Roll forming machine

Abstract

 The invention relates to a roll forming machine which comprises a frame (13) and successive pairs (18) of forming rolls, having forming rolls (1a, 1b) adjustably connected to the frame (13) and to each other by means of shafts (4a, 4b). In the roll forming machine according to the invention, the forming rolls (1a, 1b) are provided with bearings on the shafts (4a, 4b) and that at least part of the shafts (4a, 4b) are mounted on the frame (13) in an adjustable manner and locked with a desired spacing.

Description

Field of the invention

[0001] The invention relates to a roll forming machine.

Background of the invention

[0002] Various profile products are made of sheet metal by a technique called roll forming. The sheet metal is typically made of steel, aluminium or, for example, copper. Profile products used in buildings include, for example, various gutters, battens, cover plates for roofs and walls, and in some cases also so-called roof safety products, such as snow guards, service bridges, etc. Machines used for roll forming of sheet metal are called roll forming machines and roll forming lines normally when other material processing steps (such as cutting of the profile, and/or making transverse profile shapes, and/or perforating, or the like) are taken in addition to roll forming.

[0003] The roll forming machines typically consist of several pairs of rolls in succession, comprising a superimposed upper roll and a lower roll, between which sheet metal is conveyed in such a way that it is bent to a profile of a desired shape (i.e. is profiled). The forming rolls of the successive pairs of rolls are designed and placed in such a way with respect to each other that the sheet to be profiled will gradually assume the desired shape or profile. Typically, the forming rolls are mounted on the frame of the roll forming machine by means of bearing cups fastened to frame beams in an adjustable manner. The sheet metal to be formed is normally in the form of coils (or rolls) when introduced in the roll forming machine, and the finished profile is output in the form of profiled elements, cut to a suitable size, from the other end of the roll forming machine. At the terminal end of the roll forming line, a cut-to-length device is normally provided for cutting the sheet metal strip, uncoiled and profiled in the roll forming steps, into profile elements of fixed length. For example in a roofing sheet line, the elements typically have the length of one pane of roof to be clad, or shorter than this (so-called cladding elements). Metal sheets or strips can also be roll formed, but this is less common, because the most significant advantages of roll forming technology are based on continuous production.

[0004] Profiling of sheet metal by roll forming requires close control of the material in view of the forming technique. The stepwise forming of the material has to be performed in a controlled and uniform manner so that no internal stresses and unintended deviations in the shape of the profile are caused by uneven forming of the material in the sheet metal. Even a small deviation in the setting values between the pairs of forming rolls and/or in the position of the pairs of rolls with respect to other pairs of rolls may cause problems in the control of the roll forming process and thereby, among other things, above-mentioned problems of accuracy in the shape and the dimensions of the finished profile products. After the adjustments and settings giving a satisfactory final result have been found, the setting values of the pairs of rolls and the position of the successive pairs of rolls with respect to each other also have to remain constant, at least during the processing of the coil in question.

[0005] In roll forming machines of prior art, the forming rolls are supported by bearing cups mounted on the frame of the roll forming machine in such a way that the shafts of the forming rolls are not subjected to loads that would bend them. All the forces effective on the forming rolls during the roll forming are, however, transmitted in the form of point-like supporting forces via the bearing cups to the frame of the roll forming machine Therefore, the shafts mounted via the bearing cups between the frame beams do not increase the rigidity of the frame; consequently, to obtain an excellent final result, the frame structures of roll forming machines implemented according to the prior art have to be sufficiently rigid and strong. In practice, that has resulted in the necessity to make the frame structures and/or their parts, in most cases, relatively massive and thereby heavy-duty. Due to their heavy-duty frame structures, the roll forming machines of the state of art are expensive, and it is often slow and laborious to move them to and to install them on the site where they are used.

Brief summary of the invention

[0006] The aim of the invention is to provide a roll forming machine which is lighter in weight than before, but which is still sufficiently rigid and strong in view of the loads to which it is subjected during the use, so that the pairs of forming rolls therein maintain their positions with respect to the other pairs of forming rolls, and wherein the mutual position or setting of the forming rolls remains, although the frame structure is lighter in weight than before, accurately at the set value, in spite of the loads effective on the forming rolls. Furthermore, it is an aim of the invention to introduce a roll forming machine which is modular and easily transportable from one place to another.

[0007] The aim of the invention is achieved with a roll forming machine, in which the forming rolls are provided with bearings on shafts which are mounted on the frame of the machine in an adjustable manner but restrained after the adjustment. In other words, the bearings of the forming rolls are provided between the forming rolls and the shafts and not between the bearing cups and the shafts. In this way, the shafts of the forming rolls constitute a part of the load-bearing structure of the frame of the roll forming machine, by making the frame more rigid and thereby more resistant to e.g. harmful deformations in view of controlling the roll forming process than a conventional frame formed of e.g. adjacent frame beams, in the way of a lattice structure. To put it more precisely, the roll forming machine according to the invention is characterized in what will be presented in the independent claim 1. The dependent claims 2 to 10 will present some preferred embodiments of the roll forming machine according to the invention.

[0008] The roll forming machine according to the invention has the advantage that the structure of the roll forming machine becomes more rigid than before, although the components used in it are thinner in their wall thickness than before. Thanks to this, the roll forming machine implemented in this way can be easily made modular and light-weight as well as low-cost in terms of its manufacture and installation. If necessary, the light-weight and modular roll forming machine can be transported in, for example, a trailer or a truck to the site of installation of profile products.

Description of the drawings

[0009] In the following, the invention will be described in more detail with reference to the appended drawings, in which

Fig. 1

shows a roll forming machine according to the invention seen in a slanted view from above,

Fig. 2

shows a pair of forming rolls in a roll forming machine according to Fig. 1 seen in a slanted view from above,

Fig. 3

shows the pair of forming rolls according to Fig. 2 seen in a front view,

Fig. 4

shows the cross-section A-A shown in Fig. 2 of the pair of forming rolls according to Figs. 2 and 3, and

Fig. 5

shows the cross-section of a detail of the fastening point of one shaft of the pair of forming rolls shown in Figs. 2 to 4, enlarged to the scale 2:1.

Detailed description of the invention

[0010] Figures 1 to 5 show a roll forming machine according to the invention. As shown in Fig. 1, it comprises a frame 13 with a plate structure composed of side walls 14 and 15 as well as intermediate walls 16 and 17 fastened between them, in this case at both ends of the side walls 14 and 15, and acting as intermediate supports for the side walls. Between the side walls 14 and 15, several pairs 18 of forming rolls are fastened one after the other. Each pair 18 of forming rolls comprises an upper roll 1 a and a lower roll 1 b as well as a shaft 4a for the upper roll and a shaft for the lower roll 4b, spaced in a controlled manner with respect to the shaft of another pair 18 of forming rolls, fastened to the frame 13 and secured in a desired position. In the pair 18 of forming rolls, the upper roll 1 a and the lower roll 1b are normally aligned on top of each other in the longitudinal direction of the frame 13. The upper rolls 1 a are mounted on bearings 5a on the shaft 4a for the upper roll, and the lower rolls 1 b are mounted on bearings 5b on the shaft 4b for the lower roll. The bearings 5a and 5b can be, for example, grooved ball bearings or conical ball bearings. Furthermore, the pair 18 of forming rolls comprises, among other things, a transmission 9, and locating sleeves 6, 7, 10, and 12 for the shafts 4a and 4b, as well as spinner nuts or corresponding fastening members 11 for fastening and aligning the bearings 5a and 5b and the sleeves 6, 7, 10, and 12.

[0011] For adjusting the mutual rotational speeds of the upper roll 1a and the lower roll 1 b of the pair 18 of forming rolls, the upper rolls 1 a and the lower rolls 1 b can be connected to each other by synchronization gear wheels 8 shown in Fig. 2. The pair 18 of forming rolls is powered via the transmission 9. The transmission 9 can be implemented with e.g. a single actuator (e.g. electric or hydraulic motor) and a chain transmission connected to it for rotating all the upper rolls 1 a and the lower rolls 1 b, or in such a way that a separate actuator is provided for driving the upper rolls 1 a and the lower rolls 1 b of each pair 18 of forming rolls. In another possible alternative, the pairs of forming rolls to be driven by a single actuator are divided into two or more groups.

[0012] The spacing between the upper roll 1 a and the lower roll 1 b of one pair 18 of forming rolls (i.e. the setting of the pair 18 of rolls) is adjusted by the wobbler principle in the roll forming machine according to Figs. 1 to 5. In the embodiment shown in Figs. 1 to 5, the spacing between the shafts 4a and 4b is adjusted by rotating either or both of the shafts 4a and/or 4b. For this, the ends of the shaft 4a and/or 4b may be provided with, for example, an eccentric drilling for fixing screws (Fig. 5), or the ends of the shaft 4a and/or 4b may be made eccentric and fastened directly to the frame 13 or the end pieces 2a and 2b in such a way that by rotating the shaft 4a of the upper roll and/or the shaft 4b of the lower roll, its position with respect to the opposite shaft (i.e. either the shaft 4a of the upper roll or the shaft 4b of the lower roll) is changed. The eccentric features of the shafts are dimensioned so that the desired range of adjustment is achieved, for example in the range of a rotating angle of 180°. After the adjustment, the shaft 4a and/or the shaft 4b is locked at both ends between the side walls 14 and 15 of the frame 13, or end pieces 2a and 2b fastened to them, by locking members 3. Consequently, the shafts 4a and 4b do not rotate with the forming rolls 1 a and 1 b during the operation of the roll forming machine.

[0013] The locking members 3 for the shaft 4a and/or 4b of the pair 18 of forming rolls may comprise, in the simplest form, e.g. merely a threaded screw at the end of the shaft, fitted through a hole in the side wall 14 or 15 of the frame or in the separate end pieces 2a and 2b, by which screw the shaft is thus simultaneously fastened to the side wall 14 or 15 of the frame or to the end piece 2a or 2b. By tightening the screw, the shaft 4a and/or 4b can be compressed against the side wall 14 and/or 15 of the frame 13 in such a way that it is restrained. A member for increasing the friction, for example a locking ring or the like, may be provided between the end of the shaft and the side wall, to make the locking sufficiently tight to secure that the shafts 4a and/or 4b fastened in this way will not rotate by themselves during the operation of the roll forming machine. Alternatively, the locking can be implemented by locking members which are slightly more complex than above. In a locking mechanism, the shaft 4a and/or 4b is provided with a locking plate, for example in the shape of a sector, coming against the inner surface of either side wall 14 or 15 of the frame 13, having a curved groove, at which a locking screw is driven in the side wall. By means of the locking screw, the locking plate can be tightened against the side wall in such a way that the locking plate and the shaft fastened to it are locked in a desired position. With such locking members, a tighter locking is achieved than in the preceding alternative. Furthermore, with such locking members, the angle of rotation of the shafts 4a and/or 4b can be limited to a desired magnitude (for example 180°) so that the shafts 4a and/or 4b cannot rotate beyond the range of adjustment.

[0014] In the simplest form, for adjusting the shafts 4a and/or 4b, these may be provided, on opposite sides, with flat rotating surfaces, at which the shafts 4a and/or 4b can be rotated by a suitable tool, for example an open end wrench or an adjustable wrench. In more complex applications, e.g. a set of rotating levers operated by a threaded rod may be provided, to be moved by e.g. the threaded rod. Such a set of rotating levers is self-locking, so that the locking members merely have the function of securing the immobility of the shaft. At the end of the threaded rod moving the set of rotating levers, e.g. the head of a hexagonal socket-head screw may be provided, at which the threaded rod can be rotated by e.g. a battery powered drilling machine or another tool suitable for driving a screw.

[0015] In case the ends of the shaft 4a and/or the shaft 4b are fastened to the frame 13 of the roll forming machine by means of separate end pieces 2a and 2b (as shown in Figs. 2 to 5), the pair 18 of forming rolls constitutes a modular unit which can be assembled and adjusted as a separate unit in advance, and installed as an assembled and adjusted unit in the frame 13 of the roll forming machine. The end pieces can be fastened to the side walls of the frame 13 and adjusted in the longitudinal direction of the frame 13, for example, by bolts fitted through fastening holes in both of these. For this, the side walls of the frame may be provided with groove-like holes in the longitudinal direction of the frame 13, for fastening bolts of the end pieces 2a and 2b. Furthermore, the end pieces 2a and 2b may be provided with an adjustment in the vertical direction. This may be implemented e.g. in such a way that the holes for the fixing screws in the end pieces 2a and 2b are, in the vertical direction, larger by the length of the desired adjustment range in the end pieces than the diameter of the fixing screws in the vertical direction (i.e. they are groove-like in the vertical direction).

[0016] The roll forming machine shown in Figs. 1 to 5 is assembled by fastening the side walls 14 and 15 and the intermediate walls 16 and 17 of the frame together. After this, the pairs 18 of forming rolls, the transmission 9, as well as the actuators and control devices (not shown in the figures) are installed in the frame 13. The pairs 18 of forming rolls are installed in the frame 13 at fixed intervals so that the formation of the profile to be formed in one forming step will not become too extensive in relation to the space between two forming steps in succession. Consequently, the number and spacing of the pairs 18 of forming rolls will depend on the shape of the profile to be formed. Normally, a production line (roll forming line) is formed of the roll forming machine, in which a desired profile product is made of sheet metal unwound from a reel or strip of sheet metal. For this, an uncoiler is normally installed on the front side of the reel forming machine, and a cut-to-length device on the side of the terminal end of the roll forming machine, for cutting the profiled sheet metal band or strip into pieces of desired length. In a continuous line, the cut-to-length device is typically, for example, a so-called flying shear which, during the cutting, moves with the cutting point of the profile to be formed, in the travel direction of the sheet metal strip, and returns back to its initial position when the next profile is being formed.

[0017] When applying the roll forming machine according to Figs. 1 to 5, the setting between the upper roll 4a and the lower roll 4b of the pair 18 of forming rolls of the roll forming machine is adjusted suitable before the forming of the sheet metal strip is started. This is done by releasing the locking members 3 of the adjustable shafts 1a and/or 1b and by rotating the shafts within the range of rotation angle of 180° in such a way that the desired setting of the forming rolls 1a and 1b is achieved. At the initial stage, a suitable setting value is sought for each pair 18 of forming rolls, and as soon as the setting values giving a final result that meets the quality requirements has been found, the adjustable shafts 4a and/or 4b are locked by the locking members 3. During the forming, sheet metal strip is supplied to the roll forming machine from an uncoiler placed on its front side. The sheet metal strip is profiled stepwise at each pair of forming rolls in such a way that after the last pair of forming rolls, the sheet metal strip has assumed the profile form aimed at. The continuous profile strip can be cut into sheets of desired length by a cut-to-length device placed after the roll forming machine.

[0018] If the roll forming machine according to Figs. 1 to 5 is to be moved from one forming site to another, its forming rolls 1a and 1b are removed from the frame 13. The forming rolls 1 a and 1 b can be removed from the frame 13 by removing the shafts 4a and 4b of the pairs 18 of forming rolls from each other separately, if they have been fixed directly to the side walls 14 and 15 of the frame 13. If, on the other hand, the forming rolls 1 a and 1 b have been fixed by means of separate end pieces 2a and 2b, the forming rolls 1 a and 1 b can be removed from the frame 13 of the roll forming machine, one pair 18 of forming rolls after another, by removing the end pieces 2a and 2b. The advantage here is that the setting values of the pairs 18 of forming rolls remain unchanged during the transportation; that is, at the next site, no adjustment of the setting values is usually needed, if the sheet metal strip to be formed is the same type of sheet metal strip as one formed at the preceding forming site. In addition to the pairs 18 of forming rolls, the parts of the transmission 9 as well as the actuators and the control devices are removed from the frame 13 of the roll forming machine for the time of the transportation. Finally, the frame 13 can be removed from its possible fastenings and disassembled by detaching the side walls 14 and 15 and the intermediate walls 16 and 17 from each other. The disassembled separate parts are transported by a suitable means of transportation to the new site, where the frame 13 is reassembled and mounted on the desired location. After the frame 13 has been mounted, the forming rolls in the form of single upper rolls 1 a and lower rolls 1b, or in the form of forming roll pairs 18 ready fastened to end pieces 2a and 2b, as well as the other above-mentioned parts of the roll forming machine, are installed in the frame.

[0019] In many respects, the roll forming machine according to the invention can be implemented in a way different from the above-presented exemplary embodiment. For example, in the case of a modular embodiment, two or more pairs of forming rolls, instead of one pair, may be mounted on the end pieces to be fastened to the frame. In an embodiment, the side walls of the frame may consist of two or more parts connected to each other in a detachable way. Also, more intermediate walls and/or various other intermediate supports between the side walls may be provided than the above-mentioned intermediate walls for the ends of the frame. In this way, the roll forming machine is made such that its disassembly for transportation requiring relatively little space, and its reassembly for use is facilitated even if the roll forming machine were relatively large in size. Furthermore, it should be noted that the adjustable mounting of the shafts used e.g. as bearing shafts for forming rolls may be implemented in a variety of ways different from the exemplary embodiment presented above. The adjustment made by the wobbler principle can also be implemented, for example, in such a way that wobbler mechanisms separate from the shafts are provided at the ends of the shafts, on the side walls of the frame, or in the separate end pieces, for moving the shafts. Such wobbler mechanisms may have, for example, an adjustment based on, for example, a curved peg and groove mechanism formed eccentrically in connection with a separate eccentric wheel or locking plate, for moving the shafts with respect to the frame and each other. Moreover, the control mechanism does not necessarily need to operate by the wobbler principle, but another control mechanism may be feasible as well. It could be, for example, a control mechanism based on screws or wedge-like adjustment pieces or e.g. hydraulic actuators. Consequently, the roll forming machine according to the invention is not limited to the exemplary embodiments presented above, but it may vary within the scope of the appended claims.

Claims

1. A roll forming machine comprising a frame (13) and successive pairs (18) of forming rolls, with forming rolls (1 a, 1 b) adjustably connected to the frame (13) and to each other by means of shafts (4a, 4b), characterized in that the forming rolls (1 a, 1b) are provided with bearings on the shafts (4a, 4b) and that at least part of the shafts (4a, 4b) are mounted on the frame (13) in an adjustable manner and locked with a desired spacing.

2. The roll forming machine according to claim 1, characterized in that one shaft (4a, 4b) of the pair (18) of forming rolls is fastened to the frame (13) in an adjustable manner with respect to the other shaft (4a, 4b) of the same pair (18) of forming rolls.

3. The roll forming machine according to claim 1, characterized in that both shafts (4a, 4b) of the pair (18) of forming rolls are fastened to the frame (13) in an adjustable manner with respect to each other.

4. The roll forming machine according to any of the claims 1 to 3, characterized in that at least one shaft (4a, 4b) of a pair (18) of forming rolls is fastened to the frame (13) in an eccentric manner in such a way that the spacing of the shaft (4a, 4b) with respect to the other shaft (4a, 4b) of the pair (18) of forming rolls changes when the shaft (4a, 4b) is rotated with respect to its longitudinal axis.

5. The roll forming machine according to claim 4, characterized in that the range of adjustment of the shafts (4a, 4b) is within the range of a rotating angle of 180°.

6. The roll forming machine according to any of the claims 1 to 5, characterized in that the shafts (4a, 4b) are configured to be locked by locking devices (3) in a releasable manner.

7. The roll forming machine according to claim 6, characterized in that the locking devices (3) are screws driven in the shafts (4a, 4b).

8. The roll forming machine according to any of the claims 1 to 7, characterized in that the frame (13) of the roll forming machine is a plate structure which comprises side walls (14, 15) and at least two intermediate supports (16, 17) fastened between them.

9. The roll forming machine according to any of the claims 1 to 8, characterized in that the shafts of at least one pair (18) of rolls are mounted on end pieces (2a, 2b) separate from the frame (13), fastened to the side walls (14, 15) of the frame (13) in a detachable manner.

10. The roll forming machine according to claim 9, characterized in that the end pieces (2a, 2b) are fastened to the frame (13) in an adjustable manner in its longitudinal direction.

Drawing