Apparatus for and method of manufacturing roll-formed component

Patent metadata

Field	Value
Publication number	US-2021276063-A1
Application number	US-202117319573-A
Country	US
Kind code	A1
Filing date	May 13, 2021
Priority date	Dec 11, 2017
Publication date	Sep 9, 2021
Grant date	—

Abstract

To a fulcrum roll unit portion in a workpiece, a corresponding initial curvature radius is applied, and to a bending roll unit portion in a workpiece, a corresponding design curvature radius is applied. To an intermediate unit portion in a workpiece, an intermediate curvature radius set so as to continuously change from the initial curvature radius to the design curvature radius is applied. At least one of the fulcrum roll and the bending roll is moved on the basis of an integrated value obtained by integrating the amount of change in bending position in each of the intermediate unit portion and the bending roll unit portion.

First claim

What is claimed is:

1 . An apparatus configured to manufacture a roll-formed component with curvature changing along a longitudinal direction of the roll-formed component by applying roll bending to a workpiece including an elongated sheet or an elongated extrusion material along a longitudinal direction of the workpiece, the apparatus comprising:
a fulcrum roll that is positioned on an upstream side of a bending path and is configured to support the workpiece during bending, or to serve as a fulcrum of bending; a bending roll that is positioned on a downstream side of the bending path and is configured to apply bending to the workpiece; an actuator that is configured to move at least one of the fulcrum roll and the bending roll; and a controller, wherein under the following conditions:
a position allowing the fulcrum roll to be brought into contact with the workpiece is set as a fulcrum roll contact position;
a position allowing the bending roll to be brought into contact with the workpiece is set as a bending roll contact position;
the roll-formed component to be formed is composed of a plurality of unit intervals along the longitudinal direction, a portion corresponding to each of the unit intervals in the roll-formed component to be formed is set as an unit portion;
a value of a curvature radius to be applied to the workpiece at the fulcrum roll contact position is set as an initial curvature radius;
a value of a curvature radius allowed to remain in the workpiece when the workpiece is fed out from the bending roll contact position is set as a final curvature radius,
the unit portion positioned at the fulcrum roll contact position at a time when the workpiece is fed between the fulcrum roll and the bending roll is set as a fulcrum roll unit portion;
the unit portion positioned at the bending roll contact position is set as a bending roll unit portion; and
the unit portion positioned between the fulcrum roll unit portion and the bending roll unit portion is set as an intermediate unit portion,
the controller is configured to:
integrate an amount of change in a bending position in each of the intermediate unit portion and the bending roll unit portion based on the initial curvature radius and the final curvature radius at an arbitrary time point when the workpiece is fed between the fulcrum roll and the bending roll, and
cause the actuator to be driven to move at least one of the fulcrum roll or the bending roll based on the integrated amount of change.

2 . The apparatus according to claim 1 , wherein, when an intermediate curvature radius is set so as to continuously change a curvature of the intermediate unit portion from the initial curvature radius to the final curvature radius, the controller is configured to:
integrate the amount of change in bending position in each of the intermediate unit portion and the bending roll unit portion based on the intermediate curvature radius and the final curvature radius which are set at an arbitrary time point when the workpiece is fed between the fulcrum roll and the bending roll.

3 . The apparatus according to claim 1 , wherein the controller is configured to integrate the amount of change in the bending position under the following conditions:
a design value of a curvature radius of each unit portion of the roll-formed component to be formed is set as a design curvature radius, and the final curvature radius is set based on the design curvature radius.

4 . The apparatus according to claim 3 , further comprising a curvature radius database that is configured to store at least the design curvature radius and the initial curvature radius in all the unit portions of the roll-formed component to be formed, wherein the controller is configured to calculate the integrated amount of change with reference to the curvature radius database.

5 . An apparatus configured to manufacture a roll-formed component with curvature changing along a longitudinal direction of the roll-formed component by applying roll bending to a workpiece including an elongated sheet or an elongated extrusion material along a longitudinal direction of the workpiece, the apparatus comprising:
a fulcrum roll that is positioned on an upstream side in a bending path and is configured to support the workpiece during bending, or to serve as a fulcrum of bending; a bending roll that is positioned on a downstream side in the bending path and is configured to apply bending to the workpiece; an actuator that is configured to move at least one of the fulcrum roll and the bending roll; at least one of a curvature radius database or an NC program; and a controller, wherein under the following conditions:
a position allowing the fulcrum roll to be brought into contact with the workpiece is set as a fulcrum roll contact position;
a position allowing the bending roll to be brought into contact with the workpiece is set as a bending roll contact position;
the roll-formed component to be formed is composed of a plurality of unit intervals along the longitudinal direction, a portion corresponding to each of the unit intervals in the roll-formed component to be formed is set as a unit portion;
a value of a curvature radius applied to the workpiece at the fulcrum roll contact position is set as an initial curvature radius;
a value of a curvature radius allowed to remain in the workpiece when the workpiece is fed out from the bending roll contact position to achieve a design curvature radius in the roll-formed component is set as a final curvature radius,
the unit portion positioned at the fulcrum roll contact position at a time when the workpiece is fed between the fulcrum roll and the bending roll is set as a fulcrum roll unit portion;
the unit portion positioned at the bending roll contact position is set as a bending roll unit portion; and
the unit portion positioned between the fulcrum roll unit portion and the bending roll unit portion is set as an intermediate unit portion,
the curvature radius database is configured to store an integrated value of an amount of change in a bending position in each of the intermediate unit portion and the bending roll unit portion, the integrated value being calculated for each unit portion of the roll-formed component to be formed based on the initial curvature radius and the final curvature radius, the NC program is configured based on an integrated value of an amount of change in a bending position in each of the intermediate unit portion and the bending roll unit portion, the integrated value being calculated for each unit portion of the roll-formed component to be formed based on the initial curvature radius and the final curvature radius, and the controller is configured to cause the actuator to be driven to move at least one of the fulcrum roll and the bending roll with reference to at least one of the integrated value stored in the curvature radius database or the NC program.

6 . The apparatus according to claim 5 , wherein when an intermediate curvature radius for the intermediate unit portion is set so as to continuously change curvature of the intermediate unit portion from the initial curvature radius to the final curvature radius,
the curvature radius database is configured to store an integrated value of an amount of change in bending position in each of the intermediate unit portion and the bending roll unit portion, the integrated value being calculated for each unit portion of the roll-formed component to be formed based on the intermediate curvature radius and the final curvature radius, and the NC program is configured based on an integrated value of an amount of change in a bending position in each of the intermediate unit portion and the bending roll unit portion, the integrated value being cal

Assignees

• Kawasaki Heavy Ind Ltd

Inventors

• Okada Hideki
• Honda Yoichiro
• Kasumi Yasuhiro

Classifications

• B21D5/004 Primary

  with program control · CPC title

• B21D5/14

  by passing between rollers (B21D5/06 takes precedence) · CPC title

• B21D7/08

  by passing between rollers or through a curved die · CPC title

• B21D7/12

  with program control · CPC title

• B21D5/08 Primary

  making use of forming-rollers (B21D5/12 takes precedence) · CPC title