EP1245302A1 - Profilingmachine with a plurality of in-line arranged forming stations - Google Patents

Abstract

The profiling machine has a number of shaping stations (1) arranged in line for multi-stage forming of a workpiece (2). Each station has a tool (8), comprising a pair of rollers, for shaping the workpiece. Position sensors (18) are used to determine position data for all the roller tools, while a central data processing unit (3) collects and processes the position data and if necessary positions the rollers using actuators.

Description

The invention relates to a profiling machine with several in line one behind the other arranged forming stations for multi-stage forming a to be profiled Workpiece, whereby the forming stations with their position adjustable and interacting in pairs Roll forming tools are provided, between which the workpiece is passed while being reshaped. A typical example of such a profiling machine is disclosed in DE 27 32 233 B1.

Profiling machines of the type mentioned are mostly together with a infeed table upstream of the forming stations, one or more Straighteners and if necessary a cut-to-length machine set up to a Form production line for the production of finished profiles from strip material. Tool holders in the sense of this application are in particular scaffolds that at least two horizontal axes for guiding roll forming tools have, or side roller tables on which at least two on parallel vertical axes running rollers are stored.

Conceptually, a roll forming machine is a mass production machine. she can produce a very large amount of profiles of the same shape in a very short time. Due to its design, flexibility is alien to it; converting the profiling machine to a different profile shape or a different material of the workpiece to be profiled in any case requires a longer running-in or testing phase with the corresponding Reject material until the profile shape produced meets the specifications equivalent. This also applies if a profile has already been made and will be produced again later.

To reduce this disadvantage, quick-change systems have been used in the past proposed, as described for example in DE 1 527 981 are. The tool holders there are scaffolds with fixed roll forming tools, the scaffolds are designed to be interchangeable. It is obvious, that such a quick-change system for profiling machines with a larger one Number of forming stations becomes very expensive.

Furthermore, there is one in particular with more complicated profile shapes Require a large number of forming steps, a large number of setting parameters, that affect the result achieved, so that for testing a newly developed Tool, but also for running in a newly installed profiling machine and readjustment, for example when changing materials or in the case of a worsening work result, only experienced ones Special forces for adjusting the adjustable roll forming tools come into question.

The invention is therefore based on the object of a profiling machine at the outset mentioned type also for less experienced operators make and simplify a conversion of the roll forming machine.

This task is by a profiling machine with the features of the attached Claim 1 solved.

Advantageous further developments and refinements of the invention are in the claims 2 to 15 deposited.

A profiling machine of the type mentioned is thus with the invention Provide detection means, the position data of all adjustable roll forming tools capture, as well as with a central data processing device, the collects and processes the position data reported by the detection means.

In the simplest case, further processing can consist of all Position data of the roll forming tools that have been optimized for production stored as a specially marked data record for later use becomes. In this way, it is advantageously possible to return to an optimal setting at any time of the roll forming tools are used if, after a change, for example after a tool change, but also after a production lot with material of a different nature back to the conditions at that time is decreased. It is immediately obvious that such a more detailed Position data record the retraction of the machine found at once optimal values of the position data considerably simplified and the associated Production scrap is minimized.

However, the processing of the position data can alternatively or additionally go in a completely different direction and, as described below, for example with software based on the principle of neural networks and / or Fuzzy logic tools work, to a kind of self-learning system and thus to a virtual assistant during the testing phase of the profiling machine to lead.

The output of the stored and retrieved data records or the collected ones and further processed position data can be stored on an information carrier, for example, a screen, which causes the operator of the profiling machine the various roll forming tools for instructions and suggestions set; However, it is particularly advantageous if all adjustable Roll forming tools or their tool holders with the data processing device controlled motorized adjusting elements are provided. The conversion of the entire profiling machine to one earlier, for example produced profile shape can then be done "at the push of a button". Furthermore can z. B. Intermediate values when setting up and adjusting the profiling machine store it as a data record and, if there is a Changing the positions of different roll forming tools is not ideal, these changes can easily be brought back to the intermediate value. This speeds up the purely empirical process of adjustment is naturally considerable.

The acquisition means for acquiring the position data of all adjustable roll forming tools can be realized for example with laser technology, the exact position of the roll forming tools is optically detected in each case; very easy is the acquisition of the position data but when the tool holders with adjustment elements for adjusting the positions of the roll forming tools are provided, their setting values as position data of the respective roll forming tools serve. It is particularly advantageous if these adjustment elements as Servomotors are formed, which electronically transfer their respective position to the central Report data processing device and be controlled from there can.

The central data processing of the profiling machine according to the invention can be based on various types can be programmed. For the purpose of adjusting a roll forming machine It is also possible to enable inexperienced operators, for example advantageous if all position data at least during a test phase the profiling machine and the resulting Position data history prepared for further processing or evaluation, be represented in particular. Based on such temporal position data courses a trial phase can then be traced at any time later. This can, for example, make it easier for an inexperienced operator to optimize one Setting due to changes in the material properties of the workpiece to change or find an optimal setting of the machine again. Of the presentation of position data profiles also creates the prerequisite for a self-learning system based on several run-in processes and trial phases a profiling machine according to the invention "learns" how to adjust a profiling machine.

The profiling machine according to the invention offers particular advantages when at least one detector for detecting the final profile shape is available, which with the central data processing device for carrying out a comparison of the Actual shape data and the target shape data is related. This makes it possible the system not only to record the position data and the position data history, but based on the shape data provided by the detector with the to put the resulting profile shape in relation and a connection between the change of one or more profile data and the change of the To produce shape data.

In addition, measurement sensors can be provided which have the shape of the profile to be profiled Workpiece after each forming station with adjustable roll forming tools capture and forward to the central data processing device. This enables a more precise breakdown of the relationships between the Adjustment of individual forming stations and the associated changes the shape data detected by the sensors. The sensors can be devices for recording a light section, which make it possible to determine a profile cross section of the workpiece.

The central data processing device is expediently programmed in such a way that that they have all the position data of the adjustable roll forming tools the shape data obtained from the detector and / or the measurement sensors Workpiece and also the corresponding default values from the theoretically calculated profile flower considered. So much for the profiling machine with adjustment elements controllable by the central data processing device equipped, a self-regulating system can be generated, for example a profile cross-section is determined after each forming station and iteratively compared with the default values, with the positions for each iteration step the roll forming tools of the corresponding forming station are changed. The The profiling machine according to the invention is then integrated with a process Quality monitoring equipped, which detects irregularities in real time and corrected. This ensures production reliability, particularly in series production greatly increased.

Further advantages result when in the central data processing device those position data are stored that are based on theoretical Calculations during the construction of the roll forming tools. It is particularly during a CAD design of forming tools possible to simulate the theoretically occurring deformations and understand. This results in theoretical stress curves for the forming and theoretical setting values for the roll forming tools, which during the testing phase of the profiling machine then only need to be corrected. If these theoretical default values for the position data from the central Data processing device are also taken into account, results in particular a much higher efficiency of self-learning or self-regulating system; but also in general the consideration of the theoretical Default values by the operator, for example, the running-in process shorten considerably after changing tools.

An advantageous programming of the central data processing device of the Profiling machine according to the invention can, for example, the following method enable: starting from the ones obtained during the construction of the roll forming tools The theoretical values become the setting values in the test phase and thus the position data of the individual roll forming tools manually adapted and corrected, the data processing device the theoretical Already has default values and from there also logs position data history. At the same time, it logs the shape data of the workpiece with which it receives from the detector and / or from the sensors. From the The software then determines the position data courses and the shape data courses a functional relationship between the position data and the shape data and stores this functional relationship as a process behavior pattern from. The more testing phases that go through in this way, the more process behavior patterns the software of the central data processing device becomes have available to avoid unwanted shape deviations of the workpiece either make appropriate suggestions to the operator to be able to, or the corresponding adjustable molds for the preferably iterative correction. This in turn increases the Production security of the profiling machine even for inexperienced operators; long-term can also be a support tool for testing new ones Roll forming tools are created using a catalog of process behavior patterns reproduces the "feeling" of an experienced technician. This is the software of the central data processing device expediently with Provide software tools that are based on fuzzy logic principles or in Art work from neural networks.

In order to perfect the system, further sensors can be present, the Forward secondary parameters to the central data processing device, which can also influence the production result. Come here in particular the feed rate and the temperature of the Workpiece, the type and temperature of the lubricant used, the ambient temperature, the thickness and width of the workpiece, the straightness and waviness of the workpiece as well as its material properties, from coil to coil completely can be different. Some of these secondary parameters are significant Influence on the production result, especially through unwanted shape deviations of the profile, so the software of the data processing device can "learn" over time, on changed secondary parameters by appropriate Correct the positions of certain selected roll forming tools.

The system is further improved, if not only at the forming stations further processing stations, such as in particular at additional side roller tables, at the infeed table and at any intermediate and Straighteners are available with which the shape of the workpiece to be profiled and sent to the central as a form data set Data processing device is forwarded. Because even those with such additional The shape data recorded by the transducers allow conclusions to be drawn about the Suitability of certain process behavior patterns. Conversely, you can from the data processing device also suggestions or control impulses for a targeted change in the settings of additional side roller tables, the infeed table and straighteners.

A profiling machine according to the invention, with detection means for detection the position data of all adjustable roll forming tools, with the data processing device controlled motorized adjustment elements, with a detector and measuring sensors as well as a correspondingly executed software for the data processing device is equipped, gives the operator of the profiling machine So not just the possibility of being very quick and inexpensive a profile shape to another profile shape, but can also do so contribute to the testing phases of completely new roll forming tools significantly reduce. The system always improves over time more, until the reproducibility of that previously experienced by experienced technicians Feeling fine adjustments made for different profile shapes and different Boundary conditions. The system is learned via a Retracing the manual adjustment carried out by a technician in a test phase, the course of the position data in real time with all current boundary conditions are compared and a functional one Connection is created. The software does not have to start from zero, because the CAD design of the roll forming tools already results a basic setting as a first approximation. In addition, this is also a self-regulating system possible based on such a basic setting the adjustment of the profiling machine takes over completely automatically; not to mention the possibility of ongoing quality control with automatic Create corrective interventions.

The theoretically inconceivable optimization of the position data of the roll forming tools The production of a particular profile shape can thus be carried out by the present one Invention with numerical approximation methods largely to completely be automated.

Figur 1

eine perspektivische Darstellung der wesentlichen Elemente einer Profiliermaschine;

Figur 2

eine einzelne Umformstation aus Figur 1;

Figur 3

ein Detail aus Figur 1, von der Rückseite gesehen.

An exemplary embodiment of the profiling machine according to the invention is described and explained in more detail below with reference to the accompanying drawings. They show in a partially schematic representation:

Figure 1

a perspective view of the essential elements of a profiling machine;

Figure 2

a single forming station from Figure 1;

Figure 3

a detail of Figure 1, seen from the back.

The parts of a shown in Figure 1 in a schematic perspective view Profiling machine according to the invention essentially comprise eight in a row arranged forming stations 1 for multi-stage forming a to be profiled Workpiece 2 and a central data processing device 3, the is symbolized here by a monitor and via signal lines 4 with position data acquisition means 5 is connected to the forming stations 1. The forming stations 1 are attached to a symbolically represented machine frame 6.

As FIG. 2 illustrates, which shows a forming station 1 from FIG. 1 in detail, there is a forming station 1 of the present embodiment from a scaffold 7 as a tool holder for two pairs of roll forming tools 8 which are in the frame 7 are mounted on two parallel, horizontally running shafts 9, and one Side roller table 10 as a tool holder for two designed as side rollers 11 Roll forming tools.

The side rollers 11 are slidably fastened on the slide 12 in the side roller table 10, whereby two adjustment elements 13 are responsible for the displacement. The Adjustment elements 13 also serve as detection means for detecting the position data of the two side rollers 11, which is why they via signal lines 4 with the Data processing device 3 are connected.

The framework 7 essentially consists of two mutually opposite, along two guide columns 14 vertically displaceable bearing yokes 15, in which the shafts 9 of the roll-forming tools 8 are mounted. Both Shafts 9 and the associated bearing yokes 15 are each assigned one Servo motor 16 for an axial adjustment of the position of the roll forming tools 8 perform. The servomotors each act on a spindle 17 on the opposite one Each end of a position transmitter 18 as a detection means for Detect the axial position of the roll forming tools 8 attached and via signal lines 4 is connected to the data processing device 3.

The height adjustment of the bearing yokes 15 on the guide columns 14, too a vertical change in position of the roll forming tools 8, is via detection means reported to the data processing device 3 and documented there, as can best be seen from FIG. 3, which shows a section of the elements of a profiling machine according to the invention shown in FIG the other side shows: A position sensor is located on each of the two bearing yokes 15 19, the current vertical position of the respective bearing yoke 15 and thus the horizontal position of the shaft 9 and the roll-forming tools 8 via signal lines 4 reports to the central data processing device 3. This position encoder 19 can in particular be servomotors by the data processing device 3 can be controlled and the vertical adjustment of each Make bearing yokes completely independent of the other parameters.

The signal processing in the data processing device 3 takes place in the above detailed way.

LIST OF REFERENCE NUMBERS

1

forming station

2

workpiece

3

Data processing device

4

signal line

5

Position data detection means

6

machine frame

7

framework

8th

Roll forming tools

9

wave

10

Side roller table

11

side roll

12

carriage

13

adjustment

14

guide column

15

bearing yoke

16

servomotor

17

spindle

18

locator

19

locator

Claims (15)

Profiling machine with several forming stations (1) arranged in line one behind the other for multi-stage forming of a workpiece (2) to be profiled, the forming stations (1) having roll-forming tools (8) mounted in tool holders (7, 10), adjustable in their position and interacting in pairs ) are provided, between which the workpiece (2) is passed and thereby formed,
characterized in that detection means (18, 19) for detecting the position data of all adjustable roll-forming tools (8) and a central data processing device (3) for collecting and further processing the position data are provided. Profiling machine according to claim 1,
characterized in that all adjustable roll forming tools (8) or their tool holders (7, 10) are provided with motorized adjusting elements (13, 16) controlled by the data processing device (3). Profiling machine according to one of claims 1 or 2,
characterized in that the tool holders (7, 10) are provided with adjusting elements (13) for adjusting the positions of the roll-forming tools (11), the setting values of which serve as position data of the respective roll-forming tools (11). Profiling machine according to claim 3,
characterized in that the adjusting elements (13) are designed as servomotors. Profiling machine according to one of claims 1 to 4,
characterized in that the central data processing device (3) is set up in such a way that it stores all position data of the roll-forming tools (8, 11) that are optimized for production as a data record for later use. Profiling machine according to one of claims 1 to 5,
characterized in that the central data processing device (3) is set up in such a way that it logs all position data at least during a testing phase of the profiling machine and processes the resulting position data curves for further processing or evaluation. Profiling machine according to one of claims 1 to 6,
characterized in that there is at least one detector for detecting shape data of the final profile shape, which is connected to the central data processing device (3) for carrying out a comparison of the desired shape data and the actual shape data. Profiling machine according to one of claims 1 to 7,
characterized in that measuring sensors are provided which are designed such that they record the shape data of the workpiece (2) to be profiled after each forming station (1) with adjustable roll-forming tools (8, 11) and pass them on to the central data processing device (3). Profiling machine according to one of claims 7 or 8,
characterized in that the central data processing device (3) is set up in such a way that it takes into account all position data of the adjustable roll-forming tools (8, 11) with the shape data obtained from the detector and / or from the measurement sensors about the actual shape of the workpiece (2) the default values for the target shape data of the workpiece (2). Profiling machine according to one of claims 1 to 9,
characterized in that the central data processing device (3) is set up in such a way that it also takes into account the theoretical default values for the position data calculated during the construction of the roll forming tools (8, 11). Profiling machine according to claims 9 and 10,
characterized in that the central data processing device (3) is set up in such a way that, during a testing phase of the profiling machine, it records the courses of all position data of the adjustable roll-forming tools (8, 11) that have changed based on the theoretical default values, with the courses of those of the detector and / or the shape data of the workpiece obtained from the measuring sensors, as well as a functional connection between the position data and the shape data via approximation methods and stored as a process behavior pattern. Profiling machine according to claim 11,
characterized in that the central data processing device (3) is provided with software tools which operate according to fuzzy logic principles or in the manner of neural networks. Profiling machine according to one of claims 11 or 12,
characterized in that the central data processing device (3) is set up in such a way that, in the event of deviations in the shape data of the workpiece from the preset values, it selects the most suitable process behavior pattern from a stored catalog of process behavior patterns and uses these to determine suggestions for correcting the position data. Profiling machine according to one of claims 1 to 13,
characterized in that further sensors for transmitting secondary parameters, such as in particular the feed rate and the temperature of the workpiece, the type and temperature of the lubricant used, the ambient temperature, the thickness and width of the workpiece, the straightness and waviness of the workpiece and its material properties the central data processing device (3) is present. Profiling machine according to one of claims 7 to 14,
characterized in that at further processing stations, such as in particular at additional side roller tables and straightening devices, there are further measurement sensors which are designed in such a way that they each forward the shape data of the workpiece to be profiled to the central data processing device (3).

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