Molding system

Abstract

This molding system comprises a molding device for molding a metal material in a non-molten state. The molding device comprises at least a pair of molds which move relative to each other in a movement direction along the horizontal direction, and the molding device may perform molding by disposing the metal material in the pair of molds along a direction intersecting the movement direction.

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] Conventional molding systems use hydraulic presses to move dies up and down using hydraulic pressure. Such hydraulic presses require extensive foundation work, such as an underground pit. They also require hydraulic units and piping, and require hydraulic adjustments during trial runs, lengthening the construction time until startup. In other words, hydraulic presses have the problem of high initial costs when introduced.

[0005] The present disclosure has been made to solve such problems, and aims to provide a molding system that can be easily introduced.

[0006] The molding system according to the present disclosure is a molding system including a molding device that molds a non-molten metal material, and the molding device includes at least a pair of molds that move relatively in a horizontal direction, and molding may be performed by placing the metal material on the pair of molds in a direction that intersects the direction of movement.

[0007] In the molding system, the molding device is equipped with at least a pair of molds that move relatively in a horizontal movement direction. Therefore, unlike when moving vertically, molding can be performed with the weight of both of the pair of molds supported by the floor surface. In other words, a brake mechanism to support the weight of the pair of molds is not required. Therefore, the molding device does not require a mechanism that can generate large forces such as hydraulics, but is costly to introduce. As described above, the molding system can be easily introduced.

[0008] The metal material may be formed by placing it horizontally on the pair of molds in a direction that intersects with the direction of movement. In this case, the forming device can be lowered compared to when the metal material is placed vertically on the pair of molds. Therefore, the height restrictions on the building when introducing the forming system can be reduced.

[0009] The molding apparatus further includes a drive unit that moves the molds and a fluid supply unit that supplies fluid to the metal material. The pair of molds have a pipe molding surface for molding a flanged metal pipe and a flange molding surface. The drive unit may stop the molds at a mold closing position, which is the position of the pair of molds when the metal pipe is completed, and a primary blow position, where the flange molding surfaces are spaced apart from each other more than at the mold closing position and fluid is supplied to mold the flange. In this case, part of the metal material can be inserted between the flange molding surfaces at the primary blow position, which is a stage before the mold is completely closed. This can reduce cracking and other problems compared to molding the flange in one go.

[0010] The molding device may further include a support mechanism that supports the transported metal material at a position between the pair of molds and aligns the position of the metal material. In this case, the support mechanism can position the metal material in an accurate position.

[0011] The molding system may further include a first conveying unit that places the metal material on the pair of molds and a second conveying unit that removes the molded product from the pair of molds, and the first conveying unit and the second conveying unit may be arranged to sandwich the molding device. In this case, the metal material before molding can be quickly replaced with the molded product.

[0012] The molding apparatus may further include a pair of fluid supply units that supply fluid to the metal material, and the pair of fluid supply units may be arranged to sandwich the mold. In this case, fluid can be supplied from both sides to the metal material placed between the pair of molds.

[0013] The molding device may further include a drive unit for moving the mold, and the drive unit may have a toggle link mechanism. In this case, the mold can be moved with a large force even with a small drive force when the mold is arranged so that the movement direction is along the horizontal direction.

[0014] The toggle link mechanism may be provided with a rattle suppression mechanism that suppresses rattle that occurs in the gap that occurs in the gear for adjusting the mold thickness and in the gap in the sliding portion of the link portion of the toggle link mechanism. In the toggle link mechanism, there is a gap that occurs in the gear for adjusting the mold thickness and in the sliding portion of the link portion of the toggle link mechanism. Rattle is likely to occur in such gaps. Therefore, by suppressing these rattles with the rattle suppression mechanism, the position controllability of the mold can be improved.

[0015] The rattle suppression mechanism may include a load applying mechanism that applies a load to the toggle link mechanism. By applying a load to the toggle link mechanism, the load applying mechanism can suppress the occurrence of gaps that cause rattle. This suppresses rattle, thereby improving the position controllability of the mold.

[0016] The toggle link mechanism may include a position detection mechanism that detects the position of the movable mold. In this case, even if rattle occurs due to gaps in the gears for adjusting the mold thickness and gaps in the sliding parts of the link parts of the toggle link mechanism, the position detection mechanism detects the position of the movable mold and feedback-controls the position of the movable mold, thereby improving mold position controllability.

[0017] The drive unit may include a motor, and the motor may be provided in the direction of movement. In this case, a separate power transmission mechanism such as a V-belt or timing belt is not required, so a drive unit that is less likely to break can be provided. Also, the size of the molding system in the height direction can be limited.

[0018] The drive unit may include a motor, and the motor may be provided in a direction intersecting the movement direction. In this case, the size of the molding system in the movement direction can be reduced. Furthermore, if the motor is provided above the molding system, maintenance can be performed from above, improving maintainability.

[0019] The toggle link mechanism may include a lock-up mechanism that maintains the mold clamping force. In this case, the lock-up mechanism can maintain the mold clamping force, so that the mold can be prevented from opening even if a reaction force is received from the metal material placed inside the mold.

[0020] The lock-up mechanism may be activated when the machine is stopped. In this case, the lock-up mechanism can inhibit the mold from opening when the machine is stopped.

[0021] The forming apparatus may further include a double-acting mold, which may be positioned in either the horizontal direction or a direction intersecting the horizontal direction relative to the metal material. In this case, the double-acting mold can form the metal material into a complex shape. Here, when the pair of molds moves vertically, oxide scale tends to accumulate on the lower mold, necessitating suction or other similar procedures. In contrast, when the pair of molds moves horizontally relative to each other, oxide scale tends to fall downward, making it easy to remove by blowing it off with a blower or other similar procedures. When a double-acting mold is used, the adverse effects of oxide scale buildup become more pronounced, but these adverse effects can be suppressed by adopting a configuration that facilitates oxide scale removal.

[0022] The double-acting mold may have a moving mechanism that moves from the bottom to the top as the mold is closed during molding, and the double-acting mold may return to its original position by its own weight when the mold is opened. In this case, the mechanism for returning the double-acting mold to its original position can be made smaller or omitted.

[0023] According to the present disclosure, a molding system that can be easily introduced can be provided.

[0024] FIG. 1 is a schematic plan view showing the configuration of a molding system according to the present embodiment. FIG. 2 is a schematic front view showing the configuration of a molding system according to the present embodiment. FIG. 3 is a schematic front view showing the configuration of a molding system according to the present embodiment. FIG. 4 is a schematic side view showing the configuration of a molding system according to the present embodiment. FIG. 5 is a schematic side view showing the configuration of a molding system according to the present embodiment. FIG. 6 is an enlarged view of a mold. FIG. 7 is an enlarged view of a mold. FIG. 8 is a view explaining the operation of a support mechanism. FIG. 9 is a schematic side view showing the configuration of a molding system according to a modified example. FIG. 10 is a schematic side view showing the configuration of a molding system according to a modified example. FIG. 11 is a schematic view for explaining a lock-up mechanism. FIG. 12 is a view showing a molding mold according to a modified example. FIG. 13 is a view showing a molding mold according to a modified example.

[0025] 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.

[0026] 1 and 2 are schematic diagrams showing the configuration of a molding system 100 according to this embodiment. FIG. 1 is a plan view of the molding system 100. FIG. 2 is a front view of the molding system 100. The molding system 100 is a system that molds a non-molten metal material. Note that in FIG. 2, the structure around the mold 16 on the positive side in the Y-axis direction is omitted to facilitate understanding of the structure. In this embodiment, a heated metal pipe material 5 is used as the non-molten metal material. As shown in FIGS. 1 and 2, the molding system 100 includes a molding device 10, a material placement unit 110, a conveying unit 120, a conveying unit 130, and a control unit 140.

[0027] The forming device 10 is a device that forms a metal pipe material 5. The forming device 10 is a device that forms a heated metal pipe material 5 in a forming die 11 (mold). In this embodiment, a forming device is used as the forming device 10 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 flanged metal pipe 50.

[0028] The forming device 10 is installed on a horizontal plane F (see FIG. 2 ). The forming device 10 includes a forming die 11, a holding unit 12, a fluid supply unit 13, and a drive unit 14. In this specification, the metal pipe material 5 refers to a hollow article before completion of forming in the forming device 10. The metal pipe material 5 is a pipe material made of a hardenable steel. In the following description, an XYZ coordinate system is used. The Z-axis direction is the up-down direction. The upper side is the positive side of the Z-axis direction, and the lower side is the negative side. The X-axis direction is any direction in the horizontal direction. The Y-axis direction is the horizontal direction perpendicular to the Z-axis direction and the Y-axis direction. In this specification, the longitudinal direction of the metal pipe material 5 when forming the metal pipe material 5 in the forming device 10 is defined as the X-axis direction. One side of the X-axis direction is defined as the positive side, and the other side is defined as the negative side. One side of the Y-axis direction is defined as the positive side, and the other side is defined as the negative side.

[0029] The molding die 11 is a die for molding a metal pipe 50 from a metal pipe material 5 and includes a pair of dies 16 (dies) and a pair of dies 17 (dies) facing each other in the horizontal Y-axis direction. The dies 16 and 17 move back and forth relative to each other with the horizontal Y-axis direction as the movement direction MD. The movement direction MD may be any direction along the horizontal direction. In this embodiment, the movement direction MD is parallel to the horizontal direction, but it does not have to be horizontal, and the movement direction MD may be inclined relative to the horizontal direction. Even in such cases, the weights of the dies 16 and 17 are supported by the floor surface. While it is sufficient for at least one of the dies 16 and 17 to move, in this embodiment, the position of the dies 16 is fixed, and the dies 17 move back and forth in the Y-axis direction. The dies 16 and 17 are made of steel blocks. Each of the dies 16 and 17 has a recess for receiving the metal pipe material 5 (details will be described later). The dies 16 are fixed to a stationary platen 18. The mold 17 is fixed to a movable platen 19. Furthermore, the mold 17 is fixed to the drive unit 14 via the movable platen 19, etc. The drive unit 14 is a mechanism for moving at least one of the mold 16 and the mold 17, and in this embodiment, moves the mold 17. A cooling mechanism for cooling the molds 16 and 17 is provided inside each of the molds 16 and 17.

[0030] Here, the molding surfaces of the molds 16 and 17 will be described with reference to Figures 6 and 7. As shown in Figure 7(b), the molded product, a metal pipe 50, has a tubular pipe main body 50a and a pair of flanges 50b. Meanwhile, the molds 16 and 17 have pipe molding surfaces 16a and 17a for molding the pipe main body 50a and flange molding surfaces 16b and 17b for molding the flanges 50b. The pipe molding surfaces 16a and 17a are formed in cavities recessed from the flange molding surfaces 16b and 17b. The heated metal pipe material 5 expands within the molding mold 11, thereby coming into contact with the pipe molding surfaces 16a and 17a to form the pipe main body 50a. Furthermore, the flanges 50b are formed by a portion of the metal pipe material 5 being crushed by the flange molding surfaces 16b and 17b.

[0031] As shown in FIG. 2 , the forming apparatus 10 further includes a support mechanism 40A that supports the transported metal pipe material 5 between the pair of dies 16, 17 and aligns the position of the metal pipe material 5. The support mechanism 40A is positioned lower than the position of the metal pipe material 5 during forming. The support mechanism 40A includes a high-speed lift 41 and a support member 42. The high-speed lift 41 is configured, for example, by a cylinder having a piston rod. The high-speed lift 41 moves the support member 42 up and down. The support member 42 is supported at its lower end by the high-speed lift 41 and extends upward. The support member 42 supports the metal pipe material 5 at its upper end. The upper end of the support member 42 has a shape corresponding to the metal pipe material 5, thereby supporting the placed metal pipe material 5. Alternatively, a mechanism for clamping the metal pipe material 5 may be provided at the upper end of the support member 42. A plurality of support mechanisms 40A are provided along the X-axis direction in which the metal pipe material 5 extends. The number of support mechanisms 40A is not particularly limited. The operation of the support mechanisms 40A will be described in detail later.

[0032] As shown in FIGS. 1 and 3 , the holding unit 12 is a mechanism for holding the metal pipe material 5 disposed between the mold 16 and the mold 17. The holding unit 12 includes a holding member 21A that holds the metal pipe material 5 on the positive side of the molding mold 11 in the X-axis direction during molding, and a holding member 21B that holds the metal pipe material 5 on the negative side of the molding mold 11 in the X-axis direction. The holding members 21A and 21B may be divided into, for example, an upper member and a lower member, respectively, and may 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 and 21B are provided with a drive mechanism (not shown) and are movable in the vertical direction. Note that the holding members do not have to be divided into upper and lower portions; for example, they may be divided into left and right portions.

[0033] The fluid supply unit 13 is a mechanism for supplying a high-pressure fluid into the metal pipe material 5 held between the mold 16 and the mold 17. The fluid supply unit 13 supplies the high-pressure fluid to the metal pipe material 5 in a high-temperature state, 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 X-axis direction. The fluid supply unit 13 includes nozzles 22A and 22B that supply a fluid from openings at the ends of the metal pipe material 5 to the inside 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.

[0034] The holding members 21A, 21B of the holding unit 12, the nozzles 22A, 22B of the fluid supply unit 13, and the drive mechanisms 23A, 23B may be incorporated into the same unit together with a mechanism for moving the metal pipe material 5 in the vertical direction. Such units may be referred to as units 30A, 30B. The pair of units 30A, 30B equipped with the fluid supply unit 13 are arranged to sandwich the molding die 11 in the X-axis direction.

[0035] Units 30A and 30B are capable of reciprocating movement in the Y-axis direction along guide mechanisms 31A and 31B that are provided to extend in the Y-axis direction. As shown in Fig. 3, sliders 32 are provided on the undersides of units 30A and 30B. Guide mechanisms 31A and 31B have base portions 33 and guide members 34 that are provided on base portions 33. Guide members 34 extend in the Y-axis direction. Units 30A and 30B move in the Y-axis direction along guide members 34 via sliders 32.

[0036] The drive unit 14 is a mechanism for moving the mold 17. The drive unit 14 is provided on the negative side of the Y-axis direction relative to the molding mold 11. The drive unit 14 reciprocates the mold 17 via a movable platen 19 in the horizontal Y-axis direction, which is the movement direction MD. The molding mold 11, platens 18, 19, and drive unit 14 are disposed on a base 20 installed on a horizontal plane F. On the base 20, the platens 18, 19, which support the molds 16, 17, are disposed so as to rise upward from the base 20. Therefore, the base 20 and the horizontal plane F support the weight of the molds 16, 17 from below via the platens 18, 19. A more detailed configuration of the drive unit 14 will be described later.

[0037] The material placement unit 110 is a location where the metal pipe material 5 is placed immediately before being formed by the forming apparatus 10. The position of the material placement unit 110 is not particularly limited, but in this embodiment, the material placement unit 110 is placed on the negative side of the forming apparatus 10 in the X-axis direction. The material placement unit 110 includes a base unit 111 and a support mechanism 40B. The base unit 111 is a platform installed on a horizontal plane F. The support mechanism 40B is a mechanism that supports the metal pipe material 5 on the base unit 111 and moves it in the vertical direction. The support mechanism 40B has a configuration similar to that of the support mechanism 40B of the forming apparatus 10 described above, and includes a high-speed lift 41 and a support member 42. The support mechanism 40B receives and supports the metal pipe material 5 and moves the metal pipe material 5 to a position where it is easy for the conveying unit 120 to receive it.

[0038] In this embodiment, an electric heating unit 2 is provided on the base 111. The electric heating unit 2 is a device that electrically heats the metal pipe material 5. The electric heating unit 2 heats the metal pipe material 5 by passing electricity through the metal pipe material 5. The electric heating units 2 are arranged adjacent to each other at positions spaced apart from the molding device 10 in the X-axis direction. The electric heating unit 2 is provided on the base 111. The electric heating unit 2 includes electrodes 27A and 27B that are arranged spaced apart from each other in the X-axis direction. 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 111. The electric heating unit 2 applies electric current to the metal pipe material 5 from a power source (not shown) 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. The electrodes 27A and 27B may not be divided into upper and lower parts, but may be divided into left and right parts. Instead of providing the electric heating unit 2 in the material placement unit 110, the holding units 12 of the units 30A and 30B may also function as the electric heating unit 2. In this case, the holding members 21A and 21B are configured as electrodes.

[0039] The conveying unit 120 (first conveying unit) is a mechanism that places the metal pipe material 5 on the pair of dies 16, 17. The conveying unit 120 holds the metal pipe material 5 placed in the material placement unit 110 and transports it to the molding device 10. After transporting the metal pipe material 5 to the molding device 10, the conveying unit 120 places the metal pipe material 5 on the molding die 11. The conveying unit 130 (second conveying unit) is a mechanism that removes the metal pipe 50, which is a molded product, from the pair of dies 16, 17. The conveying unit 130 holds the metal pipe 50 molded in the molding die 11 and transports it to a location for another process. The conveying unit 120 is arranged on the negative side of the molding device 10 in the X-axis direction, and the conveying unit 130 is arranged on the positive side of the molding device 10 in the X-axis direction. With this arrangement, the conveying unit 120 and the conveying unit 130 are arranged to sandwich the molding device 10. The positions of the transport sections 120 and 130 are not particularly limited, but may be any positions that can avoid interference with the units 30A and 30B.

[0040] The transport units 120 and 130 are configured, for example, by robot arms. The transport units 120 and 130 include a main body 113, an arm 114, and a holding unit 116. The main body 113 is provided on a horizontal plane F and rotatably supports the arm 114. The arm 114 moves the holding unit 116 by a multi-joint mechanism. The holding unit 116 holds the metal pipe material 5 (metal pipe 50).

[0041] The control unit 140 is a device that controls the entire molding system 100. The control unit 140 is connected to the holding unit 12, the fluid supply unit 13, the drive unit 14, the electrical heating unit 2 (power supply), and the conveying units 120 and 130, and transmits command signals to these devices. Details of the control by the control unit 140 will be described later.

[0042] Next, the configuration of the drive unit 14 of the molding apparatus 10 will be described in detail with reference to FIGS. 4 and 5 . The drive unit 14 reciprocates a movable platen 19, which supports the mold 17, in the movement direction MD. To enable this movement, the movable platen 19 has a slider 62 that moves along a guide member 61 provided on the base 20. A base member 63 is provided on the base 20 at the negative end of the molding apparatus 10 in the Y-axis direction. The base member 63 is supported on the base 20. Furthermore, the base member 63 can move forward and backward in the Y-axis direction in FIG. 4 . The base member 63 is provided opposite the movable platen 19 while being spaced apart from each other in the Y-axis direction. The base member 63, movable platen 19, and stationary platen 18 are connected at their four corners by tie bars 64 (see also FIG. 2 ). The movable platen 19 and base member 63 move in the movement direction MD while being guided by the tie bars 64.

[0043] The drive unit 14 includes a drive force applying unit 66 and a toggle link mechanism 70. The drive force applying unit 66 is a mechanism that applies a drive force to the movable platen 19 via the toggle link mechanism 70. The toggle link mechanism 70 is a link mechanism that transmits the drive force from the drive force applying unit 66 to the movable platen 19.

[0044] The driving force application unit 66 is provided at the end of the base member 63 in the Y-axis direction. The driving force application unit 66 includes a motor 67, a ball screw 68, and a moving member 69. The motor 67 is a power source that rotates the ball screw 68. The ball screw 68 rotates by the driving force from the motor 67. The ball screw 68 extends from the motor 67 toward the positive side in the Y-axis direction and penetrates the base member 63. The moving member 69 is journaled by the ball screw 68 at a position on the positive side of the base member 63 in the Y-axis direction. The moving member 69 is a member that moves back and forth in the moving direction MD as the ball screw 68 rotates. The driving force application unit 66 is not a mechanism that generates a large force, such as a hydraulic mechanism, but a mechanism that applies driving force using an electric motor.

[0045] The toggle link mechanism 70 includes multiple link members 71, 72, and 73. Each link member 71, 72, and 73 is provided in a pair on either side of a center line CL. The center line CL is set at the center of the molding apparatus 10 when viewed in the X-axis direction. The toggle link mechanism 70 is configured symmetrically with respect to the center line CL. Therefore, only one link mechanism with respect to the center line CL will be described below. Furthermore, the toggle link mechanisms 70 shown in FIGS. 4 and 5 are provided in pairs spaced apart from each other in the X-axis direction (see FIG. 1). A pair of support portions 63a are provided at the positive end of the base member 63 in the Y-axis direction to support the link member 71 of the toggle link mechanism 70, one above the other. A pair of support portions 19a are provided at the negative end of the movable platen 19 in the Y-axis direction to support the link member 72 of the toggle link mechanism 70, one above the other.

[0046] One end of the link member 71 is rotatably connected to the support portion 63a of the base member 63 via a link portion 74. One end of the link member 72 is rotatably connected to the support portion 19a of the movable platen 19 via a link portion 76. The other end of the link member 71 and the other end of the link member 72 are rotatably connected to each other via a link portion 77. One end of the link member 73 is rotatably connected to the moving member 69 via a link portion 78. The other end of the link member 73 is rotatably connected to an intermediate position of the link member 71 via a link portion 79.

[0047] As shown in FIG. 4 , in the mold open state in which the mold 17 is separated from the mold 16 toward the negative side in the Y-axis direction, the link members 71 and 72 are bent in an L-shape so that the link portion 77 is closer to the center line CL. The link member 73 is inclined from the link portion 78 connecting it to the movable member 69 toward the positive side in the Y-axis direction, moving away from the center line CL. Next, as shown in FIG. 5 , when the ball screw 68 is rotated by the driving force of the motor 67, the movable member 69 moves toward the positive side in the Y-axis direction. At this time, when the link portion 78 moves toward the positive side in the Y-axis direction by the movable member 69, the link member 73 is pushed, and the link portion 79 moves together with the link member 71 in a direction away from the center line CL. As a result, the link member 71 rotates about the link portion 74, and the link portion 77 moves toward the positive side in the Y-axis direction. As a result, the link member 72 moves toward the positive side in the Y-axis direction together with the movable platen 19. As a result of the above, the mold 17 moves closer to the mold 16, and the mold 17 comes into contact with the mold 16, resulting in a mold closing state.

[0048] Next, the operation of the molding system 100 will be described. Note that the operation of each component is controlled by the control unit 140 sending a control signal to each component. As shown in Figures 1 and 2, first, a new metal pipe material 5 is placed in the material placement unit 110. The electrodes 27A and 27B move inward to hold the metal pipe material 5. Next, the electrical heating unit 2 electrically heats the metal pipe material 5 via the electrodes 27A and 27B. As a result, a longitudinal current flows through the metal pipe material 5, 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. The support mechanism 40B places the heated metal pipe material 5 at a high position (the position where the metal pipe material 5 is indicated by the solid line in Figure 2).

[0049] The conveying unit 120 holds the heated metal pipe material 5 and conveys it to the molding die 11 of the molding device 1. As shown in FIG. 8( a), the conveying unit 120 delivers the metal pipe material 5 to the support member 42 of the support mechanism 40A between the dies 16 and 17. After delivery, the conveying unit 120 retracts the holding unit 116 from between the dies 16 and 17. Next, the units 30A and 30B move toward the positive side of the Y-axis direction to the position of the molding die 11 (the position indicated by the units 30A and 30B in phantom lines in FIG. 1). Next, as shown in FIG. 8( b), the support mechanism 40A lowers the metal pipe material 5 and moves it toward the negative side of the Y-axis direction to the position of the holding members 21A and 21B of the units 30A and 30B. As a result, the holding members 21A and 21B hold the metal pipe material 5. The units 30A and 30B insert the nozzles 22A and 22B into the openings at the ends of the metal pipe material 5 (the state shown in FIG. 3). The support mechanism 40A retracts the support member 42 from the molding die 11.

[0050] Next, the drive unit 14 moves the mold 17 toward the negative side in the Y-axis direction via the toggle link mechanism 70 and the movable platen 19. As shown in FIG. 6( a), in the mold open state before movement, the distance between the flange molding surfaces 16b, 17b is D1. Next, as shown in FIG. 6( b), the drive unit 14 stops the mold 17 at the primary blow position where fluid is supplied to form the flange, with the flange molding surfaces 16b, 17b spaced farther apart than in the mold closed position (the position shown in FIG. 7( b)). The distance D2 between the flange molding surfaces 16b, 17b becomes smaller than D1. At this time, both ends of the metal pipe material 5 come into contact with the molds 16, 17 at the corners between the flange molding surfaces 16b, 17b and the pipe molding surfaces 16a, 17a. This area becomes the flange-prepared portion 5b that will become the flange 50b. As shown in FIG. 7( a), the fluid supply unit 13 supplies fluid to the metal pipe material 5 at the primary blow position. This causes the metal pipe material 5 to expand, and the pre-pipe portion 5a, which will become the pipe main body 50a, comes into contact with the pipe molding surfaces 16a, 17a and deforms. The pre-flange portion 5b comes into contact with the flange molding surfaces 16b, 17b and deforms. As shown in FIG. 7( b), the drive unit 14 further presses the mold 17 toward the positive side in the Y-axis direction and stops it at the mold closing position. The mold closing position corresponds to the secondary blow position. This causes the pre-flange portion 5b to be crushed into the flange 50b. The fluid supply unit 13 supplies fluid to the metal pipe material 5. This causes the pre-pipe portion 5a to be pressed against the pipe molding surfaces 16a, 17a and become the pipe main body 50a having a shape corresponding to the pipe molding surfaces 16a, 17a. When the metal pipe material 5 comes into contact with the forming surface, it is quenched by the cooled forming die 11, thereby quenching the metal pipe material 5. The primary blow position is not limited to the position shown in Fig. 6(b) and may be adjusted as appropriate depending on the shape of the die, the configuration of the device, etc.

[0051] When molding is complete, the drive unit 14 moves the mold 17 to the negative side in the Y-axis direction to open the mold. The units 30A and 30B remove the nozzles 22A and 22B from the metal pipe 50. The support mechanism 40A supports the metal pipe 50 with the support member 42. The holding members 21A and 21B release the metal pipe 50. As shown in FIG. 2, the transport unit 120 holds the metal pipe 50 with the holding unit 116 and transports it to a downstream process. This completes one cycle of operation of the molding system 100.

[0052] Next, the operation and effects of the molding system 100 according to this embodiment will be described.

[0053] In the molding system 100, the molding device 10 includes at least a pair of molds 16, 17 that move relatively in a horizontal movement direction MD. Therefore, unlike when the molds move vertically, molding can be performed with the weights of both of the pair of molds 16, 17 supported by the floor. In other words, a brake mechanism or the like to support the weight of the pair of molds 16, 17 is not required. Therefore, the molding device 10 does not require a mechanism that can generate large forces, such as hydraulics, but is costly to install. As described above, the molding system 100 can be easily installed.

[0054] The metal material may be formed by placing the metal material horizontally in a direction intersecting the movement direction MD relative to the pair of dies 16, 17. In this case, the forming device 10 can be lowered compared to when the metal material is placed vertically relative to the pair of dies 16, 17. Therefore, the height restriction in the building when introducing the forming system 100 can be reduced.

[0055] The molding device 10 further includes a drive unit 14 that moves the mold 17 and a fluid supply unit 13 that supplies fluid to the metal material. The pair of molds 16, 17 have pipe molding surfaces 16a, 17a and flange molding surfaces 16b, 17b for molding a flanged metal pipe 50. The drive unit 14 may stop the mold 17 at a mold closed position, which is the position of the pair of molds 16, 17 when the metal pipe 50 is completed, and a primary blow position, where fluid is supplied to mold the flanges with the flange molding surfaces 16b, 17b spaced apart from each other further than in the mold closed position. In this case, part of the metal material can be inserted between the flange molding surfaces 16b, 17b at the primary blow position, which is a stage before the mold is completely closed. This can reduce cracking and other problems compared to molding the flanges in one go.

[0056] The molding device 10 may further include a support mechanism 40A that supports and aligns the transported metal material at a position between the pair of dies 16, 17. In this case, the support mechanism 40A can accurately position the metal material.

[0057] The molding system 100 further includes a conveying section 120 that places the metal material on the pair of molds 16, 17, and a conveying section 130 that removes the molded product from the pair of molds 16, 17. The conveying section 120 and the conveying section 130 may be arranged to sandwich the molding device 10. In this case, the metal material before molding can be quickly replaced with the molded product.

[0058] The molding device 10 further includes a pair of fluid supply units 13 that supply fluid to the metal material, and the pair of fluid supply units 13 may be arranged to sandwich the molds 16, 17. In this case, fluid can be supplied from both sides to the metal material placed between the pair of molds 16, 17.

[0059] The molding device 10 further includes a drive unit 14 that moves the dies 16 and 17, and the drive unit 14 may have a toggle link mechanism 70. In this case, the dies 16 and 17 are arranged so that the movement direction MD is along the horizontal direction, and even a small drive force can move the dies with a large force.

[0060] For example, an expansion molding device that uses a hydraulic press to move the mold vertically requires extensive foundation work, such as an underground pit. Furthermore, hydraulic units and piping are required, and hydraulic adjustments are necessary during trial runs, lengthening the construction period until startup. In other words, hydraulic presses have the problem of high initial costs at the time of implementation. In contrast, the molding device 10 of this embodiment uses a mechanism that moves the mold horizontally, eliminating the need for hydraulic equipment and piping. Since it can be installed at floor level, there is no need to create an underground pit, thereby reducing construction costs. The mechanism for moving the mold using a toggle link mechanism is a mechanism previously used in injection molding devices. Therefore, it can be used to replace existing injection molding devices, significantly reducing costs. Furthermore, because it has an electric drive unit rather than a hydraulic one, it allows for arbitrary sliding motion, unlike hydraulic systems.

[0061] The drive unit 14 includes a motor 67, and the motor 67 may be provided in the movement direction MD. In this case, a separate power transmission mechanism such as a V-belt or timing belt is not required, making it possible to provide a drive unit 14 that is less likely to break. In addition, the size of the molding system 100 in the height direction can be limited.

[0062] The present disclosure is not limited to the above-described embodiments.

[0063] The molding apparatus is not limited to the one that performs the thermal expansion molding as described above. For example, the present disclosure may also be applied to molding apparatuses for sheet metal forming, hydroforming, etc.

[0064] As the non-molten metal material, in addition to a heated metal pipe material, a metal pipe material at room temperature, a heated metal plate, a metal plate at room temperature, etc. may be used.

[0065] Fig. 9 is a schematic side view showing the configuration of a molding system 100 according to a modified example. In the toggle link mechanism 70, gaps may occur in the gears for adjusting the mold thickness, and gaps may occur in the sliding parts of the link portions of the toggle link mechanism 70. These gaps are prone to cause rattles. In response to this, as shown in Fig. 9, the toggle link mechanism 70 may be provided with a rattle suppression mechanism 200 that suppresses rattles that occur in the above-mentioned gaps. By suppressing these rattles with the rattle suppression mechanism 200, the position controllability of the molds 16, 17 can be improved.

[0066] The rattle suppression mechanism 200 may include a load applying mechanism 201 that applies a load to the toggle link mechanism 70. The load applying mechanism 201 is configured with a damper. The load applying mechanism 201 includes a piston portion 202 and a rod portion 203. The piston portion 202 is provided on the base member 63. The rod portion 203 extends from the piston portion 202 toward the movable platen 19 in the positive Y-axis direction. The end of the rod portion 203 on the positive Y-axis direction is connected to the movable platen 19 via a joint portion 204. The load applying mechanism 201 can apply a load that pulls the movable platen 19 toward the toggle link mechanism 70. In this way, by applying a load to the toggle link mechanism 70, the load applying mechanism 201 can suppress the occurrence of gaps that cause rattle. This suppression of rattle improves the position controllability of the molds 16, 17.

[0067] FIG. 10 is a schematic side view showing the configuration of a molding system 100 according to a modified example. As shown in FIG. 10 , the toggle link mechanism 70 may include a position detection mechanism 210 that detects the position of the movable mold 17. The position detection mechanism 210 has a position detection sensor 211 that detects the position of the operating mold 17. The position detection sensor 211 is not particularly limited, and a laser sensor or the like may be used. In FIG. 10 , the position detection sensor 211 is provided on the fixed mold 16, but the mounting position is not particularly limited as long as it is detectable. In this case, even if rattle occurs due to gaps in the mold thickness adjustment gear, gaps between the mold thickness position adjustment nut and the toggle support, and gaps in the sliding portions of the link portions of the toggle link mechanism, the position detection mechanism 210 can detect the position of the movable mold 17, thereby feedback-controlling the position of the movable mold 17, thereby improving the position controllability of the mold 17.

[0068] In the above-described embodiment, the motor 67 is provided in the movement direction MD. Alternatively, the motor 67 may be provided in a direction intersecting the movement direction MD. In this case, the size of the molding system 100 in the movement direction MD can be reduced. Furthermore, when the motor 67 is disposed on the upper side of the molding system 100 (see, for example, the motor 67 shown by the phantom line in FIG. 9 ), maintenance can be performed from above, improving maintainability.

[0069] FIG. 11 is a schematic diagram illustrating a lockup mechanism 250. The toggle link mechanism 70 may include a lockup mechanism 250 that maintains the mold clamping force. In this case, the lockup mechanism 250 can maintain the mold clamping force and thus prevent mold opening even when a reaction force is received from the metal material placed inside the mold. The lockup mechanism 250 may be activated during shutdown. In this case, the lockup mechanism 250 can prevent mold opening during shutdown. For example, even if the drive unit 14 is shut off due to a shutdown while internal pressure remains in the metal material, the lockup mechanism 250 can mechanically withstand the reaction force of the metal material, thereby preventing the mold 17 from being pushed back by the reaction force and causing the metal material to burst. An example of a shutdown is an emergency shutdown. An emergency shutdown is a shutdown of the apparatus when a safety device is deemed dangerous (e.g., the safety device is released, an emergency button is pressed, etc.). In addition to an emergency shutdown, the lockup mechanism 250 may be activated during a process shutdown, such as a power shutdown. For example, similar processing may be performed when the motor is stopped due to overload (temperature monitoring), or when there is an abnormality or monitoring processing such as an inverter abnormality or cycle monitoring abnormality. Furthermore, the lock-up mechanism 250 may be used to maintain the mold clamping force during setup work while the mold is being installed. In this case, the mold clamping force can be applied for a long period of time with a low motor load.

[0070] 12(b), when the angle of the link member 73 connected to the moving member 69 forms 90° with respect to the center line CL, the toggle magnification becomes infinite, and the mold clamping state of the molding die 11 can be maintained without motor thrust. This state is called the "lock-up state."

[0071] For example, as shown in FIG. 11( a), if the crosshead 80 (a member that rotates relative to the ball screw 68 and moves the moving member 69) is positioned further back than in the lockup state during an emergency stop, the crosshead 80 may be retracted by a reaction force from the mold 17. On the other hand, the lockup mechanism 250 shown in FIG. 11( b) positions the crosshead 80 further forward than in the lockup state during an emergency stop. An enlarged view of the link member 73 in this state is shown in FIG. 12( a). As shown in FIG. 12( a), the angle θ that the link member 73 makes with respect to the center line CL is greater than 90°. From this state, as shown in FIG. 12( b), when a reaction force F1 is applied from the mold 17, the crosshead 80 and the moving member 69 retract. At this time, the angle θ of the link member 73 with respect to the center line CL becomes 90°, resulting in a lockup state. This mechanically stops the movement of the crosshead 80 and the moving member 69.

[0072] The molding apparatus 10 may employ a molding die 212 as shown in FIG. 13. The molding die 212 includes dies 216 and 217 that move relatively in the horizontal direction, and double-acting dies 220 and 221. The die 216 is a fixed die whose position is fixed. The die 217 is a movable die that moves horizontally relative to the die 216. The double-acting die 220 is disposed below the metal material in a direction intersecting the horizontal direction (vertical direction). The double-acting die 221 is disposed above the metal material in a direction intersecting the horizontal direction (vertical direction). Such a molding die 212 can mold a flanged metal pipe 260 (see FIG. 15).

[0073] The die 216 includes a forming section 218 having a forming surface. The forming section 218 has a forming surface 218a that forms the pipe body of the flanged metal pipe 260, and a flange forming surface 218b that forms the flange. The die 217 includes a forming section 219 having a forming surface. The forming section 219 has a forming surface 219a that forms the pipe body of the flanged metal pipe 260, and a flange forming surface 219b that forms the flange.

[0074] The double-acting die 220 is provided relative to the die 217, which is a movable die. Therefore, the double-acting die 220 moves horizontally together with the die 217. The double-acting die 220 has a forming section 222 having a forming surface and a support section 223 that supports the forming section 222. The forming section 222 has a forming surface 222a that forms the pipe main body of the flanged metal pipe 260. The support section 223 supports the forming section 222 at its upper end. The double-acting die 220 has a guide mechanism 224 that allows the forming section 222 and the support section 223 to move up and down and restricts their movement in the horizontal direction. The guide mechanism 224 is provided below the support section 223 and is connected to the support section 223. The guide mechanism 224 has a cylinder section 224a fixed to the die 217 and a rod section 224b that moves up and down together with the support section 223.

[0075] The double-acting mold 220 also has a moving mechanism 226 that moves from the bottom to the top as the mold is closed during molding. The moving mechanism 226 is configured with a tapered surface 227 formed on the positive side of the Y-axis direction at the lower end of the support portion 223. The tapered surface 227 is inclined upward as it approaches the positive side of the Y-axis direction. The tapered surface 227 comes into contact with and is guided by a guide tapered surface 228 formed on the mold 216, which is the fixed mold. The guide tapered surface 228 is formed on the end face on the negative side of the Y-axis direction of the mold 216, extending toward the negative side in the Y-axis direction. The guide tapered surface 228 is inclined downward as it approaches the negative side in the Y-axis direction.

[0076] As shown in FIG. 6 , when the double-acting mold 220 moves in the mold closing direction D1 (negative side in the Y-axis direction) together with the mold 217, which is a movable mold, the tapered surface 227 comes into contact with the guide tapered surface 228 on the fixed mold side. When the double-acting mold 220 moves further in the mold closing direction D1 from that state, the tapered surface 227 is guided by the guide tapered surface 228, and the double-acting mold 220 moves in the diagonally upward direction D2. In this way, during molding, the double-acting mold 220 is moved from the bottom to the top by the movement mechanism 226 as the mold is closed. As a result, the double-acting mold 220 closes upward relative to the mold 217, which is a movable mold. During mold opening, the double-acting mold 220 moves in the negative side in the Y-axis direction together with the mold 217. Accordingly, the tapered surface 227 slides down diagonally downward (opposite direction to D2) along the guide tapered surface 228. At this time, the double-acting die 220 moves downward under its own weight. In this way, the double-acting die 220 returns to its original position under its own weight when the die is opened. Note that the guide mechanism 224 may have an elastic member (spring) that pulls the double-acting die 220 downward when the die is opened, but it is not necessary to have such an elastic member.

[0077] The double-acting die 221 is a die for controlling the size of the flange portion during molding. The double-acting die 221 is connected to a drive mechanism 229 provided on the die 216, which is a fixed die. The drive mechanism 229 is a mechanism for reciprocating the double-acting die 221 diagonally up and down. During the primary blow shown in FIG. 14 , the drive mechanism 229 moves the double-acting die 221 diagonally downward toward the negative side in the Y-axis direction. As a result, the double-acting die 221 is positioned in the space between the flange molding surface 218b and the flange molding surface 219b. After the primary blow, the drive mechanism 229 moves the double-acting die 221 diagonally upward toward the positive side in the Y-axis direction, and the double-acting die 221 is retracted (see FIG. 15 ).

[0078] 14 and 15 , the procedure for forming a flanged metal pipe 260 using the forming die 212 will be described. First, a metal pipe material 5 is placed between the dies 216 and 217, and the movable die 217 is moved to the primary blow position (the position shown in FIG. 14 ). At this time, as shown in FIG. 14 , the double-acting die 221 is positioned in the space between the flange forming surface 218b and the flange forming surface 219b. In this state, the forming portions 218, 219, and 222 are not in a completely closed state. The metal pipe material 5 is deformed into a shape corresponding to each forming surface of the forming portions 218, 219, and 222. In this state, the metal pipe material 5 is subjected to primary blowing. As a result, a portion of the metal pipe material 5 (the flange-prepared portion) enters the space between the flange forming surface 218b and the flange forming surface 219b. The length of the flange-prepared portion is regulated by the double-acting die 221.

[0079] Next, the drive mechanism 229 retracts the double-acting die 221 from the space between the flange forming surface 218b and the flange forming surface 219b. The double-acting die 220 is further moved together with the metal mold 217 in the die closing direction D1 to the secondary blow position (the position shown in FIG. 15 ). In this state, the forming sections 218, 219, and 222 are in a completely closed state. The metal pipe material 5 is deformed into a shape corresponding to each forming surface of the forming sections 218, 219, and 222. In this state, the secondary blow is performed to complete the flanged metal pipe 260.

[0080] As described above, the forming apparatus 10 further includes double-acting dies 220 and 221, which may be positioned in either the horizontal or transverse direction relative to the metal material. In this case, the double-acting dies 220 and 221 can form the metal material into a complex shape. Here, when the pair of dies 216 and 217 move vertically, oxide scale tends to accumulate on the lower die, necessitating suction or other similar procedures. In contrast, when the pair of dies 216 and 217 move horizontally relative to each other, oxide scale tends to fall downward, making it easy to remove by blowing it off with a blower or other similar procedures. For example, oxide scale SK1 adhering to die 216 falls downward, and oxide scale SK2 adhering to die 217 falls downward (see FIG. 13 ). When the double-acting dies 220 and 221 are used, the adverse effects of oxide scale buildup become more pronounced. Therefore, in the forming device 10, by adopting a configuration that makes it easy to remove oxide scale, it is possible to suppress this adverse effect.

[0081] The double-acting mold 220 has a moving mechanism 226 that moves from the lower side to the upper side as the mold is closed during molding, and the double-acting mold 220 may return to its original position by its own weight when the mold is opened. In this case, the mechanism for returning the double-acting mold 220 to its original position can be made smaller or omitted. For example, if the double-acting mold 220 is provided above the metal material, a mechanism for lifting the weight of the double-acting mold 220 from the lower side to the upper side is required when the double-acting mold 220 is retracted after molding. Because the moving mechanism 226 can be retracted using the weight of the double-acting mold 220, a lifting mechanism can be eliminated.

[0082] If the double-acting mold 220 receives a downward force due to the internal pressure of the metal material while the operation is stopped, this force may be converted into a reaction force F2 in the opposite direction to the mold clamping force by the movement mechanism 226. However, since the molding apparatus 10 has the lock-up mechanism 250 (see FIG. 11) described above, it is able to maintain the mold clamping force even against such a reaction force F2.

[0083] 5...metal pipe material (metal material), 10...molding device, 13...fluid supply unit, 14...drive unit, 16, 17...mold (die), 40A...support mechanism, 50...metal pipe, 100...molding system, 120...conveying unit (first conveying unit), 130...conveying unit (second conveying unit), 200...rattle suppression mechanism, 201...load application mechanism, 210...position detection mechanism, 220, 221...double-acting mold, 226...moving mechanism, 250...lock-up mechanism.

Claims

1. A molding system comprising a molding device for molding a non-molten metal material, the molding device having at least a pair of molds that move relatively in a moving direction along a horizontal direction, and molding is performed by placing the metal material onto the pair of molds in a direction intersecting the moving direction.

2. The molding system according to claim 1, wherein the metal material is molded by placing the metal material on the pair of molds in a direction that intersects with the direction of movement and is also horizontal.

3. The molding system according to claim 1, further comprising: a drive unit which moves the molds; and a fluid supply unit which supplies fluid to the metal material, wherein the pair of molds have a pipe molding surface for molding a metal pipe with a flange, and a flange molding surface, and the drive unit stops the molds at a mold closing position which is the position of the pair of molds when the metal pipe is completed, and a primary blow position where the fluid is supplied to mold the flanges with the flange molding surfaces spaced apart from each other further than at the mold closing position.

4. The molding system according to claim 1, wherein the molding device further comprises a support mechanism for supporting the transported metal material at a position between the pair of molds and aligning the position of the metal material.

5. A molding system as described in claim 1, further comprising: a first conveying unit that places the metal material on the pair of molds; and a second conveying unit that removes a molded product from the pair of molds, the first conveying unit and the second conveying unit being positioned so as to sandwich the molding device.

6. The molding system according to claim 1, wherein the molding device further comprises a pair of fluid supply units that supply fluid to the metal material, the pair of fluid supply units being arranged to sandwich the mold.

7. The molding system according to claim 1, wherein the molding device further comprises a drive unit for moving the mold, the drive unit having a toggle link mechanism.

8. A molding system as described in claim 7, wherein the toggle link mechanism is provided with a rattle suppression mechanism that suppresses rattle that occurs in the gap that occurs in the gear for adjusting the mold thickness and in the gap in the sliding portion of the link portion of the toggle link mechanism.

9. A molding system according to claim 8, wherein the rattle suppression mechanism includes a load applying mechanism that applies a load to the toggle link mechanism.

10. The molding system according to claim 7, wherein the toggle link mechanism includes a position detection mechanism for detecting the position of the movable mold.

11. The molding system of claim 7, wherein the drive comprises a motor, the motor being provided in the direction of movement.

12. The molding system according to claim 7, wherein the drive unit includes a motor, the motor being arranged in a direction intersecting the direction of movement.

13. The molding system of claim 7, wherein the toggle link mechanism includes a lock-up mechanism that maintains a clamping force.

14. The molding system according to claim 13, wherein the lock-up mechanism is activated when stopped.

15. The forming system according to claim 1, wherein the forming device further comprises a double-acting die, the double-acting die being disposed in either one of the directions intersecting the horizontal direction relative to the metal material.

16. The molding system according to claim 15, wherein the double-acting mold has a moving mechanism that moves from the lower side to the upper side as the mold is closed during molding, and the double-acting mold returns to its original position under its own weight when the mold is opened.

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