WO2010134495A1 - 曲げ加工装置 - Google Patents
曲げ加工装置 Download PDFInfo
- Publication number
- WO2010134495A1 WO2010134495A1 PCT/JP2010/058300 JP2010058300W WO2010134495A1 WO 2010134495 A1 WO2010134495 A1 WO 2010134495A1 JP 2010058300 W JP2010058300 W JP 2010058300W WO 2010134495 A1 WO2010134495 A1 WO 2010134495A1
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- WIPO (PCT)
- Prior art keywords
- metal material
- steel pipe
- chuck
- bending apparatus
- bending
- Prior art date
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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
- B21D7/16—Auxiliary equipment, e.g. for heating or cooling of bends
-
- 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
- B21D7/12—Bending rods, profiles, or tubes with programme control
-
- 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
- B21D7/16—Auxiliary equipment, e.g. for heating or cooling of bends
- B21D7/162—Heating equipment
Definitions
- the present invention relates to a bending apparatus. Specifically, the present invention relates to a bending apparatus for manufacturing a bending member by performing a two-dimensional or three-dimensional bending process on a long metal material having a closed cross section.
- a metal strength member, reinforcement member, or structural member having a bent shape is used for automobiles, various machines, and the like. These bending members are required to have high strength, light weight, and small size. Conventionally, this kind of bending member is manufactured by, for example, welding of a press-processed product, punching of a thick plate, and further forging. However, it is difficult to further reduce the weight and size of the bending member manufactured by these manufacturing methods.
- Non-Patent Document 1 discloses manufacturing such a bending member by so-called tube hydroforming.
- tube hydroforming method there are various problems in the tube hydroforming method, such as the development of materials that will be used as raw materials and the increase in the degree of freedom of moldable shapes. It is disclosed that there is.
- FIG. 13 is an explanatory view showing an outline of the bending apparatus 0.
- the bending device 0 is a feed device 3 that uses, for example, a ball screw from a upstream side to a downstream side of a steel pipe 1 that is supported by a support means 2 so as to be movable in the axial direction.
- the steel pipe 1 is rapidly heated to a temperature range in which it can be partially quenched by the high-frequency heating coil 5 downstream of the support means 2, and (b) water-cooling disposed downstream of the high-frequency heating coil 5.
- the steel pipe 1 is rapidly cooled by the apparatus 6, and (c) the position of the movable roller die 4 having at least one pair of roll pairs 4a that can be supported while feeding the steel pipe 1 is changed two-dimensionally or three-dimensionally to heat the steel pipe 1
- the bending member 8 is manufactured with high work efficiency while ensuring sufficient bending accuracy by applying a bending moment to the formed portion and performing the bending.
- the bending device 0 has the following problems (a) to (e) unless the feeding device 3 properly holds the front end and the rear end of the steel pipe 1. (A) The bending member 8 does not have sufficient dimensional accuracy.
- the object of the present invention is to solve these problems (a) to (e) of the bending apparatus 0, and to achieve a long length having a closed cross section with higher productivity and superior dimensional accuracy than the bending apparatus 0. It is providing the bending apparatus for manufacturing a metal bending member.
- a feed preventing device 3 of the bending device 0, a deformation preventing device disposed downstream of the movable roller die 4 with respect to the feeding direction of the steel tube 1, and the like are disposed inside or outside the steel tube 1 to grip the steel tube 1. It is based on the knowledge that the above problems (a) to (e) can be solved by having a cylindrical chuck, and (ii) optimizing the shape, structure, and function of the chuck.
- the present invention includes the following first support mechanism, heating mechanism, cooling mechanism, second support mechanism, and deformation prevention mechanism, and at least one of the second support mechanism and / or deformation prevention mechanism includes the following chuck: It is a bending apparatus characterized by having.
- 1st support mechanism It is arrange
- Heating mechanism It is arranged at a second position downstream of the first position in the feeding direction of the metal material, and heats part or all of the metal material to be fed.
- Cooling mechanism disposed at a third position downstream of the second position in the feeding direction of the metal material, and cooling a portion heated by the heating mechanism in the metal material to be fed into a part of the metal material Forming hot parts.
- Second support mechanism disposed in a fourth position downstream of the third position in the metal material feeding direction, and in a two-dimensional or three-dimensional direction while supporting at least one portion of the metal material to be fed. A bending moment is given to the hot part of the metal material by moving, and the metal material is bent into a desired shape.
- Deformation prevention mechanism It is arranged at a fifth position downstream from the fourth position in the feeding direction of the metal material, and prevents deformation of the metal material to be fed.
- Chuck A cylindrical body having a circular, polygonal or irregular cross section and gripping a metal material.
- a feed mechanism that feeds the metal material in the longitudinal direction thereof, preferably a feed mechanism having the chuck, or (II) a first support mechanism feeds the metal material in the longitudinal direction thereof. It is desirable.
- the chuck is inserted inside the metal material and abuts against the inner surface of the metal material, and it is further desirable that the outer method of the cylindrical body is expandable.
- the chuck is installed outside the metal material and abuts against the outer surface of the metal material, and it is desirable that the inner method of the cylindrical body be reduced.
- the chuck can prevent the intrusion of the cooling water into the metal material by sealing the inside of the metal material or making the inside of the metal material a positive pressure. .
- the cylindrical body is installed so that its central axis substantially coincides with the central axis of the metal material, or has an external method that substantially matches the external method of the metal material.
- the cylindrical body has a chuck claw and an opening / closing bar made of a high hardness material.
- the cylindrical body has a plurality of structural members divided in the circumferential direction and an insulating member disposed between two structural members disposed adjacent to each other.
- the cylindrical body has nonmagnetic properties.
- the cylindrical body is made of, for example, ceramics, austenitic stainless steel such as SUS304, or nickel alloy.
- the cylindrical body has a laminated structure.
- laminated structure means a structure formed by stacking thin metal plates. Inductive current due to high frequency is less likely to flow through the cylindrical body having a laminated structure, and thereby the chuck is less likely to be induction heated.
- a metal strength member, reinforcing member or structural member having a shape bent in two dimensions or three dimensions is reliably manufactured with high work efficiency while ensuring sufficient dimensional accuracy. Will be able to.
- FIG. 1 is a perspective view showing a configuration example of a bending apparatus according to the present invention.
- FIG. 2 is an explanatory diagram illustrating a configuration example of the first industrial robot, the second industrial robot, the heating coil support robot, or the third industrial robot.
- FIG. 3A is an explanatory view schematically showing a long chuck as an effector when the steel pipe is directly gripped by the second industrial robot as the second support means, and
- FIG. ) Is an explanatory view schematically showing a short chuck as an effector when the steel pipe is directly gripped by the second industrial robot as the second support means, and
- FIG. 4 is an explanatory view showing that a long chuck can reduce a bending load.
- FIG. 5 (a) is an explanatory view showing an extracted type of chuck that is disposed outside the steel pipe and abuts against the outer surface of the steel pipe to grip the tip of the steel pipe, and
- FIG. 6 is an explanatory view schematically showing an example of a chuck used in the third industrial robot in FIG.
- FIG. 7 is an explanatory view schematically showing an example of a chuck used in the feeding device in FIG. 8 (a) and 8 (b) both schematically illustrate an enlargement mechanism of the outer method of the chuck that is inserted into the steel pipe and abuts against the inner surface of the steel pipe to grip the tip of the steel pipe.
- FIG. 9A is an explanatory view schematically showing a configuration example of a chuck suitable for use in the bending apparatus of the present invention.
- FIG. 9B shows a chuck of a comparative example, and FIG. ) Shows a chuck according to an example of the present invention.
- FIG. 9A is an explanatory view schematically showing a configuration example of a chuck suitable for use in the bending apparatus of the present invention.
- FIG. 9B shows a chuck of a comparative example
- FIG. ) Shows a chuck
- FIG. 10 is an explanatory diagram showing a configuration example of a sleeve-type chuck with a slit, which is suitable for use in the bending apparatus of the present invention.
- FIG. 11 (a) is an explanatory view showing a configuration example of a hydraulic sleeve type chuck suitable for use in the bending apparatus of the present invention
- FIG. 11 (b) is an explanatory view showing a modification thereof. It is.
- FIG. 12 is an explanatory view showing a mechanism for making the inside of the steel pipe positive pressure.
- FIG. 13 is an explanatory diagram schematically showing the configuration of the bending apparatus disclosed in Patent Document 1. As shown in FIG.
- the present invention will be described with reference to the accompanying drawings.
- the case where the “hollow metal material having a closed cross section” in the present invention is a steel pipe 17 is taken as an example.
- the present invention is not limited to the steel pipe, and the hollow metal material having a closed cross section is used. If it is a metal material (for example, a square tube or a deformed tube), it is equally applied.
- FIG. 1 is a perspective view conceptually showing a part of a configuration example of a bending apparatus 10 according to the present invention with simplification and omission.
- the first industrial robot 18, the heating coil holding robot 27, the second industrial robot 26, and the third industrial robot 28 are conceptualized and simplified of manipulators and the like.
- the bending apparatus 10 includes a feed mechanism 11, a first support mechanism 12, a heating mechanism 13, a cooling mechanism 14, a second support mechanism 15, and a deformation prevention mechanism 16.
- the feed mechanism 11 feeds the steel pipe 17 in the longitudinal direction.
- the feed mechanism 11 is constituted by a first industrial robot 18.
- FIG. 2 is an explanatory diagram illustrating a configuration example of the first industrial robot 18, the second industrial robot 26, the heating coil support robot 27, or the third industrial robot 28.
- the first industrial robot 18, the second industrial robot 26, the heating coil support robot 27, or the third industrial robot 28 (hereinafter referred to as “each robot”) is a so-called vertical articulated robot. And have a first axis to a sixth axis.
- the first axis turns the upper arm 19 in a horizontal plane.
- the second axis turns the upper arm 19 back and forth.
- the third axis pivots the forearm 20 up and down.
- the fourth axis rotates the forearm 20.
- the fifth axis pivots the wrist 20a up and down.
- the sixth axis rotates the wrist 20a.
- Each robot may have a seventh axis for turning the upper arm 19 as needed in addition to the first to sixth axes.
- the first to seventh axes are driven by an AC servo motor.
- Each robot like other general-purpose industrial robots, has a controller 21 that comprehensively controls the operations of the first to sixth axes and an input device 22 for teaching the operations of the first to sixth axes. And have.
- An effector (end effector) 24 is provided at the tip of the wrist 20 a of the first industrial robot 18.
- the effector (end effector) 24 grips the steel pipe 17 accommodated in the pallet 23 arranged in the vicinity of the side of the first industrial robot 18, and the gripped steel pipe 17 is heated by the first support means 12 and the heating means. It is used when penetrating through holes respectively provided in the means 13.
- the effector 24 directly grips the steel pipe 17 by the second industrial robot 26 without using the movable roller die 25 as a second support mechanism 15 to be described later as well as when the steel pipe 17 is fed by the feed mechanism 11. In this case, it is used when the steel pipe 17 is supported by the deformation preventing mechanism 16.
- the effector 24 greatly affects the dimensional accuracy and productivity of the bent member manufactured by the bending apparatus 10.
- the effector 24 will be described in detail.
- an effector in the case where the steel pipe 17 is directly gripped by the second industrial robot 26 without using the movable roller die 25 as the second support mechanism 15 is taken as an example.
- the situation is the same for the effector 24 in the feed mechanism 11 and the effector 29 in the deformation prevention mechanism 16.
- FIG. 3A schematically shows a long chuck 30 as an effector when the steel pipe 17 is directly gripped by the second industrial robot 26 without using the movable roller die 25 as the second support mechanism 15.
- FIG. 3B is an explanatory diagram schematically showing an effector in the case where the steel pipe 17 is directly gripped by the second industrial robot 26 without using the movable roller die 25 as the second support mechanism 15.
- FIG. 3C is an explanatory view schematically showing a short chuck 31 of FIG. 3, and FIG. 3C is a diagram showing a direct grip of the steel pipe 17 by the second industrial robot 26 without using the movable roller die 25 as the second support mechanism 15. It is explanatory drawing which shows typically the elongate chuck
- Each of the chucks 30 to 32 is formed of a cylindrical body for gripping the distal end portion of the steel pipe 17.
- the chuck 30 is disposed outside the steel pipe 17.
- the chuck 30 grips the distal end portion of the steel pipe 17 by contacting the outer surface 17b of the steel pipe 17.
- the chuck 30 is configured such that its inner diameter can be reduced by an appropriate mechanism described later.
- the chuck 31 and the chuck 32 are both inserted into the steel pipe 17.
- the chucks 31 and 32 hold the tip of the steel pipe 17 by contacting the inner surface of the steel pipe 17.
- the chucks 31 and 32 are configured such that their outer diameters can be expanded by an appropriate mechanism described later.
- Each of the chucks 30 to 32 appropriately hold the tip of the steel pipe 17 fed in the axial direction. For this reason, the bending apparatus 10 bends the steel pipe 17 with sufficient processing accuracy.
- Each of the chucks 30 to 32 has a tube end seal mechanism that contacts a seal surface formed on the tube end portion, or an inner surface seal mechanism that contacts a seal surface formed on the inner surface of the tube. Accordingly, the chucks 30 to 32 seal the steel pipe 17 by directly contacting the pipe end portion or the pipe inner surface of the steel pipe 17.
- the chucks 30 to 32 prevent water from entering the inside of the steel pipe 17, so that the steel pipe 17 is appropriately heated by the high-frequency heating coil 13a. For this reason, the bending apparatus 10 bends the steel pipe 17 with sufficient processing accuracy.
- the chuck 30 is composed of a long cylindrical body. For this reason, the bending load W is suppressed to be small, and the second industrial robot 26 is prevented from interfering with surrounding devices even when the bending process is started from the vicinity of the distal end portion of the steel pipe 17. .
- the chuck 31 is composed of a short cylindrical body.
- the steel pipe 17 is quenched from the pipe end portion of the steel pipe 17 and the product yield is improved.
- the chuck 32 is constituted by a long cylindrical body, the bending load W is suppressed to be small.
- the second industrial robot 26 is prevented from interfering with surrounding devices even when bending is started from the vicinity of the tip of the steel pipe 17, and the steel pipe 17 is quenched from the pipe end. Product yield is improved.
- FIG. 4 is an explanatory diagram showing that the chucks 30 and 32 can reduce the bending load W.
- the symbol W indicates the bending load
- the symbol M indicates the moment required for bending the steel pipe 17
- the symbol l 1 indicates the chuck length
- the symbol l 2 indicates the chuck margin
- the symbol l 3 indicates the steel pipe. The distance from the edge part of 17 to the starting point of a bending process is shown.
- L the longer L is, the smaller W can be.
- the allowable load of the bending machine is limited, it is possible to shorten l 3 by increasing l 1 .
- the moment required when bending a steel pipe having an outer diameter of 25 mm and a wall thickness of 1.0 mm under the condition of a curvature radius of 200 mm is about 36 N ⁇ m.
- the allowable bending load is 500 N
- W 1440N> 500N
- W 720N> 500N.
- FIG. 5 (a) is an explanatory view showing an extracted type of chuck 33 that grips the tip of the steel pipe by being placed outside the steel pipe and abutting against the outer surface of the steel pipe. It is explanatory drawing which extracts and shows the type
- FIG. 5C is an explanatory view showing various chucks 35 to 43.
- the chucks 35 and 36 are disposed outside the steel pipe and abut on the outer surface of the steel pipe.
- the chucks 37 and 38 are inserted into the steel pipe and abut against the inner surface of the steel pipe.
- the chucks 39 and 40 are disposed outside the steel pipe so as to contact the outer surface of the steel pipe, and are also inserted into the steel pipe so as to contact the inner surface of the steel pipe.
- the chucks 41 to 43 are all square tube chucks. Even in the case of a square tube, in order to obtain a sufficient holding force and securely hold the square tube, the chucks 41 to 43 are inserted into the steel pipe so as to contact the inner surface of the steel pipe and to the inner corner of the square pipe. It is desirable to abut.
- the chuck includes the first support device 12, the heating device 13, the cooling device 14, and the first one. This is desirable in order to reliably pass through the two support devices 15.
- FIG. 6 is an explanatory view schematically showing an example of the chuck 44 used in the third industrial robot 28 in FIG.
- Reference numeral 45 in FIG. 6 indicates a cylinder.
- the chuck 44 is a long chuck having an outer diameter that is approximately the same as the outer diameter of the steel pipe 17. It is desirable.
- FIG. 7 is an explanatory view schematically showing an example of the chuck 46 used in the feeder mechanism in FIG.
- Reference numeral 47 in FIG. 7 denotes a support guide.
- a long chuck 46 having an outer diameter that substantially matches the outer diameter of the steel pipe 17 is used. Is desirable.
- the chuck 48 includes a shaft 51 disposed in a cylindrical main body 50 so as to be freely pulled out by a cylinder (not shown) and the like, and an opening / closing bar 52 disposed at the tip of the shaft 51, for example.
- Four chuck claws 53 are positioned on the oblique side of the opening / closing bar 52 so as to be positioned in the axial direction of the main body 50.
- the chuck claw 53 moves in the radial direction, thereby increasing or decreasing the outer method of the chuck 48.
- the chuck 49 includes a shaft 51 disposed in a cylindrical main body 50 so as to be freely drawn and pulled out by a cylinder (not shown), and a conical bar 54 disposed at the tip of the shaft 51.
- a large number of segments 55 and elastic body claws 56 are arranged on the hypotenuse of the conical bar 54.
- the segment 55 moves in the radial direction, thereby increasing or decreasing the outer method of the chuck 49.
- the chuck 48-1 is a modification of the chuck 48, and the open / close bar 52 has a tapered shape. Since the tapered opening / closing bar 52 can increase the cross-sectional area of the joint portion with the shaft 51, the strength of the opening / closing bar 52 is increased.
- the chuck pawl 53 desirably has a dovetail groove extending in the axial direction of the main body 50 in order to reliably perform unclamping.
- the material of the chuck claws 53 and the open / close bar 52 include austenitic stainless steel or tool steel.
- Austenitic stainless steel is suitable because it is a non-magnetic material and is difficult to be induction-heated, but is slightly inferior in wear resistance (scratch resistance) and seizure resistance.
- tool steel is excellent in cold durability. Although the tool steel is a magnetic material and is easily affected by induction heating, there is no practical problem if it is not induction heated to the vicinity of the chuck claw 53.
- the main body 50 is preferably a non-magnetic material such as austenitic stainless steel.
- FIG. 9A is an explanatory view schematically showing a configuration example of a chuck 57 suitable for use in the bending apparatus 10 of the present invention
- FIG. 9B shows a chuck 58 of a comparative example
- 9 (c) shows the chuck 57 of the present invention example.
- the chuck 58 includes constituent members 57 a and 57 b and an insulating member 59.
- the structural members 57a and 57b are divided into a plurality (two in the illustrated example) in the circumferential direction.
- the insulating member 59 is disposed between two constituent members 57a and 57b disposed adjacent to each other.
- the insulating member 59 is made of, for example, polytetrafluoroethylene.
- FIG. 10 is an explanatory diagram showing a configuration of a sleeve-type chuck 60 with a slit, which is suitable for use in the bending apparatus of the present invention.
- the chuck 60 has a shaft 51 disposed in a cylindrical main body 50 so as to be freely pulled out by a cylinder (not shown), and an opening / closing bar 52 disposed at the tip of the shaft 51.
- a sleeve 61 having a slit 62 and a seal ring 63 are positioned and arranged in the axial direction of the main body 50.
- the sleeve 61 with the slit is elastically deformed by the shaft 51 moving in the axial direction of the main body 50 and is expanded or contracted. Thereby, the outer method of the chuck 60 is increased or decreased.
- the sleeve 61 Since the sleeve 61 has a plurality of slits 62, even if it is made of metal, it can be elastically deformed with a small force and is not easily heated by induction heating. Note that the sleeve 61 is sufficiently prevented from being induction-heated only by the sleeve 61 being made of a non-magnetic material.
- the slit 62 is desirably provided when the strength of the sleeve 61 is sufficiently secured.
- FIG. 11A is an explanatory view showing a configuration of a hydraulic sleeve-type chuck 70 suitable for use in the bending apparatus of the present invention
- FIG. 11B shows a modified example 70-1. It is explanatory drawing shown.
- a flow path 72 of the high-pressure liquid 71 generated using a high-pressure pump (not shown) is formed inside the chuck 70.
- a sleeve 73 made of an elastic body is provided on the outer periphery of the tip of the main body of the chuck 70.
- the sleeve 73 is bulged and deformed by flowing the high-pressure liquid 71 through the flow path 72. Since the chuck 70 can reduce the outer diameter of the tip of the main body, it can also be used for a small-diameter inner diameter chuck.
- the sleeve 73 is preferably made of a heat resistant metal.
- the cylinder 74 In the chuck 70-1, the cylinder 74 generates the high-pressure liquid 71.
- cross-sectional area A 1 of the operation of the cylinder 74 is larger than the cross-sectional area A 2 of the flow path 72, the pressure P 2 of the passage 72, even when the working pressure P 1 of the cylinder 74 is small, increased.
- FIG. 12 is an explanatory view showing a mechanism for making the inside of the steel pipe 17 positive pressure. If the material of the seal member at the pipe end of the steel pipe 17 is a soft material such as rubber, the durability of the seal member may be insufficient. Moreover, when the material of the seal member is a metal material, water may not be able to be prevented from entering the inside of the steel pipe 17.
- a feed side chuck 76 having a flow path 75 for supplying compressed air or compressed inert gas built in an open / close bar is used as a mechanism for setting the inside of the steel pipe 17 to a positive pressure. It is desirable to use a mechanism in which compressed air or compressed inert gas is supplied into the steel pipe 17 and compressed air or compressed inert gas is ejected from the side where the outlet side chuck 77 is disposed. Thereby, since the inside of the steel pipe 17 is maintained at a positive pressure, it is possible to completely prevent the cooling water from the cooling device 14 from entering the inside of the steel pipe 17.
- an inert gas such as nitrogen gas
- the chuck described above for example, when gripping the inner surface of a workpiece having a polygonal cross-sectional shape such as a quadrangle or an irregular cross-sectional shape having corners, By gripping the chuck so that the chuck comes into contact with each corner of the peripheral surface, the gripping force can be increased, and the core of the workpiece can be reliably put out.
- the cycle time of the bending apparatus 10 is reduced and the productivity is improved. Both are planned.
- the first support mechanism 12 is fixedly arranged at the first position A.
- the first support mechanism 12 supports the steel pipe 17 while feeding it.
- the first support mechanism 12 is configured by a die, like the bending apparatus 0.
- the die has at least one pair of roll pairs 12a and 12a that can be supported while feeding the steel pipe 17 (in the illustrated example, another pair of roll pairs 12b and 12b is provided, for a total of two pairs).
- Such dies are well known to those skilled in the art, and thus the description of the first support mechanism 12 is omitted.
- the first support mechanism 12 is configured as described above.
- Heating mechanism 13 The heating mechanism 13 is supported and arranged by the heating coil support robot 27 at a second position B downstream of the first position A in the feed direction of the steel pipe 17. The heating mechanism 13 heats part or all of the steel pipe 17 to be sent.
- An induction heating apparatus having a heating coil 13 a arranged away from the periphery of the steel pipe 17 is used as the heating mechanism 13. Since the heating coil 13a is well-known and commonly used by those skilled in the art, a description of the heating mechanism 13 is omitted.
- the cooling mechanism 14 is fixedly arranged at a third position C downstream of the second position B in the feed direction of the steel pipe 17.
- the cooling mechanism 14 forms a high-temperature part in a part of the steel pipe 17 by cooling the part heated by the heating mechanism 13 in the steel pipe 17 to be sent.
- the cooling mechanism 14 uses, for example, a water cooling device.
- the water cooling apparatus has cooling water injection nozzles 14 a and 14 b that are arranged apart from the outer surface of the steel pipe 17.
- Such cooling water injection nozzles 14a and 14b are well known and commonly used by those skilled in the art, and thus description of the cooling mechanism 14 is omitted.
- the second support mechanism 15 is disposed at a fourth position D downstream of the third position C in the feed direction of the steel pipe 17.
- the second support mechanism 15 moves in a two-dimensional or three-dimensional direction while supporting at least one portion of the steel pipe 17 to be fed, so that a high-temperature portion between positions B to C (heated and deformed resistance) in the steel pipe 17 is supported. A bending moment is applied to the portion where the steel pipe 17 is greatly reduced, and the steel pipe 17 is bent into a desired shape.
- the second support mechanism 15 is a movable roller die 25 as in the bending device 0.
- the movable roller die 25 has at least one set of roll pairs 25 a and 25 b that can be supported while feeding the steel pipe 17.
- an effector such as a gripper held by the second industrial robot 26 may be used as the second support mechanism 15, and the steel pipe 17 may be directly held by this effector. .
- the movable roller die 25 is supported by the second industrial robot 26.
- the second industrial robot 26 is a so-called vertical articulated robot, has first to sixth axes, and has a seventh as necessary. You may have an axis.
- the first to seventh axes are driven by an AC servo motor.
- a gripper 26 a is provided at the tip of the wrist 20 a of the second industrial robot 26 as an effector (end effector) for holding the movable roller die 25.
- the effector may be of a type other than the gripper 26a.
- the deformation prevention mechanism 16 is disposed at a fifth position E downstream of the fourth position D in the feed direction of the steel pipe 17. The deformation prevention mechanism 16 prevents deformation of the steel pipe 17 to be sent.
- the third industrial robot 28 is used as the deformation prevention mechanism 16. Similar to the first industrial robot 18 and the second industrial robot 26 described above, the third industrial robot 28 is a so-called vertical articulated robot having first to sixth axes, and if necessary. And may have a seventh axis. The first to seventh axes are driven by an AC servo motor.
- the various chucks described with reference to FIGS. 3 to 11 are provided at the tip of the wrist 20a of the third industrial robot 28 as an effector (end effector) for holding the tip 17a of the steel pipe 17. Used.
- the term “warm” means a heating temperature range in which the deformation resistance of the metal material is lower than that at room temperature.
- a certain metal material has a temperature range of about 500 ° C. to 800 ° C.
- “Hot” means a heating temperature range in which the deformation resistance of the metal material is lower than that at room temperature and the metal material is required to be quenched.
- the temperature range is 870 ° C. or higher. is there.
- the quenching process can be performed by cooling at a predetermined cooling rate after reaching a predetermined temperature for quenching. Therefore, it is possible to prevent the occurrence of processing distortion such as thermal distortion.
- the bending apparatus 10 is configured as described above. Since at least one of the feed mechanism 11 and the deformation prevention mechanism 16 has a cylindrical chuck capable of gripping the steel pipe 17, the effects listed below are exhibited.
- the feed mechanism 11 can appropriately hold the front end and the rear end of the steel pipe 17, and can perform bending with sufficient processing accuracy.
- the feed mechanism 11 can prevent oxidation inside the steel pipe 1 exposed to the atmosphere in a high temperature state.
- the steel pipe 17 to be bent can sequentially pass through the support mechanism 12, the high-frequency heating coil 13a, and the water cooling mechanism 14, and the bending process can be reliably performed.
- the chuck for gripping the steel pipe 17 is prevented from being induction-heated by the high-frequency heating coil 13a, and the steel pipe 17 can be reliably held from the start to the end of the bending process. Is sufficiently enhanced.
Abstract
Description
図13に示すように、曲げ加工装置0は、支持手段2によりその軸方向へ移動自在に支持された素材である鋼管1を上流側から下流側へ向けて、例えばボールネジを用いた送り装置3により送りながら、(a)支持手段2の下流で高周波加熱コイル5により鋼管1を部分的に焼入れが可能な温度域に急速に加熱し、(b)高周波加熱コイル5の下流に配置される水冷装置6により鋼管1を急冷し、かつ(c)鋼管1を送りながら支持可能であるロール対4aを少なくとも一組有する可動ローラーダイス4の位置を二次元又は三次元で変更して鋼管1の加熱された部分に曲げモーメントを付与して曲げ加工を行うことによって、曲げ部材8を、十分な曲げ加工精度を確保しながら高い作業能率で、製造する。
(a)曲げ部材8が充分な寸法精度を有さないこと。
(e)鋼管1の保持部が高周波加熱コイル5により変形可能な温度に加熱され、これにより、曲げ部材8の寸法精度が低下すること。
(i)曲げ加工装置0の送り装置3や、鋼管1の送り方向に関して可動ローラーダイス4の下流に配置される変形防止装置等が、鋼管1の内部または外部に配置されて鋼管1を把持する筒状のチャックを有すること、および
(ii)このチャックの形状や構造、さらには機能を最適化すること
によって上記課題(a)~(e)を解決できるという知見に基づく。
加熱機構;金属材の送り方向について第1の位置よりも下流の第2の位置に配置されるとともに、送られる金属材の一部または全部を加熱すること。
チャック;円形、多角形または異形形状の横断面を有する筒状体を有し、金属材を把持すること。
本発明では、チャックが、金属材の外部に設置されて金属材の外面に当接することが望ましく、筒状体の内法が縮小自在であることが望ましい。
本発明では、筒状体が、高硬度材料からなるチャック爪および開閉バーを有することが望ましい。
本発明では、筒状体が非磁性を有することが望ましい。具体的には、筒状体が例えばセラミックス、SUS304等のオーステナイト系ステンレス鋼、さらにはニッケル合金からなることが、望ましい。
1 鋼管
2 支持手段
3 送り装置
4 可動ローラーダイス
4a ロール対
5 高周波加熱コイル
6 水冷装置
8 曲げ部材
10 本発明に係る曲げ加工装置
11 送り手段
12 第1の支持手段
12a、12a ロール対
13 加熱手段
13a 加熱コイル
14 冷却手段
14a、14b 冷却水噴射ノズル
15 第2の支持手段
16 変形防止手段
17 鋼管
17a 先端部
18 第1の産業用ロボット
19 上腕
20 前腕
20a 手首
21 コントローラー
22 入力装置
23 パレット
24 効果器(エンドエフェクタ)
25 可動ローラーダイス
25a、25b ロール対
26 第2の産業用ロボット
26a グリッパー
27 高周波コイル支持ロボット
28 第3の産業用ロボット
29 グリッパー
30~44、46、48、49、57、58 チャック
45 シリンダ
47 支持ガイド
50 本体
51 シャフト
52 開閉バー
53 チャック爪
54 円錐バー
55 セグメント
56 弾性体爪
57a、57b 構成部材
59 絶縁部材
60 チャック
61 スリーブ
62 スリット
63 シールリング
70、70-1 チャック
71 高圧液体
72 流路
73 スリーブ
74 シリンダ
[送り機構11]
送り機構11は、鋼管17をその長手方向へ送る。送り機構11は第1の産業用ロボット18により構成される。
図2は、第1の産業用ロボット18、第2の産業用ロボット26、加熱コイル支持ロボット27または第3の産業用ロボット28の構成例を示す説明図である。
各ロボットは、他の汎用の産業用ロボットと同様に、いずれも、第1~6軸の動作を総合的に制御するコントローラー21と、第1~6軸の動作を教示するための入力装置22とを有する。
以降の説明では、第2の支持機構15として可動ローラーダイス25を用いずに第2の産業用ロボット26によって鋼管17を直接掴持する場合における効果器を例にとる。送り機構11における効果器24や変形防止機構16における効果器29であっても事情は同じである。
チャック30は、鋼管17の外部に配置される。チャック30は、鋼管17の外面17bに当接することによって鋼管17の先端部を把持する。チャック30は、その内径が後述する適宜機構によって縮小自在に構成される。
チャック30~32は、いずれも、管端部に形成されるシール面に接触する管端シール機構、または管内面に形成されるシール面に接触する内面シール機構を有する。これにより、チャック30~32は、鋼管17の管端部または管内面に直接当接することによって鋼管17を封止する。チャック30~32は、鋼管17の内部への水の侵入を防止するので、高周波加熱コイル13aによる鋼管17の昇温が適正に行われる。このため、曲げ加工装置10は、十分な加工精度で鋼管17に曲げ加工を行う。
さらに、チャック32は、長尺の筒状体により構成されるので、曲げ荷重Wが小さく抑制される。第2の産業用ロボット26が周囲の装置と干渉することが、鋼管17の先端部の近傍から曲げ加工を開始する場合にも防止されるとともに、鋼管17の焼入れが管端部から行われ、製品の歩留りが向上する。
図4中の符号Wは曲げ荷重を示し、符号Mは鋼管17の曲げに必要なモーメントを示し、符号l1はチャック長さを示し、符号l2はチャック代を示し、符号l3は鋼管17の端部から曲げ加工の開始点までの距離を示す。
曲げ許容荷重が500Nであると、
L=dの場合にはW=1440N>500Nとなり、またL=2dの場合にはW=720N>500Nとなるため、いずれの場合にも曲げ加工を行うことができない。これに対し、L=3dの場合にはW=480N>500Nとなり、L=4dの場合にはW=360N>500Nとなり、さらに、L=5dの場合にはW=288N>500Nとなるので、いずれの場合にも曲げ加工を行うことができる。
図5(a)は、鋼管の外部に配置されて鋼管の外面に当接することによって鋼管の先端部を把持する型式のチャック33を抽出して示す説明図であり、図5(b)は、鋼管の内部に挿設されて鋼管の内面に当接することによって鋼管の先端部を把持する型式のチャック34を抽出して示す説明図である。
図5(c)は、各種のチャック35~43を示す説明図である。
チャック37、38は、鋼管の内部に挿設されて鋼管の内面に当接する。
チャック39、40は、鋼管の外部に配置されて鋼管の外面に当接するとともに鋼管の内部にも挿設されて鋼管の内面に当接する。
図6に示すように、鋼管17がその前端部の近傍から焼入れながら曲げ加工される場合には、チャック44が鋼管17の外径と略一致する寸法の外径を有する長尺のチャックであることが望ましい。
図7に示すように、鋼管17がその後端部の近傍まで焼入れながら曲げ加工を行われる場合にも、鋼管17の外径と略一致する寸法の外径を有する長尺のチャック46を用いることが望ましい。
チャック爪53、開閉バー52の材質は、オーステナイト系ステンレス鋼または工具鋼が例示される。オーステナイト系ステンレス鋼は、非磁性体であるので誘導加熱され難いため好適であるが、耐摩耗性(耐傷付き性)および耐焼き付き性が若干劣る。一方、工具鋼は、冷間での耐久性に優れる。工具鋼は、磁性体であり、誘導加熱の影響を受け易いものの、チャック爪53の近傍まで誘導加熱しなければ、実用上問題ない。なお、本体50は、オーステナイト系ステンレス鋼等の非磁性体であることが望ましい。
チャック60は、その円筒状の本体50の内部に、図示しないシリンダ等によって出し引き自在に配置されたシャフト51と、シャフト51の先端に配置された例えば開閉バー52とを有する。開閉バー52の斜辺には、スリット62を有するスリーブ61と、シールリング63とが、本体50の軸方向について位置決めされて配置される。スリット付きのスリーブ61が、シャフト51が本体50の軸方向へ移動することによって弾性変形し、拡径または縮径する。これにより、チャック60の外法が増加または減少する。
なお、スリーブ61が非磁性体により構成されるだけでも、スリーブ61が誘導加熱されることが充分に防止される。スリット62は、スリーブ61の強度が充分に確保される場合に設けることが望ましい。
鋼管17の管端のシール部材の材質が例えばゴムのような軟材質であると、シール部材の耐久性が不足する場合がある。また、シール部材の材質が金属材料であると、鋼管17の内部への水の侵入を防止できない場合がある。
以上説明したチャックは、例えば四角形等の多角形の横断面形状を有する被加工材や角部を有する異形の横断面形状を有する被加工材の内面を把持する場合には、被加工材の内周面の各角部にチャックが当接するようにして把持することにより、把持力を高めることができるとともに、被加工材の芯を確実に出すことができる。
第1の支持機構12は、第1の位置Aに固定して配置される。第1の支持機構12は、鋼管17を送りながら支持する。第1の支持機構12は、曲げ加工装置0と同様に、ダイスにより構成される。ダイスは、鋼管17を送りながら支持可能であるロール対12a、12aを少なくとも一組(図示例ではロール対12b、12bをもう一組有し、合計二組)有する。このようなダイスは、当業者にとっては周知慣用であるので、第1の支持機構12に関する説明は省略する。
[加熱機構13]
加熱機構13は、鋼管17の送り方向について第1の位置Aよりも下流の第2の位置Bに、加熱コイル支持ロボット27により支持されて配置される。加熱機構13は、送られる鋼管17の一部または全部を加熱する。
冷却機構14は、鋼管17の送り方向について第2の位置Bよりも下流の第3の位置Cに固定して配置される。冷却機構14は、送られる鋼管17における加熱機構13により加熱された部分を冷却することによって、鋼管17の一部に高温部分を形成する。
第2の支持機構15は、鋼管17の送り方向について第3の位置Cよりも下流の第4の位置Dに配置される。第2の支持機構15は、送られる鋼管17の少なくとも一箇所を支持しながら二次元または三次元の方向へ移動することによって、鋼管17における位置B~C間の高温部分(加熱されて変形抵抗が大幅に低下した部分)に曲げモーメントを与え、鋼管17を所望の形状に曲げ加工する。
また、第2の産業用ロボット26は、上述した第1の産業用ロボット18と同様に、いずれも、いわゆる垂直多関節ロボットであり、第1~6軸を有し、必要に応じて第7軸を有してもよい。第1~7軸はACサーボモーターにより駆動される。
変形防止機構16は、鋼管17の送り方向について第4の位置Dよりも下流の第5の位置Eに配置される。変形防止機構16は、送られる鋼管17の変形を防止する。
第3の産業用ロボット28は、上述した第1の産業用ロボット18や第2の産業用ロボット26と同様に、いわゆる垂直多関節ロボットであり、第1~6軸を有し、必要に応じて第7軸を有してもよい。第1~7軸はACサーボモーターにより駆動される。
送り機構11および変形防止機構16の少なくとも一方が、鋼管17を把持することができる筒状のチャックを有するので、以下に列記する効果が奏される。
(b)送り機構11は、高温状態で大気に曝された鋼管1の内部の酸化を防止できる。
(d)鋼管17の内部への水の侵入が防止され、高周波加熱コイル13aによる鋼管17の加熱が目標通りに行われるため、曲げ加工精度が十分に高められる。
(f)鋼管17を把持するチャックが高周波加熱コイル13aにより誘導加熱されることが防止され、曲げ加工の開始から終了までの間で鋼管17の確実に保持し続けることができるので、曲げ加工精度が充分に高められる。
Claims (16)
- 下記第1の支持機構、加熱機構、冷却機構、第2の支持機構および変形防止機構を備えるとともに、前記第2の支持機構および/または前記変形防止機構のうちの少なくとも一つは、下記チャックを有することを特徴とする曲げ加工装置:
第1の支持機構:第1の位置に配置されるとともに、中空の金属材を送りながら支持すること、
加熱機構;前記金属材の送り方向について前記第1の位置よりも下流の第2の位置に配置されるとともに、送られる前記金属材の一部または全部を加熱すること、
冷却機構;前記金属材の送り方向について前記第2の位置よりも下流の第3の位置に配置されるとともに、送られる前記金属材における前記加熱機構により加熱された部分を冷却することによって前記金属材の一部に高温部分を形成すること、
第2の支持機構;前記金属材の送り方向について前記第3の位置よりも下流の第4の位置に配置されるとともに、送られる前記金属材の少なくとも一箇所を支持しながら二次元または三次元の方向へ移動することによって前記高温部分に曲げモーメントを与え、前記金属材を所望の形状に曲げ加工すること、
変形防止機構;前記金属材の送り方向について前記第4の位置よりも下流の第5の位置に配置されるとともに、送られる前記金属材の変形を防止すること、および
チャック;円形、多角形または異形形状の横断面を有する筒状体を有し、前記金属材を把持すること。 - さらに、前記金属材をその長手方向へ送る送り機構を備える請求項1に記載された曲げ加工装置。
- 前記送り機構は前記チャックを有する請求項2に記載された曲げ加工装置。
- 前記第1の支持機構は、前記金属材をその長手方向へ送る請求項1に記載された曲げ加工装置。
- 前記チャックは、前記金属材の内部に挿設されて該金属材の内面に当接する請求項1に記載された曲げ加工装置。
- 前記筒状体の外法は拡大自在である請求項1に記載された曲げ加工装置。
- 前記チャックは、前記金属材の外部に設置されて該金属材の外面に当接する請求項1に記載された曲げ加工装置。
- 前記筒状体の内法は縮小自在である請求項1に記載された曲げ加工装置。
- 前記チャックは、前記金属材の内部を封止する請求項1に記載された曲げ加工装置。
- 前記チャックは、前記金属材の内部を正圧にする請求項1に記載された曲げ加工装置。
- 前記筒状体は、その中心軸が前記金属材の中心軸と略一致するように、設置される請求項1に記載された曲げ加工装置。
- 前記筒状体は、前記金属材の外法と略一致する外法を有する請求項1に記載された曲げ加工装置。
- 前記筒状体は、高硬度材料からなるチャック爪および開閉バーを有する請求項1に記載された曲げ加工装置。
- 前記筒状体は、周方向に分割された複数の構成部材と、隣り合って配置される二つの構成部材の間に配置される絶縁部材とを有する請求項1に記載された曲げ加工装置。
- 前記筒状体は非磁性を有する請求項1に記載された曲げ加工装置。
- 前記筒状体は積層構造を有する請求項1に記載された曲げ加工装置。
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