US20130305798A1 - Round bender - Google Patents
Round bender Download PDFInfo
- Publication number
- US20130305798A1 US20130305798A1 US13/476,349 US201213476349A US2013305798A1 US 20130305798 A1 US20130305798 A1 US 20130305798A1 US 201213476349 A US201213476349 A US 201213476349A US 2013305798 A1 US2013305798 A1 US 2013305798A1
- Authority
- US
- United States
- Prior art keywords
- bending roll
- bender
- pair
- frames
- rotational shaft
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D7/00—Bending rods, profiles, or tubes
- B21D7/08—Bending rods, profiles, or tubes by passing between rollers or through a curved die
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D5/00—Bending sheet metal along straight lines, e.g. to form simple curves
- B21D5/06—Bending sheet metal along straight lines, e.g. to form simple curves by drawing procedure making use of dies or forming-rollers, e.g. making profiles
- B21D5/08—Bending sheet metal along straight lines, e.g. to form simple curves by drawing procedure making use of dies or forming-rollers, e.g. making profiles making use of forming-rollers
- B21D5/086—Bending sheet metal along straight lines, e.g. to form simple curves by drawing procedure making use of dies or forming-rollers, e.g. making profiles making use of forming-rollers for obtaining closed hollow profiles
Definitions
- the present invention relates to a round bender. More particularly, the present invention relates to a round bender that bends an end portion of the shaped beam having a predetermined curvature to have another curvature different from the predetermined curvature.
- a product having a predetermined curvature such as a bumper beam for vehicles is manufactured by bending, after a straight shaped beam is formed by roll forming method, the straight shaped beam to have the predetermined curvature by means of a round bender.
- a coil is uncoiled and the uncoiled coil is bent to various shapes by passing a roll former unit.
- the roll former unit includes a plurality of roll formers that are sequentially disposed, and each roll former is provided with an upper forming roll and a lower forming roll.
- the roll forming method is used for manufacturing beams of linear type (particularly, a bumper beam for a vehicle) which is bent to the various shapes.
- FIG. 1 is a schematic diagram of a typical roll forming system and steps of a roll forming method.
- the typical roll forming system and method thereof includes an uncoiler 1 at a front portion of a process line, and the uncoiler 1 performs an uncoil step S 1 at which a coil 10 is uncoiled.
- a straightener 2 is provided at the rear of the uncoiler 1 in the process line and performs a straightening step S 2 at which the coil 10 uncoiled from the uncoiler 1 is straightened to a panel 20 of plate shape.
- a brake press 3 is disposed at the rear of the straightener 2 in the process line and performs a piercing step S 3 at which a plurality of holes for assembling is formed at the panel 20 supplied from the straightener 2 .
- a roll forming unit 4 including at least seven roll formers R 1 -R 7 is disposed at the rear of the brake press 3 in the process line.
- the roll forming unit 4 performs a roll forming step S 4 at which the panel 20 passing through the uncoiler 1 , the straightener 2 , and the brake press 3 is sequentially bent such that a shaped beam 30 is formed.
- a laser welding device 5 is disposed at the rear of the roll forming unit 4 in the process line and performs a welding step S 5 at which a laser beam outputting from a laser oscillator 5 a is irradiated to a welding portion of the shaped beam 30 .
- a round bender 6 is provided at the rear of the laser welding device 5 in the process line and performs a bending step S 6 .
- the shaped beam 30 passes through the round bender 6 such that the shaped beam 40 having the curvature is formed.
- a cutting press 7 for cutting the shaped beam 40 to have a dimension of product is provided at the rear of the round bender 6 in the process line, and performs a cutting step S 7 .
- FIG. 2 is a side view of a typical round bender.
- the round bender 6 includes five bending roll units.
- a first bending roll unit BR 1 includes upper and lower bending rolls and is disposed at a front portion on a bender frame 6 a in the process line.
- the first bending roll unit BR 1 guides the shaped beam 30 passing through the welding step S 5 .
- a second bending roll unit BR 2 includes upper and lower bending rolls and is disposed at the rear of the first bending roll unit BR 1 on the roll frame 6 a .
- the second bending roll unit BR 2 slidably supports the shaped beam 30 along the curvature direction.
- third, fourth, and fifth bending roll units BR 3 , BR 4 , and BR 5 are sequentially disposed at the rear of the second bending roll unit BR 2 on the roll frame 6 a along the curvature and respectively include upper and lower bending rolls.
- the shaped beam 30 passes through the third, fourth, and fifth bending roll units BR 3 , BR 4 , and BR 5 sequentially such that the shaped beam 40 having the curvature is formed.
- a bumper beam 50 for vehicles shown in FIG. 3 is manufactured by the roll forming system and the roll forming method.
- the bumper beams 50 are disposed at a front portion and a rear portion of the vehicle along a width direction of the vehicle, and are connected to a front side member (not shown) through a stay (not shown).
- a bumper beam 50 having multiple curvatures is used for classy design of the vehicle and preventing interference with other components of a bumper unit.
- curvature radii of both end portions is smaller than that of a middle portion.
- the bumper beam 50 includes a first curvature portion 51 having a first curvature radius that is the same as the predetermined curvature and a second curvature portion 52 disposed at both end portions of the first curvature portion 51 and having a second curvature radius different from the first curvature radius.
- an additional bending step should be performed by means of an additional bending unit so as to form the second curvature portions 52 at the both end portions of the bumper beam 50 shown in FIG. 3 .
- the present invention has been made in an effort to provide a round bender having advantages of manufacturing a shaped beam having a first curvature portion and a second curvature portion without mounting an additional bending unit by improving a conventional round bender.
- a round bender may include a plurality of bending roll units disposed along a process line between a pair of bender frames so as to bend a straight shaped beam to have a curvature.
- Each of the plurality of bending roll units may include upper and lower bending rolls rotating between the pair of bender frames and may be adapted to bend the shaped beam to have the curvature when the shaped beam passes between the upper and lower bending rolls.
- a lower bending roll of a rearmost bending roll unit disposed on a rearmost part of the process line may be configured to be rotatable with reference to an upper bending roll of the rearmost bending roll unit so as to change a curvature radius of some portion of the shaped beam.
- the round bender may further include a curvature changing means rotating the lower bending roll of the rearmost bending roll unit with reference to the upper bending roll of the rearmost bending roll unit, wherein the curvature changing means are disposed at the rearmost bending roll unit between the pair of bender frames such that a rotational shaft of the upper bending roll is rotatably supported at the pair of bender frames, and a rotational shaft of the lower bending roll is movably disposed in a penetration hole formed at the pair of bender frames.
- the curvature changing means may include: a cylinder disposed at a middle portion above the pair of bender frames, and hinged to the pair of bender frames through a hinge bracket; and a rotating fork having an upper end hinged to a rod of the cylinder, and connected to the rotational shafts of the upper and lower bending rolls of the rearmost bending roll unit at an outer of the pair of bender frames so as to rotate the rotational shaft of the lower bending roll in the penetration hole with respect to the rotational shaft of the upper bending roll according to operation of the cylinder.
- the rotating fork may include: a connecting bar disposed above the pair of bender frames and having a hinge end protruded from a middle portion of an upper surface of the connecting bar and hinged to the rod of the cylinder; and a pair of rotating bars disposed at the outer of the pair of bender frames corresponding to the rearmost bending roll unit, wherein an upper end of the rotating bar is connected to an end of the connecting bar, the rotational shaft of the upper bending roll is rotatably mounted at an upper portion of the rotating bar, and a slide hole is formed at a lower portion of the rotating bar such that the rotational shaft of the lower bending roll is rotatably mounted at a slider slidably mounted in the slide hole.
- the rotational shaft of the upper bending roll may be rotatably mounted at a sliding block slidably mounted in a slide recess formed at an upper portion of the bender frame.
- a round bender may bend a straight shaped beam to have a curvature.
- the round bender may include: a pair of bender frames mounted apart from each other on both sides of a base; a first bending roll unit including an upper bending roll and a lower bending roll, disposed at a front portion on a process line between the pair of bender frames, and guiding the shaped beam; a second bending roll unit including an upper bending roll and a lower bending roll, disposed at the rear of the first bending roll unit between the pair of bender frames, and slidably supporting the shaped beam along a curvature direction; third, fourth, and fifth bending roll units respectively including an upper bending roll and a lower bending roll, sequentially disposed at the rear of the second bending roll unit between the pair of bender frames along the curvature, and forming the shaped beam to have a predetermined curvature when the shaped beam passes therethrough; and a curvature changing means disposed between the bender frame and the fifth bending roll unit and rotating the lower bending roll of the fifth bending roll unit with reference to the upper
- the curvature changing means may be mounted at the fifth bending roll unit between the pair of bender frames such that a rotational shaft of the upper bending roll is rotatably supported at the pair of bender frames, and a rotational shaft of the lower bending roll is movably disposed in a penetration hole formed at the pair of bender frames.
- the curvature changing means may include: a cylinder disposed at a middle portion above the pair of bender frames, and hinged to the pair of bender frames through a hinge bracket; and a rotating fork having an upper end hinged to a rod of the cylinder, and connected to the rotational shafts of the upper and lower bending rolls of the fifth bending roll unit at an outer of the pair of bender frames so as to rotate the rotational shaft of the lower bending roll in the penetration hole with respect to the rotational shaft of the upper bending roll according to operation of the cylinder.
- the rotating fork may include: a connecting bar disposed above the pair of bender frames and having a hinge end protruded from a middle portion of an upper surface of the connecting bar and hinged to the rod of the cylinder; and a pair of rotating bars disposed at the outer of the pair of bender frames corresponding to the fifth bending roll unit, wherein an upper end of the rotating bar is connected to an end of the connecting bar, the rotational shaft of the upper bending roll is rotatably mounted at an upper portion of the rotating bar, and a slide hole is formed at a lower portion of the rotating bar such that the rotational shaft of the lower bending roll is rotatably mounted at a slider slidably mounted in the slide hole.
- the rotational shaft of the upper bending roll of the fifth bending roll unit may be rotatably mounted at a sliding block slidably mounted in a slide recess formed at an upper portion of the bender frame.
- a round bender may include at least three bending roll units disposed along a process line between a pair of bender frames so as to bend a straight shaped beam and including upper and lower bending rolls.
- a lower bending roll of a rearmost bending roll unit on a process line may be configured to be rotatable with reference to an upper bending roll of the rearmost bending roll unit so as to change a curvature radius of some portion of the shaped beam.
- the round bender may further include a curvature changing means rotating the lower bending roll of the rearmost bending roll unit with reference to the upper bending roll of the rearmost bending roll unit, wherein the curvature changing means are disposed at the rearmost bending roll unit between the pair of bender frames such that a rotational shaft of the upper bending roll is rotatably supported at the pair of bender frames, and a rotational shaft of the lower bending roll is movably disposed in a penetration hole formed at the pair of bender frames.
- the curvature changing means may include: a cylinder disposed at a middle portion above the pair of bender frames, and hinged to the pair of bender frames through a hinge bracket; and a rotating fork having an upper end hinged to a rod of the cylinder, and connected to the rotational shafts of the upper and lower bending rolls of the rearmost bending roll unit at an outer of the pair of bender frames so as to rotate the rotational shaft of the lower bending roll in the penetration hole with respect to the rotational shaft of the upper bending roll according to operation of the cylinder.
- the rotating fork may include: a connecting bar disposed above the pair of bender frames and having a hinge end protruded from a middle portion of an upper surface of the connecting bar and hinged to the rod of the cylinder; and a pair of rotating bars disposed at the outer of the pair of bender frames corresponding to the rearmost bending roll unit, wherein an upper end of the rotating bar is connected to an end of the connecting bar, the rotational shaft of the upper bending roll is rotatably mounted at an upper portion of the rotating bar, and a slide hole is formed at a lower portion of the rotating bar such that the rotational shaft of the lower bending roll is rotatably mounted at a slider slidably mounted in the slide hole.
- the rotational shaft of the upper bending roll may be rotatably mounted at a sliding block slidably mounted in a slide recess formed at an upper portion of the bender frame.
- the round bender may further include power delivery means mounted at the lower bending rolls of the bending roll units and delivering power therebetween.
- position detecting means for detecting a position of a slider block is disposed between the sliding block used at the fifth bending roll unit or the rearmost bending roll unit and the bender frame guiding the sliding block.
- the position detecting means may include: a marking needle mounted at the sliding block; and a graduated ruler attached to the bender frame corresponding to the marking needle.
- FIG. 1 is a schematic diagram of a typical roll forming system and steps of a roll forming method.
- FIG. 2 is a side view of a typical round bender.
- FIG. 3 is a perspective view of a typical bumper beam.
- FIG. 4 is a perspective view of a round bender according to an exemplary embodiment of the present invention.
- FIG. 5 is another perspective view of a round bender according to an exemplary embodiment of the present invention.
- FIG. 6 is a partially projected perspective view of a round bender according to an exemplary embodiment of the present invention.
- FIG. 7 is a partial cross-sectional view of a round bender according to an exemplary embodiment of the present invention.
- FIG. 8 to FIG. 10 are schematic diagrams for showing operation of curvature changing means applied to a round bender according to an exemplary embodiment of the present invention.
- a round bender 6 according to an exemplary embodiment of the present invention is used in a roll forming system shown in FIG. 1 and bends a straight shaped beam 30 formed by roll forming to have a curvature.
- a roll forming system and method thereof to which the round bender 6 according to an exemplary embodiment of the present invention is applied includes an uncoiler 1 at a front portion of a process line, and the uncoiler 1 performs an uncoil step S 1 at which a coil 10 is uncoiled.
- a straightener 2 is provided at the rear of the uncoiler 1 in the process line and performs a straightening step S 2 at which the coil 10 uncoiled from the uncoiler 1 is straightened to a panel 20 of plate shape.
- a brake press 3 is disposed at the rear of the straightener 2 in the process line and performs a piercing step S 3 at which a plurality of holes for assembling is formed at the panel 20 supplied from the straightener 2 .
- a roll forming unit 4 including at least seven roll formers R 1 -R 7 is disposed at the rear of the brake press 3 in the process line.
- the roll forming unit 4 performs a roll forming step S 4 at which the panel 20 passing through the uncoiler 1 , the straightener 2 , and the brake press 3 is sequentially bent such that a shaped beam 30 is formed.
- a laser welding device 5 is disposed at the rear of the roll forming unit 4 in the process line and performs a welding step S 5 at which a laser beam outputting from a laser oscillator 5 a is irradiated to a welding portion of the shaped beam 30 .
- the round bender 6 is disposed at the rear of the laser welding device 5 in the process line and performs a bending step S 6 .
- the shaped beam 40 having different curvatures at a middle portion and both end portions thereof is formed while the shaped beam 30 passes through the round bender 6 .
- a cutting press 7 for cutting the shaped beam 40 to have a dimension of product is provided at the rear of the round bender 6 in the process line, and performs a cutting step S 7 .
- a bumper beam 50 shown in FIG. 3 including a first curvature portion 51 having a first curvature radius at the middle portion thereof and a second curvature portion 52 having a second curvature radius smaller than the first curvature radius at both end portions thereof is manufactured by the roll forming system and method thereof to which the round bender 6 according to an exemplary embodiment of the present invention is applied.
- FIG. 4 and FIG. 5 are perspective views of a round bender according to an exemplary embodiment of the present invention
- FIG. 6 is a partially projected perspective view of a round bender according to an exemplary embodiment of the present invention
- FIG. 7 is a partial cross-sectional view of a round bender according to an exemplary embodiment of the present invention.
- the round bender 6 includes five bending roll units BR 1 -BR 5 , and bends the straight shaped beam 30 formed by roll forming to have the curvature.
- the round bender 6 according to an exemplary embodiment of the present invention includes five bending roll units BR 1 -BR 5 , but is not limited thereto.
- the round bender 6 includes a base 61 , a pair of bender frames 63 , the first to the fifth bending roll units BR 1 -BR 5 disposed along the process line and curvature changing means 65 .
- the base 61 is mounted on a mounting table of the roll forming system along the process line, and the pair of bender frames 63 is mounted on both sides of the base 61 along the process line and is disposed apart from each other.
- the pair of bender frames 63 are connected so as to maintain a distance therebetween through a plurality of connecting pipes 67 .
- slide recesses SG are formed at a pair of bender frame 63 , and sliders SR is slidably mounted in the slide recesses SG.
- the first bending roll unit BR 1 includes a first upper bending roll UR 1 and a first lower bending roll LR 1 , and is disposed at a front portion of the process line between the pair of bender frames 63 .
- the first bending roll unit BR 1 guides the shaped beam 30 .
- Each of the first upper bending roll UR 1 and the first lower bending roll LR 1 includes a rotational shaft S, and both ends of the rotational shaft S is rotatably mounted at the sliders SR mounted in the slide recesses SG.
- the second bending roll unit BR 2 includes a second upper bending roll UR 2 and a second lower bending roll LR 2 , and is disposed at the rear of the first bending roll unit BR 1 between the pair of bender frames 63 .
- the second bending roll unit BR 2 slidably supports the shaped beam 30 along a curvature direction.
- Each of the second upper bending roll UR 2 and the second lower bending roll LR 2 includes a rotational shaft S, and both ends of the rotational shaft S is roatatbly mounted at the sliders SR mounted in the slide recesses SG.
- the sliders SR used at the first bending roll unit BR 1 and the second bending roll unit BR 2 is divided into an upper slider and a lower slider, and each of the sliders SR is fixed to the slide recess SG of the bender frame 63 through an adjusting bolt AB.
- a position of the slider SR can be adjusted by means of the adjusting bolt AB.
- the third, fourth, and fifth bending roll units BR 3 , BR 4 , and BR 5 respectively include a third upper bending roll UR 3 and a third lower bending roll LR 3 , a fourth upper bending roll UR 4 and a fourth lower bending roll LR 4 , and a fifth upper bending roll UR 5 and a fifth lower bending roll LR 5 , and are sequentially disposed at the rear of the second bending roll unit BR 2 between the pair of bender frames 63 along the curvature.
- the shaped beam 30 is formed to have a predetermined curvature while passing through the third, fourth, and fifth bending roll units BR 3 , BR 4 , and BR 5 .
- each of the third and fourth lower bending rolls LR 3 and LR 4 include a rotational shaft S, and both ends of the rotational shaft S are rotatably mounted at lower portions of movable blocks MB slidably mounted in the slide recesses SG.
- each of the third and fourth upper bending rolls UR 3 and UR 4 includes a rotational shaft S, and both ends of the rotational shaft S are rotatably mounted at the sliders SR slidably mounted in slide holes SH formed at upper portions of the movable blocks MB.
- the fifth upper bending roll UR 5 includes a rotational shaft S, and both end portions of the rotational shaft S is rotatably mounted through bearing units BU at sliding blocks SB slidably mounted in the slide recesses SG formed at upper portions of the bender frames 63 .
- the fifth lower bending roll LR 5 includes a rotational shaft S, and the rotational shaft S is movably disposed in a process line direction through penetration holes H formed at lower portions of the bender frames 63 .
- both ends of the rotational shaft S of the fifth lower bending roll LR 5 are rotatably supported by the curvature changing means 65 .
- the curvature changing means 65 are disposed between the bender frames 63 and the fifth bending roll unit BR 5 so as to rotate the fifth lower bending roll LR 5 in the penetration hole H with reference to the fifth upper bending roll UR 5 by a predetermined angle. Therefore, the curvature changing means 65 moves to the fifth lower bending roll LR 5 such that curvature radius of both end portions of the shaped beam 30 formed to have the curvature becomes smaller.
- the curvature changing means 65 include a cylinder 71 and a rotating fork 73 .
- the cylinder 71 is disposed at a middle portion above the pair of bender frames 63 .
- the cylinder 71 is hinged to the pair of bender frames 63 through a hinge bracket 75 .
- the cylinder 71 may be a hydraulic pressure cylinder, but is not limited thereto. Operating pressure of the hydraulic pressure cylinder is hydraulic pressure.
- An upper end of the rotating fork 73 is hinged to a rod 81 of the cylinder 71 .
- the rotating fork 73 is connected to the rotational shafts S of the fifth upper bending roll UR 5 and the fifth lower bending roll LR 5 at an outer of the pair of bender frames 63 so as to rotate the rotational shaft S of the fifth lower bending roll LR 5 in the penetration hole H with reference to the rotational shaft S of the fifth upper bending roll UR 5 according to operation of the cylinder 71 .
- the rotating fork 73 includes a connecting bar 77 and two rotating bars 79 .
- the connecting bar 77 is disposed above the pair of bender frames 63 along a width direction.
- a hinge end 83 is protruded from a middle portion of an upper surface of the connecting bar 77 , and the hinge end 83 is hinged to the rod 81 of the cylinder 71 through a hinge fork 85 .
- the two rotating bars 79 are disposed at an outer of the pair of bender frames 63 corresponding to the fifth bending roll unit BR 5 , and an upper end of each of the rotating bars 79 is connected to each of both ends of the connecting bar 77 .
- Both ends of the rotational shaft S of the fifth upper bending roll UR 5 are mounted at upper portions of the rotating bars 79 through bearing units BU, and a slide hole SH is formed at a lower portion of each of the rotating bars 79 .
- a slider SR is slidably mounted in the slide hole SH, and both ends of the rotational shaft S of the fifth lower bending roll LR 5 are rotatably mounted at the sliders SR.
- the rotating fork 73 rotates the rotational shaft S of the fifth lower bending roll LR 5 with reference to the rotational shaft S of the fifth upper bending roll UR 5 according to forward/rearward operation of the cylinder 71 so as to change a position of the fifth lower bending roll LR 5 to the fifth upper bending roll UR 5 . Therefore, the shaped beam is bent to have multiple curvatures such that curvature radius of some portion of the shaped beam 30 is different from that of other portion of the shaped beam 30 .
- position detecting means 80 for detecting positions of the sliders SR or the sliding blocks are disposed between the sliders SR or the sliding blocks SB used at the first to the fifth bending roll units BR 1 -BR 5 and the pair of bender frames 63 , the movable blocks MB or the rotating fork 73 guiding the sliders SR or the sliding blocks SB.
- the position detecting means 80 includes a marking needle 87 and a graduated ruler 89 .
- the marking needle 87 is mounted at a side of the slider SR or the sliding block SB, and the graduated ruler 89 is attached to the pair of bender frames 63 , the movable blocks MB or the rotating fork 73 corresponding to the marking needle 87 .
- a stopper 90 for restricting rotating angle of the rotating fork 73 is mounted at an upper portion of the rearmost bender frame 63 .
- the stopper 90 includes a stopper ring 91 and a stopper rod 93 .
- An end portion of the stopper rod 93 is mounted at the bender frame 63 and the stopper ring 91 is mounted at the other end portion of the stopper rod 93 .
- the stopper ring 91 is positioned at the rear of the rotating bar 79 of the rotating fork 73 and is adapted to support a rear surface of the rotating bar 79 .
- power delivery means are mounted at the lower bending rolls LR 1 -LR 5 of the first to the fifth bending roll units BR 1 -BR 5 and deliver the power therebetween.
- the power delivery means includes sprocket SP and chains C.
- the sprockets SP are mounted at end portions of the rotational shafts S of the first to the fifth lower bending rolls LR 1 -LR 5 at an outer of one bender frame 63 , and the chains C connect the sprockets SP.
- the power delivery means include the chains and the sprockets, but are not limited thereto. Pulleys and belts instead of the sprockets SP and the chains C may be used as the power delivery means.
- the fifth bending roll unit BR 5 is not connected to the fourth bending roll unit BR 4 through the chain C and is operated by movement of the shaped beam 30 in a normal condition. In a case that supply of the shaped beam 30 is finished, however, the fifth bending roll unit BR 5 is temporarily connected to the fourth bending roll unit BR 4 through the chain C and receive power from the fourth bending roll unit BR 4 so as to push the end portion of the shaped beam 30 .
- the round bender 6 is disposed at the rear of the laser welding device 5 of the roll forming system in the process line, and is adapted to bent the shaped beam 40 to have different curvatures at the middle portion and both end portions thereof when the shaped beam 30 supplied from the laser welding device 5 passes through the first to the fifth bending roll units BR 1 -BR 5 .
- the shaped beam 30 is guided by the first upper bending roll UR 1 and the first lower bending roll LR 1 of the first bending roll unit BR 1 and is slidably supported by the second upper bending roll UR 2 and the second lower bending roll LR 2 of the second bending roll unit BR 2 along the curvature direction.
- the shaped beam 30 is formed to have the predetermined curvature when passing through the third, fourth, and fifth bending roll units BR 3 , BR 4 , and BR 5 .
- the cylinder 71 moves to the rearward as shown in FIG. 9 .
- the rotating fork 73 is rotated about the rotational shaft S of the fifth upper bending roll UR 5 by a predetermined angle ⁇ , and thus the fifth lower bending roll LR 5 is rotated with reference to the fifth upper bending roll UR 5 to the rearward in the process line.
- the some portion of the shaped beam 30 passes between the fifth upper bending roll UR 5 and the fifth lower bending roll LR 5 of the fifth bending roll unit BR 5 .
- the some portion of the shaped beam 30 has a smaller curvature radius than that of other portion of the shaped beam 30 .
- a bumper beam 50 shown in FIG. 3 , including a first curvature portion 51 having a first curvature radius at a middle portion thereof and a second curvature portion 52 having a second curvature radius that is smaller than the first curvature radius at both end portions thereof can be manufactured in one process.
- a position of the fifth bending roll unit BR 5 is changed. So as to change the position of the fifth bending roll unit BR 5 , as shown in FIG. 10 , the adjusting bolt AB of the slider SR where the rotational shaft S of the fifth upper bending roll UR 5 is mounted is controlled so as to control a position of the slider SR.
- the fifth upper bending roll UR 5 is moved with the slider SR, and the fifth lower bending roll LR 5 together with the rotating fork 73 is moved with a distance to the fifth upper bending roll UR 5 being maintained.
- a round bender can manufacture a shaped beam having a first curvature portion and a second curvature portion without mounting an additional bending unit.
Abstract
A round bender is disclosed. The round bender may include a plurality of bending roll units disposed along a process line between a pair of bender frames so as to bend a straight shaped beam to have a curvature. Each of the plurality of bending roll units may include upper and lower bending rolls rotating between the pair of bender frames and may be adapted to bend the shaped beam to have the curvature when the shaped beam passes between the upper and lower bending rolls. A lower bending roll of a rearmost bending roll unit disposed on a rearmost part of the process line may be configured to be rotatable with reference to an upper bending roll of the rearmost bending roll unit so as to change a curvature radius of some portion of the shaped beam.
Description
- This application claims priority to and the benefit of Korean Patent Application Nos. 10-2012-0052036 and 10-2012-0052037 filed in the Korean Intellectual Property Office on May 16, 2012, the entire contents of which are incorporated herein by reference.
- (a) Field of the Invention
- The present invention relates to a round bender. More particularly, the present invention relates to a round bender that bends an end portion of the shaped beam having a predetermined curvature to have another curvature different from the predetermined curvature.
- (b) Description of the Related Art
- Generally, a product having a predetermined curvature such as a bumper beam for vehicles is manufactured by bending, after a straight shaped beam is formed by roll forming method, the straight shaped beam to have the predetermined curvature by means of a round bender.
- According to roll forming method, a coil is uncoiled and the uncoiled coil is bent to various shapes by passing a roll former unit. The roll former unit includes a plurality of roll formers that are sequentially disposed, and each roll former is provided with an upper forming roll and a lower forming roll. The roll forming method is used for manufacturing beams of linear type (particularly, a bumper beam for a vehicle) which is bent to the various shapes.
-
FIG. 1 is a schematic diagram of a typical roll forming system and steps of a roll forming method. - Referring to
FIG. 1 , the typical roll forming system and method thereof includes an uncoiler 1 at a front portion of a process line, and the uncoiler 1 performs an uncoil step S1 at which acoil 10 is uncoiled. - A straightener 2 is provided at the rear of the uncoiler 1 in the process line and performs a straightening step S2 at which the
coil 10 uncoiled from the uncoiler 1 is straightened to apanel 20 of plate shape. - A
brake press 3 is disposed at the rear of the straightener 2 in the process line and performs a piercing step S3 at which a plurality of holes for assembling is formed at thepanel 20 supplied from the straightener 2. - A roll forming unit 4 including at least seven roll formers R1-R7 is disposed at the rear of the
brake press 3 in the process line. The roll forming unit 4 performs a roll forming step S4 at which thepanel 20 passing through the uncoiler 1, the straightener 2, and thebrake press 3 is sequentially bent such that ashaped beam 30 is formed. - A
laser welding device 5 is disposed at the rear of the roll forming unit 4 in the process line and performs a welding step S5 at which a laser beam outputting from alaser oscillator 5 a is irradiated to a welding portion of theshaped beam 30. - In addition, a
round bender 6 is provided at the rear of thelaser welding device 5 in the process line and performs a bending step S6. At the bending step S6, theshaped beam 30 passes through theround bender 6 such that theshaped beam 40 having the curvature is formed. - A cutting press 7 for cutting the
shaped beam 40 to have a dimension of product is provided at the rear of theround bender 6 in the process line, and performs a cutting step S7. -
FIG. 2 is a side view of a typical round bender. - Referring to
FIG. 2 , theround bender 6 includes five bending roll units. - A first bending roll unit BR1 includes upper and lower bending rolls and is disposed at a front portion on a
bender frame 6 a in the process line. The first bending roll unit BR1 guides theshaped beam 30 passing through the welding step S5. - A second bending roll unit BR2 includes upper and lower bending rolls and is disposed at the rear of the first bending roll unit BR1 on the
roll frame 6 a. The second bending roll unit BR2 slidably supports theshaped beam 30 along the curvature direction. - In addition, third, fourth, and fifth bending roll units BR3, BR4, and BR5 are sequentially disposed at the rear of the second bending roll unit BR2 on the
roll frame 6 a along the curvature and respectively include upper and lower bending rolls. - The
shaped beam 30 passes through the third, fourth, and fifth bending roll units BR3, BR4, and BR5 sequentially such that theshaped beam 40 having the curvature is formed. - A
bumper beam 50 for vehicles shown inFIG. 3 is manufactured by the roll forming system and the roll forming method. - The
bumper beams 50 are disposed at a front portion and a rear portion of the vehicle along a width direction of the vehicle, and are connected to a front side member (not shown) through a stay (not shown). - A
bumper beam 50 having multiple curvatures is used for classy design of the vehicle and preventing interference with other components of a bumper unit. - In the
bumper beam 50 having the multiple curvatures, as shown inFIG. 3 , curvature radii of both end portions is smaller than that of a middle portion. - That is, the
bumper beam 50 includes afirst curvature portion 51 having a first curvature radius that is the same as the predetermined curvature and asecond curvature portion 52 disposed at both end portions of thefirst curvature portion 51 and having a second curvature radius different from the first curvature radius. - Since the
conventional round bender 6 shown inFIG. 2 , however, can form theshaped beam 40 having one curvature, an additional bending step should be performed by means of an additional bending unit so as to form thesecond curvature portions 52 at the both end portions of thebumper beam 50 shown inFIG. 3 . - Therefore, manufacturing processes for the bumper beam, manufacturing cost, and installation cost for installing the additional bending unit may increase.
- The above information disclosed in this Background section is only for enhancement of understanding of the background of the invention and therefore it may contain information that does not form the prior art that is already known in this country to a person of ordinary skill in the art.
- The present invention has been made in an effort to provide a round bender having advantages of manufacturing a shaped beam having a first curvature portion and a second curvature portion without mounting an additional bending unit by improving a conventional round bender.
- A round bender according to an exemplary embodiment of the present invention may include a plurality of bending roll units disposed along a process line between a pair of bender frames so as to bend a straight shaped beam to have a curvature.
- Each of the plurality of bending roll units may include upper and lower bending rolls rotating between the pair of bender frames and may be adapted to bend the shaped beam to have the curvature when the shaped beam passes between the upper and lower bending rolls.
- A lower bending roll of a rearmost bending roll unit disposed on a rearmost part of the process line may be configured to be rotatable with reference to an upper bending roll of the rearmost bending roll unit so as to change a curvature radius of some portion of the shaped beam.
- The round bender may further include a curvature changing means rotating the lower bending roll of the rearmost bending roll unit with reference to the upper bending roll of the rearmost bending roll unit, wherein the curvature changing means are disposed at the rearmost bending roll unit between the pair of bender frames such that a rotational shaft of the upper bending roll is rotatably supported at the pair of bender frames, and a rotational shaft of the lower bending roll is movably disposed in a penetration hole formed at the pair of bender frames.
- The curvature changing means may include: a cylinder disposed at a middle portion above the pair of bender frames, and hinged to the pair of bender frames through a hinge bracket; and a rotating fork having an upper end hinged to a rod of the cylinder, and connected to the rotational shafts of the upper and lower bending rolls of the rearmost bending roll unit at an outer of the pair of bender frames so as to rotate the rotational shaft of the lower bending roll in the penetration hole with respect to the rotational shaft of the upper bending roll according to operation of the cylinder.
- The rotating fork may include: a connecting bar disposed above the pair of bender frames and having a hinge end protruded from a middle portion of an upper surface of the connecting bar and hinged to the rod of the cylinder; and a pair of rotating bars disposed at the outer of the pair of bender frames corresponding to the rearmost bending roll unit, wherein an upper end of the rotating bar is connected to an end of the connecting bar, the rotational shaft of the upper bending roll is rotatably mounted at an upper portion of the rotating bar, and a slide hole is formed at a lower portion of the rotating bar such that the rotational shaft of the lower bending roll is rotatably mounted at a slider slidably mounted in the slide hole.
- The rotational shaft of the upper bending roll may be rotatably mounted at a sliding block slidably mounted in a slide recess formed at an upper portion of the bender frame.
- A round bender according to another exemplary embodiment of the present invention may bend a straight shaped beam to have a curvature.
- The round bender may include: a pair of bender frames mounted apart from each other on both sides of a base; a first bending roll unit including an upper bending roll and a lower bending roll, disposed at a front portion on a process line between the pair of bender frames, and guiding the shaped beam; a second bending roll unit including an upper bending roll and a lower bending roll, disposed at the rear of the first bending roll unit between the pair of bender frames, and slidably supporting the shaped beam along a curvature direction; third, fourth, and fifth bending roll units respectively including an upper bending roll and a lower bending roll, sequentially disposed at the rear of the second bending roll unit between the pair of bender frames along the curvature, and forming the shaped beam to have a predetermined curvature when the shaped beam passes therethrough; and a curvature changing means disposed between the bender frame and the fifth bending roll unit and rotating the lower bending roll of the fifth bending roll unit with reference to the upper bending roll of the fifth bending roll unit so as to change a curvature radius of some portion of the shaped beam.
- The curvature changing means may be mounted at the fifth bending roll unit between the pair of bender frames such that a rotational shaft of the upper bending roll is rotatably supported at the pair of bender frames, and a rotational shaft of the lower bending roll is movably disposed in a penetration hole formed at the pair of bender frames.
- The curvature changing means may include: a cylinder disposed at a middle portion above the pair of bender frames, and hinged to the pair of bender frames through a hinge bracket; and a rotating fork having an upper end hinged to a rod of the cylinder, and connected to the rotational shafts of the upper and lower bending rolls of the fifth bending roll unit at an outer of the pair of bender frames so as to rotate the rotational shaft of the lower bending roll in the penetration hole with respect to the rotational shaft of the upper bending roll according to operation of the cylinder.
- The rotating fork may include: a connecting bar disposed above the pair of bender frames and having a hinge end protruded from a middle portion of an upper surface of the connecting bar and hinged to the rod of the cylinder; and a pair of rotating bars disposed at the outer of the pair of bender frames corresponding to the fifth bending roll unit, wherein an upper end of the rotating bar is connected to an end of the connecting bar, the rotational shaft of the upper bending roll is rotatably mounted at an upper portion of the rotating bar, and a slide hole is formed at a lower portion of the rotating bar such that the rotational shaft of the lower bending roll is rotatably mounted at a slider slidably mounted in the slide hole.
- The rotational shaft of the upper bending roll of the fifth bending roll unit may be rotatably mounted at a sliding block slidably mounted in a slide recess formed at an upper portion of the bender frame.
- A round bender according to other exemplary embodiment of the present invention may include at least three bending roll units disposed along a process line between a pair of bender frames so as to bend a straight shaped beam and including upper and lower bending rolls.
- A lower bending roll of a rearmost bending roll unit on a process line may be configured to be rotatable with reference to an upper bending roll of the rearmost bending roll unit so as to change a curvature radius of some portion of the shaped beam.
- The round bender may further include a curvature changing means rotating the lower bending roll of the rearmost bending roll unit with reference to the upper bending roll of the rearmost bending roll unit, wherein the curvature changing means are disposed at the rearmost bending roll unit between the pair of bender frames such that a rotational shaft of the upper bending roll is rotatably supported at the pair of bender frames, and a rotational shaft of the lower bending roll is movably disposed in a penetration hole formed at the pair of bender frames.
- The curvature changing means may include: a cylinder disposed at a middle portion above the pair of bender frames, and hinged to the pair of bender frames through a hinge bracket; and a rotating fork having an upper end hinged to a rod of the cylinder, and connected to the rotational shafts of the upper and lower bending rolls of the rearmost bending roll unit at an outer of the pair of bender frames so as to rotate the rotational shaft of the lower bending roll in the penetration hole with respect to the rotational shaft of the upper bending roll according to operation of the cylinder.
- The rotating fork may include: a connecting bar disposed above the pair of bender frames and having a hinge end protruded from a middle portion of an upper surface of the connecting bar and hinged to the rod of the cylinder; and a pair of rotating bars disposed at the outer of the pair of bender frames corresponding to the rearmost bending roll unit, wherein an upper end of the rotating bar is connected to an end of the connecting bar, the rotational shaft of the upper bending roll is rotatably mounted at an upper portion of the rotating bar, and a slide hole is formed at a lower portion of the rotating bar such that the rotational shaft of the lower bending roll is rotatably mounted at a slider slidably mounted in the slide hole.
- The rotational shaft of the upper bending roll may be rotatably mounted at a sliding block slidably mounted in a slide recess formed at an upper portion of the bender frame.
- In one or more exemplary embodiments of the present invention, the round bender may further include power delivery means mounted at the lower bending rolls of the bending roll units and delivering power therebetween.
- In one or more exemplary embodiments of the present invention, position detecting means for detecting a position of a slider block is disposed between the sliding block used at the fifth bending roll unit or the rearmost bending roll unit and the bender frame guiding the sliding block.
- The position detecting means may include: a marking needle mounted at the sliding block; and a graduated ruler attached to the bender frame corresponding to the marking needle.
-
FIG. 1 is a schematic diagram of a typical roll forming system and steps of a roll forming method. -
FIG. 2 is a side view of a typical round bender. -
FIG. 3 is a perspective view of a typical bumper beam. -
FIG. 4 is a perspective view of a round bender according to an exemplary embodiment of the present invention. -
FIG. 5 is another perspective view of a round bender according to an exemplary embodiment of the present invention. -
FIG. 6 is a partially projected perspective view of a round bender according to an exemplary embodiment of the present invention. -
FIG. 7 is a partial cross-sectional view of a round bender according to an exemplary embodiment of the present invention. -
FIG. 8 toFIG. 10 are schematic diagrams for showing operation of curvature changing means applied to a round bender according to an exemplary embodiment of the present invention. -
-
<Description of symbols> 1: uncoiler 2: straightener 3: brake press 4: roll forming unit 5: laser welding device 6: round bender 7: cutting press 10: coil 20: panel 30, 40: shaped beam 50: bumper beam 51: first curvature portion 52: second curvature portion 61: base 63: bender frame 65: curvature changing means 67: connecting pipe 71: cylinder 73: rotating fork 75: hinge bracket 77: connecting bar 79: rotating bar 80: position detecting means 81: rod 83: hinge end 85: hinge fork 87: marking needle 89: graduated ruler 90: stopper 91: stopper ring 93: stopper rod BR1-BR5: first to the fifth bending roll units UR1-UR5: first to the fifth upper bending rolls LR1-LR5: first to the fifth lower bending rolls S: rotational shaft SG: slide recess SR: slider AB: adjusting bolt MB: movable block SH: slide hole BU: bearing unit H: penetration hole SP: sprocket C: chain - Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings.
- For clarifying description of an exemplary embodiment of the present invention, descriptions not related to the exemplary embodiment of the present invention will be omitted.
- In the detailed description, ordinal numbers are used for distinguishing constituent elements having the same terms, and have no specific meanings.
- A
round bender 6 according to an exemplary embodiment of the present invention is used in a roll forming system shown inFIG. 1 and bends a straight shapedbeam 30 formed by roll forming to have a curvature. - That is, referring to
FIG. 1 , a roll forming system and method thereof to which theround bender 6 according to an exemplary embodiment of the present invention is applied includes an uncoiler 1 at a front portion of a process line, and the uncoiler 1 performs an uncoil step S1 at which acoil 10 is uncoiled. - A straightener 2 is provided at the rear of the uncoiler 1 in the process line and performs a straightening step S2 at which the
coil 10 uncoiled from the uncoiler 1 is straightened to apanel 20 of plate shape. - A
brake press 3 is disposed at the rear of the straightener 2 in the process line and performs a piercing step S3 at which a plurality of holes for assembling is formed at thepanel 20 supplied from the straightener 2. - A roll forming unit 4 including at least seven roll formers R1-R7 is disposed at the rear of the
brake press 3 in the process line. The roll forming unit 4 performs a roll forming step S4 at which thepanel 20 passing through the uncoiler 1, the straightener 2, and thebrake press 3 is sequentially bent such that a shapedbeam 30 is formed. - A
laser welding device 5 is disposed at the rear of the roll forming unit 4 in the process line and performs a welding step S5 at which a laser beam outputting from alaser oscillator 5 a is irradiated to a welding portion of the shapedbeam 30. - The
round bender 6 according to an exemplary embodiment of the present invention is disposed at the rear of thelaser welding device 5 in the process line and performs a bending step S6. At the bending step S6, the shapedbeam 40 having different curvatures at a middle portion and both end portions thereof is formed while the shapedbeam 30 passes through theround bender 6. - A cutting press 7 for cutting the shaped
beam 40 to have a dimension of product is provided at the rear of theround bender 6 in the process line, and performs a cutting step S7. - Therefore, a
bumper beam 50 shown inFIG. 3 including afirst curvature portion 51 having a first curvature radius at the middle portion thereof and asecond curvature portion 52 having a second curvature radius smaller than the first curvature radius at both end portions thereof is manufactured by the roll forming system and method thereof to which theround bender 6 according to an exemplary embodiment of the present invention is applied. -
FIG. 4 andFIG. 5 are perspective views of a round bender according to an exemplary embodiment of the present invention;FIG. 6 is a partially projected perspective view of a round bender according to an exemplary embodiment of the present invention; andFIG. 7 is a partial cross-sectional view of a round bender according to an exemplary embodiment of the present invention. - Referring to
FIG. 4 toFIG. 6 , theround bender 6 according to an exemplary embodiment of the present invention includes five bending roll units BR1-BR5, and bends the straight shapedbeam 30 formed by roll forming to have the curvature. Theround bender 6 according to an exemplary embodiment of the present invention includes five bending roll units BR1-BR5, but is not limited thereto. - The
round bender 6 according to an exemplary embodiment of the present invention includes abase 61, a pair of bender frames 63, the first to the fifth bending roll units BR1-BR5 disposed along the process line andcurvature changing means 65. - The
base 61 is mounted on a mounting table of the roll forming system along the process line, and the pair of bender frames 63 is mounted on both sides of thebase 61 along the process line and is disposed apart from each other. - The pair of bender frames 63 are connected so as to maintain a distance therebetween through a plurality of connecting
pipes 67. In addition, slide recesses SG are formed at a pair ofbender frame 63, and sliders SR is slidably mounted in the slide recesses SG. - Referring to
FIG. 4 toFIG. 7 , the first bending roll unit BR1 includes a first upper bending roll UR1 and a first lower bending roll LR1, and is disposed at a front portion of the process line between the pair of bender frames 63. The first bending roll unit BR1 guides the shapedbeam 30. - Each of the first upper bending roll UR1 and the first lower bending roll LR1 includes a rotational shaft S, and both ends of the rotational shaft S is rotatably mounted at the sliders SR mounted in the slide recesses SG.
- The second bending roll unit BR2 includes a second upper bending roll UR2 and a second lower bending roll LR2, and is disposed at the rear of the first bending roll unit BR1 between the pair of bender frames 63. The second bending roll unit BR2 slidably supports the shaped
beam 30 along a curvature direction. - Each of the second upper bending roll UR2 and the second lower bending roll LR2 includes a rotational shaft S, and both ends of the rotational shaft S is roatatbly mounted at the sliders SR mounted in the slide recesses SG.
- Herein, the sliders SR used at the first bending roll unit BR1 and the second bending roll unit BR2 is divided into an upper slider and a lower slider, and each of the sliders SR is fixed to the slide recess SG of the
bender frame 63 through an adjusting bolt AB. A position of the slider SR can be adjusted by means of the adjusting bolt AB. - The third, fourth, and fifth bending roll units BR3, BR4, and BR5 respectively include a third upper bending roll UR3 and a third lower bending roll LR3, a fourth upper bending roll UR4 and a fourth lower bending roll LR4, and a fifth upper bending roll UR5 and a fifth lower bending roll LR5, and are sequentially disposed at the rear of the second bending roll unit BR2 between the pair of bender frames 63 along the curvature. The shaped
beam 30 is formed to have a predetermined curvature while passing through the third, fourth, and fifth bending roll units BR3, BR4, and BR5. - Herein, each of the third and fourth lower bending rolls LR3 and LR4 include a rotational shaft S, and both ends of the rotational shaft S are rotatably mounted at lower portions of movable blocks MB slidably mounted in the slide recesses SG. In addition, each of the third and fourth upper bending rolls UR3 and UR4 includes a rotational shaft S, and both ends of the rotational shaft S are rotatably mounted at the sliders SR slidably mounted in slide holes SH formed at upper portions of the movable blocks MB.
- In addition, referring to
FIG. 6 , the fifth upper bending roll UR5 includes a rotational shaft S, and both end portions of the rotational shaft S is rotatably mounted through bearing units BU at sliding blocks SB slidably mounted in the slide recesses SG formed at upper portions of the bender frames 63. In addition, the fifth lower bending roll LR5 includes a rotational shaft S, and the rotational shaft S is movably disposed in a process line direction through penetration holes H formed at lower portions of the bender frames 63. - Herein, both ends of the rotational shaft S of the fifth lower bending roll LR5 are rotatably supported by the curvature changing means 65. The curvature changing means 65 are disposed between the bender frames 63 and the fifth bending roll unit BR5 so as to rotate the fifth lower bending roll LR5 in the penetration hole H with reference to the fifth upper bending roll UR5 by a predetermined angle. Therefore, the curvature changing means 65 moves to the fifth lower bending roll LR5 such that curvature radius of both end portions of the shaped
beam 30 formed to have the curvature becomes smaller. - That is, the curvature changing means 65 include a
cylinder 71 and arotating fork 73. Thecylinder 71 is disposed at a middle portion above the pair of bender frames 63. Thecylinder 71 is hinged to the pair of bender frames 63 through ahinge bracket 75. - Herein, the
cylinder 71 may be a hydraulic pressure cylinder, but is not limited thereto. Operating pressure of the hydraulic pressure cylinder is hydraulic pressure. - An upper end of the
rotating fork 73 is hinged to arod 81 of thecylinder 71. Therotating fork 73 is connected to the rotational shafts S of the fifth upper bending roll UR5 and the fifth lower bending roll LR5 at an outer of the pair of bender frames 63 so as to rotate the rotational shaft S of the fifth lower bending roll LR5 in the penetration hole H with reference to the rotational shaft S of the fifth upper bending roll UR5 according to operation of thecylinder 71. - The
rotating fork 73 includes a connectingbar 77 and tworotating bars 79. The connectingbar 77 is disposed above the pair of bender frames 63 along a width direction. Ahinge end 83 is protruded from a middle portion of an upper surface of the connectingbar 77, and thehinge end 83 is hinged to therod 81 of thecylinder 71 through ahinge fork 85. - In addition, the two
rotating bars 79 are disposed at an outer of the pair of bender frames 63 corresponding to the fifth bending roll unit BR5, and an upper end of each of therotating bars 79 is connected to each of both ends of the connectingbar 77. - Both ends of the rotational shaft S of the fifth upper bending roll UR5 are mounted at upper portions of the
rotating bars 79 through bearing units BU, and a slide hole SH is formed at a lower portion of each of the rotating bars 79. A slider SR is slidably mounted in the slide hole SH, and both ends of the rotational shaft S of the fifth lower bending roll LR5 are rotatably mounted at the sliders SR. - That is, the
rotating fork 73 rotates the rotational shaft S of the fifth lower bending roll LR5 with reference to the rotational shaft S of the fifth upper bending roll UR5 according to forward/rearward operation of thecylinder 71 so as to change a position of the fifth lower bending roll LR5 to the fifth upper bending roll UR5. Therefore, the shaped beam is bent to have multiple curvatures such that curvature radius of some portion of the shapedbeam 30 is different from that of other portion of the shapedbeam 30. - Referring to
FIG. 4 , position detecting means 80 for detecting positions of the sliders SR or the sliding blocks are disposed between the sliders SR or the sliding blocks SB used at the first to the fifth bending roll units BR1-BR5 and the pair of bender frames 63, the movable blocks MB or therotating fork 73 guiding the sliders SR or the sliding blocks SB. - The position detecting means 80 includes a marking
needle 87 and agraduated ruler 89. The markingneedle 87 is mounted at a side of the slider SR or the sliding block SB, and the graduatedruler 89 is attached to the pair of bender frames 63, the movable blocks MB or therotating fork 73 corresponding to the markingneedle 87. - In addition, a
stopper 90 for restricting rotating angle of therotating fork 73 is mounted at an upper portion of therearmost bender frame 63. Thestopper 90 includes astopper ring 91 and astopper rod 93. An end portion of thestopper rod 93 is mounted at thebender frame 63 and thestopper ring 91 is mounted at the other end portion of thestopper rod 93. Thestopper ring 91 is positioned at the rear of the rotatingbar 79 of therotating fork 73 and is adapted to support a rear surface of the rotatingbar 79. - In addition, referring to
FIG. 5 , power delivery means are mounted at the lower bending rolls LR1-LR5 of the first to the fifth bending roll units BR1-BR5 and deliver the power therebetween. - The power delivery means includes sprocket SP and chains C. The sprockets SP are mounted at end portions of the rotational shafts S of the first to the fifth lower bending rolls LR1-LR5 at an outer of one
bender frame 63, and the chains C connect the sprockets SP. - The power delivery means according to an exemplary embodiment of the present invention include the chains and the sprockets, but are not limited thereto. Pulleys and belts instead of the sprockets SP and the chains C may be used as the power delivery means.
- The fifth bending roll unit BR5 is not connected to the fourth bending roll unit BR4 through the chain C and is operated by movement of the shaped
beam 30 in a normal condition. In a case that supply of the shapedbeam 30 is finished, however, the fifth bending roll unit BR5 is temporarily connected to the fourth bending roll unit BR4 through the chain C and receive power from the fourth bending roll unit BR4 so as to push the end portion of the shapedbeam 30. - Operation of the
round bender 6 according to an exemplary embodiment of the present invention will be described in detail with reference toFIG. 8 toFIG. 10 . - As shown in
FIG. 8 , theround bender 6 according to an exemplary embodiment of the present invention is disposed at the rear of thelaser welding device 5 of the roll forming system in the process line, and is adapted to bent the shapedbeam 40 to have different curvatures at the middle portion and both end portions thereof when the shapedbeam 30 supplied from thelaser welding device 5 passes through the first to the fifth bending roll units BR1-BR5. - That is, the shaped
beam 30 is guided by the first upper bending roll UR1 and the first lower bending roll LR1 of the first bending roll unit BR1 and is slidably supported by the second upper bending roll UR2 and the second lower bending roll LR2 of the second bending roll unit BR2 along the curvature direction. - After that, the shaped
beam 30 is formed to have the predetermined curvature when passing through the third, fourth, and fifth bending roll units BR3, BR4, and BR5. In a case that curvature radius of some portion of the shapedbeam 30 is to be smaller than that of other portion of the shapedbeam 30, thecylinder 71 moves to the rearward as shown inFIG. 9 . - In this case, the
rotating fork 73 is rotated about the rotational shaft S of the fifth upper bending roll UR5 by a predetermined angle θ, and thus the fifth lower bending roll LR5 is rotated with reference to the fifth upper bending roll UR5 to the rearward in the process line. - At this state, the some portion of the shaped
beam 30 passes between the fifth upper bending roll UR5 and the fifth lower bending roll LR5 of the fifth bending roll unit BR5. At this time, the some portion of the shapedbeam 30 has a smaller curvature radius than that of other portion of the shapedbeam 30. - Therefore, if the shaped
beam 30 should have multiple curvatures, curvatures of the shapedbeam 30 can be controlled by forward/rearward operation of thecylinder 71. Therefore, abumper beam 50, shown inFIG. 3 , including afirst curvature portion 51 having a first curvature radius at a middle portion thereof and asecond curvature portion 52 having a second curvature radius that is smaller than the first curvature radius at both end portions thereof can be manufactured in one process. - If dimensions of the shaped
beam 30 is different or curvature of the shapedbeam 30 should be adjusted, a position of the fifth bending roll unit BR5 is changed. So as to change the position of the fifth bending roll unit BR5, as shown inFIG. 10 , the adjusting bolt AB of the slider SR where the rotational shaft S of the fifth upper bending roll UR5 is mounted is controlled so as to control a position of the slider SR. - In this case, the fifth upper bending roll UR5 is moved with the slider SR, and the fifth lower bending roll LR5 together with the
rotating fork 73 is moved with a distance to the fifth upper bending roll UR5 being maintained. - A round bender according to an exemplary embodiment of the present invention can manufacture a shaped beam having a first curvature portion and a second curvature portion without mounting an additional bending unit.
- Therefore, manufacturing process and cost may be reduced and installation cost for installing an additional bending unit may not be necessary.
- While this invention has been described in connection with what is presently considered to be practical exemplary embodiments, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.
Claims (20)
1. A round bender comprising a plurality of bending roll units disposed along a process line between a pair of bender frames so as to bend a straight shaped beam to have a curvature,
wherein each of the plurality of bending roll units include upper and lower bending rolls rotating between the pair of bender frames and is adapted to bend the shaped beam to have the curvature when the shaped beam passes between the upper and lower bending rolls, and
wherein a lower bending roll of a rearmost bending roll unit disposed on a rearmost part of the process line is configured to be rotatable with reference to an upper bending roll of the rearmost bending roll unit so as to change a curvature radius of some portion of the shaped beam.
2. The round bender of claim 1 , further comprising a curvature changing means rotating the lower bending roll of the rearmost bending roll unit with reference to the upper bending roll of the rearmost bending roll unit,
wherein the curvature changing means are disposed at the rearmost bending roll unit between the pair of bender frames such that a rotational shaft of the upper bending roll is rotatably supported at the pair of bender frames, and a rotational shaft of the lower bending roll is movably disposed in a penetration hole formed at the pair of bender frames.
3. The round bender of claim 2 , wherein the curvature changing means comprise:
a cylinder disposed at a middle portion above the pair of bender frames, and hinged to the pair of bender frames through a hinge bracket; and
a rotating fork having an upper end hinged to a rod of the cylinder, and connected to the rotational shafts of the upper and lower bending rolls of the rearmost bending roll unit at an outer of the pair of bender frames so as to rotate the rotational shaft of the lower bending roll in the penetration hole with respect to the rotational shaft of the upper bending roll according to operation of the cylinder.
4. The round bender of claim 3 , wherein the rotating fork comprises:
a connecting bar disposed above the pair of bender frames and having a hinge end protruded from a middle portion of an upper surface of the connecting bar and hinged to the rod of the cylinder; and
a pair of rotating bars disposed at the outer of the pair of bender frames corresponding to the rearmost bending roll unit, wherein an upper end of the rotating bar is connected to an end of the connecting bar, the rotational shaft of the upper bending roll is rotatably mounted at an upper portion of the rotating bar, and a slide hole is formed at a lower portion of the rotating bar such that the rotational shaft of the lower bending roll is rotatably mounted at a slider slidably mounted in the slide hole.
5. The round bender of claim 3 , wherein the rotational shaft of the upper bending roll is rotatably mounted at a sliding block slidably mounted in a slide recess formed at an upper portion of the bender frame.
6. A round bender for bending a straight shaped beam to have a curvature, comprising:
a pair of bender frames mounted apart from each other on both sides of a base;
a first bending roll unit including an upper bending roll and a lower bending roll, disposed at a front portion on a process line between the pair of bender frames, and guiding the shaped beam;
a second bending roll unit including an upper bending roll and a lower bending roll, disposed at the rear of the first bending roll unit between the pair of bender frames, and slidably supporting the shaped beam along a curvature direction;
third, fourth, and fifth bending roll units respectively including an upper bending roll and a lower bending roll, sequentially disposed at the rear of the second bending roll unit between the pair of bender frames along the curvature, and forming the shaped beam to have a predetermined curvature when the shaped beam passes therethrough; and
a curvature changing means disposed between the bender frame and the fifth bending roll unit and rotating the lower bending roll of the fifth bending roll unit with reference to the upper bending roll of the fifth bending roll unit so as to change a curvature radius of some portion of the shaped beam.
7. The round bender of claim 6 , wherein the curvature changing means is mounted at the fifth bending roll unit between the pair of bender frames such that a rotational shaft of the upper bending roll is rotatably supported at the pair of bender frames, and a rotational shaft of the lower bending roll is movably disposed in a penetration hole formed at the pair of bender frames.
8. The round bender of claim 7 , wherein the curvature changing means comprise:
a cylinder disposed at a middle portion above the pair of bender frames, and hinged to the pair of bender frames through a hinge bracket; and
a rotating fork having an upper end hinged to a rod of the cylinder, and connected to the rotational shafts of the upper and lower bending rolls of the fifth bending roll unit at an outer of the pair of bender frames so as to rotate the rotational shaft of the lower bending roll in the penetration hole with respect to the rotational shaft of the upper bending roll according to operation of the cylinder.
9. The round bender of claim 8 , wherein the rotating fork comprises:
a connecting bar disposed above the pair of bender frames and having a hinge end protruded from a middle portion of an upper surface of the connecting bar and hinged to the rod of the cylinder; and
a pair of rotating bars disposed at the outer of the pair of bender frames corresponding to the fifth bending roll unit, wherein an upper end of the rotating bar is connected to an end of the connecting bar, the rotational shaft of the upper bending roll is rotatably mounted at an upper portion of the rotating bar, and a slide hole is formed at a lower portion of the rotating bar such that the rotational shaft of the lower bending roll is rotatably mounted at a slider slidably mounted in the slide hole.
10. The round bender of claim 8 , wherein the rotational shaft of the upper bending roll of the fifth bending roll unit is rotatably mounted at a sliding block slidably mounted in a slide recess formed at an upper portion of the bender frame.
11. A round bender comprising at least three bending roll units disposed along a process line between a pair of bender frames so as to bend a straight shaped beam and including upper and lower bending rolls,
wherein a lower bending roll of a rearmost bending roll unit on a process line is configured to be rotatable with reference to an upper bending roll of the rearmost bending roll unit so as to change a curvature radius of some portion of the shaped beam.
12. The round bender of claim 11 , further comprising a curvature changing means rotating the lower bending roll of the rearmost bending roll unit with reference to the upper bending roll of the rearmost bending roll unit,
wherein the curvature changing means are disposed at the rearmost bending roll unit between the pair of bender frames such that a rotational shaft of the upper bending roll is rotatably supported at the pair of bender frames, and a rotational shaft of the lower bending roll is movably disposed in a penetration hole formed at the pair of bender frames.
13. The round bender of claim 12 , wherein the curvature changing means comprise:
a cylinder disposed at a middle portion above the pair of bender frames, and hinged to the pair of bender frames through a hinge bracket; and
a rotating fork having an upper end hinged to a rod of the cylinder, and connected to the rotational shafts of the upper and lower bending rolls of the rearmost bending roll unit at an outer of the pair of bender frames so as to rotate the rotational shaft of the lower bending roll in the penetration hole with respect to the rotational shaft of the upper bending roll according to operation of the cylinder.
14. The round bender of claim 13 , wherein the rotating fork comprises:
a connecting bar disposed above the pair of bender frames and having a hinge end protruded from a middle portion of an upper surface of the connecting bar and hinged to the rod of the cylinder; and
a pair of rotating bars disposed at the outer of the pair of bender frames corresponding to the rearmost bending roll unit, wherein an upper end of the rotating bar is connected to an end of the connecting bar, the rotational shaft of the upper bending roll is rotatably mounted at an upper portion of the rotating bar, and a slide hole is formed at a lower portion of the rotating bar such that the rotational shaft of the lower bending roll is rotatably mounted at a slider slidably mounted in the slide hole.
15. The round bender of claim 13 , wherein the rotational shaft of the upper bending roll is rotatably mounted at a sliding block slidably mounted in a slide recess formed at an upper portion of the bender frame.
16. The round bender of claim 1 , further comprising power delivery means mounted at the lower bending rolls of the bending roll units and delivering power therebetween.
17. The round bender of claim 6 , further comprising power delivery means mounted at the lower bending rolls of the first to the fifth bending roll units and delivering power therebetween.
18. The round bender of claim 11 , further comprising power delivery means mounted at the lower bending rolls of the bending roll units and delivering power therebetween.
19. The round bender of claim 10 , wherein position detecting means for detecting a position of a slider block is disposed between the sliding block used at the fifth bending roll unit and the bender frame guiding the sliding block.
20. The round bender of claim 19 , wherein the position detecting means comprise:
a marking needle mounted at the sliding block; and
a graduated ruler attached to the bender frame corresponding to the marking needle.
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
KR1020120052037A KR101413193B1 (en) | 2012-05-16 | 2012-05-16 | Round bender |
KR10-2012-0052036 | 2012-05-16 | ||
KR10-2012-0052037 | 2012-05-16 | ||
KR1020120052036A KR101413759B1 (en) | 2012-05-16 | 2012-05-16 | Round bender |
Publications (1)
Publication Number | Publication Date |
---|---|
US20130305798A1 true US20130305798A1 (en) | 2013-11-21 |
Family
ID=49510917
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US13/476,349 Abandoned US20130305798A1 (en) | 2012-05-16 | 2012-05-21 | Round bender |
Country Status (3)
Country | Link |
---|---|
US (1) | US20130305798A1 (en) |
CN (1) | CN103418650A (en) |
DE (1) | DE102012108280A1 (en) |
Cited By (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2016120698A1 (en) * | 2015-01-30 | 2016-08-04 | Pietro Passone | Method for the production of curved pieces from a continuous metal element |
JP2017119307A (en) * | 2015-12-28 | 2017-07-06 | 川崎重工業株式会社 | Manufacturing device and manufacturing method for roll molding component having variable width |
WO2017159806A1 (en) * | 2016-03-17 | 2017-09-21 | 川崎重工業株式会社 | Roll bending device |
US20170326609A1 (en) * | 2016-05-10 | 2017-11-16 | Fives Oto S.P.A. | Forming unit for a profiling machine line |
IT201600097987A1 (en) * | 2016-09-29 | 2018-03-29 | Zone Creative S R L | PROFILING MACHINE, PARTICULARLY FOR THE REALIZATION OF ARTICLES OF JEWELERY, SILVERWARE AND JEWELERY |
IT201800004328A1 (en) * | 2018-04-09 | 2019-10-09 | PLANT FOR PROCESSING STRUCTURAL ELEMENTS | |
US10449591B2 (en) * | 2013-12-30 | 2019-10-22 | Sungwoo Hitech Co., Ltd. | Sheet roll forming method, and running cutter and round bender applied thereto |
US11559835B2 (en) * | 2018-11-30 | 2023-01-24 | Mitsubishi Heavy Industries, Ltd. | Processing device, and method for controlling processing device |
Families Citing this family (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN104550360B (en) * | 2015-01-08 | 2016-08-24 | 德阳凯达门业有限公司 | The iron pipe bar folder of adjustable of its bow |
CN105711050B (en) * | 2016-03-24 | 2020-12-18 | 中山市悦辰电子实业有限公司 | Method for forming arc-shaped sound box shell |
CN108687184A (en) * | 2018-04-03 | 2018-10-23 | 浙江创大汽车部件有限公司 | The bending equipment of front and rear beam |
CN116371983B (en) * | 2023-06-06 | 2023-08-18 | 山东鲁旺机械设备有限公司 | Pipe fitting bending device for building hanging basket |
Citations (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3763690A (en) * | 1972-04-17 | 1973-10-09 | Dreis & Krump Manuf Co | Press brake ram leveling |
US4391116A (en) * | 1979-12-03 | 1983-07-05 | Teruaki Yogo | Lace bending apparatus |
US4653301A (en) * | 1984-10-02 | 1987-03-31 | Mauro Meliga | Bending machine for pipes, sections and similar |
US4850212A (en) * | 1988-05-13 | 1989-07-25 | Frey Samuel W | Bending apparatus |
US6820451B2 (en) * | 2000-01-14 | 2004-11-23 | Magna International Inc. | Sweep forming assembly and method |
US7337642B2 (en) * | 2005-06-13 | 2008-03-04 | Shape Corporation | Roll-former apparatus with rapid-adjust sweep box |
US8307685B2 (en) * | 2008-04-09 | 2012-11-13 | Shape Corp. | Multi-directionally swept beam, roll former, and method |
US20120323354A1 (en) * | 2011-06-14 | 2012-12-20 | M.I.C. Industries, Inc. | Systems and Methods for Making Panels from Sheet Material Using Adaptive Control |
Family Cites Families (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
KR100934898B1 (en) * | 2007-11-22 | 2010-01-06 | 주식회사 성우하이텍 | Curvature bending system |
KR20110068456A (en) * | 2009-12-16 | 2011-06-22 | (주)모인시스 | Method and auto control device for roll bending |
-
2012
- 2012-05-21 US US13/476,349 patent/US20130305798A1/en not_active Abandoned
- 2012-09-06 DE DE102012108280A patent/DE102012108280A1/en not_active Ceased
- 2012-09-27 CN CN2012103743721A patent/CN103418650A/en active Pending
Patent Citations (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3763690A (en) * | 1972-04-17 | 1973-10-09 | Dreis & Krump Manuf Co | Press brake ram leveling |
US4391116A (en) * | 1979-12-03 | 1983-07-05 | Teruaki Yogo | Lace bending apparatus |
US4653301A (en) * | 1984-10-02 | 1987-03-31 | Mauro Meliga | Bending machine for pipes, sections and similar |
US4850212A (en) * | 1988-05-13 | 1989-07-25 | Frey Samuel W | Bending apparatus |
US6820451B2 (en) * | 2000-01-14 | 2004-11-23 | Magna International Inc. | Sweep forming assembly and method |
US7337642B2 (en) * | 2005-06-13 | 2008-03-04 | Shape Corporation | Roll-former apparatus with rapid-adjust sweep box |
US8307685B2 (en) * | 2008-04-09 | 2012-11-13 | Shape Corp. | Multi-directionally swept beam, roll former, and method |
US20120323354A1 (en) * | 2011-06-14 | 2012-12-20 | M.I.C. Industries, Inc. | Systems and Methods for Making Panels from Sheet Material Using Adaptive Control |
Cited By (11)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US10449591B2 (en) * | 2013-12-30 | 2019-10-22 | Sungwoo Hitech Co., Ltd. | Sheet roll forming method, and running cutter and round bender applied thereto |
WO2016120698A1 (en) * | 2015-01-30 | 2016-08-04 | Pietro Passone | Method for the production of curved pieces from a continuous metal element |
US10646910B2 (en) * | 2015-01-30 | 2020-05-12 | Baomarc Automotive Solutions S.p.A. | Methods for the production of curved pieces from continuous metal elements |
JP2017119307A (en) * | 2015-12-28 | 2017-07-06 | 川崎重工業株式会社 | Manufacturing device and manufacturing method for roll molding component having variable width |
WO2017159806A1 (en) * | 2016-03-17 | 2017-09-21 | 川崎重工業株式会社 | Roll bending device |
JPWO2017159806A1 (en) * | 2016-03-17 | 2019-01-17 | 川崎重工業株式会社 | Roll bending equipment |
US20170326609A1 (en) * | 2016-05-10 | 2017-11-16 | Fives Oto S.P.A. | Forming unit for a profiling machine line |
IT201600097987A1 (en) * | 2016-09-29 | 2018-03-29 | Zone Creative S R L | PROFILING MACHINE, PARTICULARLY FOR THE REALIZATION OF ARTICLES OF JEWELERY, SILVERWARE AND JEWELERY |
IT201800004328A1 (en) * | 2018-04-09 | 2019-10-09 | PLANT FOR PROCESSING STRUCTURAL ELEMENTS | |
WO2019197953A1 (en) * | 2018-04-09 | 2019-10-17 | Manni Green Tech S.R.L. | Plant for processing profiled elements |
US11559835B2 (en) * | 2018-11-30 | 2023-01-24 | Mitsubishi Heavy Industries, Ltd. | Processing device, and method for controlling processing device |
Also Published As
Publication number | Publication date |
---|---|
CN103418650A (en) | 2013-12-04 |
DE102012108280A1 (en) | 2013-11-21 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US20130305798A1 (en) | Round bender | |
EP2261014B1 (en) | Forming apparatus, shoe thereof and forming method | |
US8707749B2 (en) | Roll forming system and roll forming method | |
JP5523579B2 (en) | Molding method and molding equipment | |
US10449591B2 (en) | Sheet roll forming method, and running cutter and round bender applied thereto | |
US20110179842A1 (en) | System for cold roll forming profiles having variable cross-sections | |
EP1022072A2 (en) | Roll-forming machine | |
US8991230B2 (en) | Roll forming method and shaped beam produced by using the same | |
JP5268834B2 (en) | Molding apparatus and molding method | |
CN108472705B (en) | Bending method | |
KR20120077092A (en) | Round bender and roll forming system provided with the same | |
KR101927832B1 (en) | Uncoil device for 2 cavity roll forming system | |
US8783084B2 (en) | Supply station | |
US20080216541A1 (en) | Roll-Forming Machine Having Changeover Mechanism | |
US8847107B2 (en) | Laser welding device for roll forming system and control method thereof | |
KR102387146B1 (en) | Round bender | |
KR20040044977A (en) | A method of bending metal roofing sheets and a bending apparatus | |
KR20160139243A (en) | Sheet heating apparatus for flexible roll forming system | |
WO2013145307A1 (en) | Molding device | |
KR20140079949A (en) | Roll forming system and method thereof | |
KR101413193B1 (en) | Round bender | |
KR101444179B1 (en) | Flexible roll forming unit | |
KR20120075020A (en) | Roll laser welding device | |
KR101413759B1 (en) | Round bender | |
KR20180078633A (en) | 2 cavity roll forming device |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
AS | Assignment |
Owner name: SUNGWOO HITECH CO., LTD., KOREA, REPUBLIC OF Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:LEE, MUN YONG;JUNG, JIN HO;REEL/FRAME:028335/0919 Effective date: 20120607 |
|
STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |