operator's fixing element (4), only the pulley (1) (to the hub) (2) pulling it out in the axial direction (without touching it at all), - Place the new pulley (1) or the repaired pulley (1) onto the hub (2) 25 The installation process involves applying force in the axial direction. The invention involves the use of high-quality steel, with a roller (1) in contact with the sheet metal. is limited and the amount of steel used in the production of each reel (1) Savings of approximately 60% are achieved. Separate the pulley (1) and the hub (2). High-volume machining operations are possible thanks to its production in parts. 30 The pulley (1) and the hub (2) are reduced separately according to their geometries. This allows for processing; thus reducing processing times, machine utilization times, labor costs, and Cutting tool wear is reduced. Only during the roll forming process. The pulley (1) that is directly exposed to wear is subjected to heat treatment. The pulley (1) The mass of the heat-treated part due to its thin wall thickness The cooking time is reduced, the baking time is shortened, and energy consumption is lowered. Furthermore... A homogeneous hardness distribution is obtained throughout the roller (1); during heat treatment 5 The risks of cracking, internal stress, and deformation that may occur are reduced. Roll During the forming process, wear occurs on the outer (1) of the roller in contact with the sheet metal. It occurs on the surface. In case of wear or maintenance, the hub (2) shaft It remains fixed on it and can be replaced with a new pulley (1) by simply removing the pulley (1) It is being replaced. Thus, the umbilical cord (2) is made reusable, and the spare 10 Parts requirements and maintenance costs are reduced. The pulley (1) from the hub (2) Being detachable, roller (1) and mold changes are easier and faster. This ensures that production line downtime is reduced. This is being reduced and the overall equipment efficiency of the line is being increased. Different shaping Rollers with geometries (1) mounted on a standard hub (2) with the same dimensions. It is designed to be attached. In the preferred application, the navel (2) is approximately It has a diameter of 150 mm. Thus, the same hub (2) can be used for different rollers (1), The flexibility of changing the pulley (1) and the variety of apparatus used are ensured. is being reduced. In one application of the invention, the fastening element (4) consists of a setscrew bolt and a fastening 20 The element housing (5) has at least one setscrew bolt housing.

Claims

11 REQUESTS 1. Used in coil forming machines to give form to sheet metal. a versatile, modular shaping system with interchangeable rollers. It has a device and its characteristic is; - obtained by applying axial force on the hub (2), the sheet metal it receives 5 sheet metal which comes into contact with and receives rotational movement from the hub (2) The roller (1) that shapes, has an outer perimeter (8), - attached to the shaft (M) of the roll sheet forming machine, onto which the roller is placed (1) it is mounted and locked, the rotational movement it receives from the machine shaft (M) Hub (2) that transfers to the pulley (1), 10 - to ensure that the hub (2) is fixed to the shaft (M) the shaft wedge (3) The shaft keyway (7) located on the hub (2) where it is placed, - fixing the hub (1) to the shaft (M) of the roll sheet forming machine To ensure this, the shaft is mounted in the keyway (7) located inside the hub (2). made shaft wedge (3), 15 - bending forces and torques from the shaft (M) to the outermost roller (1) surface axially on the pulley (1) on the hub (2) which enables the transfer. a secure, interlocking mechanism that prevents slipping. It includes.

2. Modular and interchangeable roller forming device conforming to Claim 1 20 Its feature is the interlocking mechanism. - located inside the pulley (1) and outside the hub (2), pulley (1) When attached to the belly (2), it forms the opening where the wedge (9) will be placed, wedge (9) to ensure the fixing of the hub (2) and the pulley (1) at least one wedge channel (6) where it is fitted, 25 - by inserting the pulley (1) into the wedge channel (6) and locking the pulley (1) to the hub (2) and the hub (2) at least one that enables the axial fixation of the pulley (1) on it. number of daggers (9), - connection located on the outside of the navel (2) and under the wedge canal (6) at least one fastening element socket (5) where the element (4) is mounted, 30 - by being inserted into the connector housing (5) the wedge (9) is secured It must contain at least one connecting element (4). 12 3. Modular forming device with interchangeable rollers, conforming to Claim 2. its feature is that the fastening element (4) is a setscrew bolt and fastening element its housing (5) must contain at least one setscrew bolt housing.

4. Modular forming device with interchangeable rollers, conforming to Claim 1. and its feature is; suitable for the hub (2), sheet metal U profile, C profile or corner profile 5 shaping the outer perimeter (8) suitable for these profiles in order to give one of their forms It includes interchangeable rollers (1) with geometries.

5. Modular and interchangeable roller forming assembly in accordance with Claim 1. Its feature is that it contains a hub (2) with an outer diameter of 120-150 mm.

6. Modular and interchangeable roller forming device conforming to Claim 1. 10 Its feature is that it contains a roller (1) with an outer diameter of 300-400 mm.

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