Profile straightening apparatus for a profiling system

Abstract

A profile straightening apparatus 5 for a profiling system which is used to produce a metal profile 4 by roll profiling along a longitudinal axis of the metal profile. The profile straightening apparatus is intended for correcting axial deviations of the metal profile from a prescribed profile geometry, and includes a frame 8 and having at least two interacting correction rollers 6, 7, which are mounted in the frame, receive the metal profile between them and, in relation to the longitudinal axis of the metal profile, are adjustable in two radial directions and also in at least one direction of rotation. The profile straightening apparatus is equipped with force measuring sensors for any forces F.sub.y, F.sub.z acting in the metal profile in one or both radial directions and for any torques M.sub.x acting in the metal profile in a direction of rotation about the longitudinal axis.

Claims

1. A method for correcting axial deviations of a metal profile (4) from a prescribed profile geometry in a profiling system which is used to produce the metal profile (4) by roll profiling along a longitudinal axis (9) of the metal profile (4), using a profile straightening apparatus (5) including at least two interacting correction rollers (6, 7) mounted to a frame (8), the at least two interacting correction rollers (6, 7) being adjustable in at least two radial directions and also in at least one direction of rotation, and force measuring sensors adapted to detect forces (Fy, Fz) acting on the metal profile (4) in the radial directions and for any torques (Mx) acting on the metal profile (4) in a direction of rotation about the longitudinal axis (9), the method comprising: moving the metal profile (4) into the profile straightening apparatus (5), which is integrated in the profiling system or is connected downstream thereof, ascertaining, before the metal profile (4) reaches a downstream machining station, at least one of any radial forces (Fy, Fz) acting on the metal profile (4) in the profile straightening apparatus (5) or any torques (Mx) using the force measuring sensors, and calculating adjustment values for an adjustment of the correction rollers (6, 7) in at least one of the radial directions or the direction of rotation from the at least one of the radial forces or torques to be used for the correction rollers (6, 7) in order to correct axial deviations of the metal profile (4) from the prescribed profile geometry.

2. A method for correcting axial deviations of a metal profile (4) from a prescribed profile geometry in a profiling system which is used to produce the metal profile (4) by roll profiling along a longitudinal axis (9) of the metal profile (4), using a profile straightening apparatus (5) including at least two interacting correction rollers (6, 7) mounted to a frame (8), the at least two interacting correction rollers (6, 7) being adjustable in at least two radial directions and also in at least one direction of rotation, and force measuring sensors adapted to detect forces (Fy, Fz) acting on the metal profile (4) in the radial directions and for any torques (Mx) acting on the metal profile (4) in a direction of rotation about the longitudinal axis (9), the method comprising: ascertaining at least one of any radial forces (Fy, Fz) acting on the metal profile (4) in the profile straightening apparatus (5) or any torques (Mx) using the force measuring sensors, inputting at least one of the ascertained forces (Fy, Fz) or torques (Mx) into a controller (10), the controller (10) calculating adjustment values therefrom for an adjustment of the correction rollers (6, 7) in at least one of the radial directions or the direction of rotation, and outputting the adjustment values as recommended actions for adjustment of the correction rollers (6, 7).

3. The method according to claim 2, wherein the force measuring sensors input the at least one of the ascertained forces (Fy, Fz) or the torques (Mx) into the controller (10), the controller (10) calculates the adjustment values therefrom for the adjustment of the correction rollers (6, 7) in at least one of the radial directions or in the direction of rotation and actuates adjustment drives of the profile straightening apparatus in order to adjust the correction rollers (6, 7) in accordance with the adjustment values.

4. The method according to claim 3, wherein the metal profile (4) is moved into the profile straightening apparatus (5), which is integrated in the profiling system or is connected downstream thereof, and, before the metal profile (4) reaches a machining station arranged downstream of the profile straightening apparatus (5), the at least one of any radial forces (Fy, Fz) acting on the metal profile (4) in the profile straightening apparatus (5) or the any torques (Mx) are ascertained by the force measuring sensors, and the adjustment values for the adjustment of the correction rollers (6, 7) in at least one of the radial directions or the direction of rotation are calculated therefrom, to be used for the correction rollers (6, 7) to be adjusted in order to correct axial deviations of the metal profile (4) from the prescribed profile geometry.

5. The method according to claim 3, wherein the profile straightening apparatus (5) includes a measuring station (16) arranged downstream of the correction rollers (6, 7) with respect to the direction of movement of the metal profile (4), the measuring station being configured for geometric measurement of the metal profile (4) and being operatively connected to the controller (10), and the method includes checking the calculated adjustment value based on geometric measurement data of the measuring station (16) and upon detecting deviations providing corresponding correction values for calculation the adjustment values.

6. The method according to claim 2, wherein the adjustment values are output as recommended actions for operating personnel to adjust the correction rollers (6, 7) through manual adjustment.

7. The method according to claim 2, further comprising outputting an alarm signal, from an alarm of the profile straightening apparatus, if a magnitude of the forces (F.sub.y, F.sub.z) or torques (M.sub.x) ascertained by the force measuring sensors change beyond a prescribed threshold value.

8. The method according to claim 3, further comprising adjusting the correction rollers (6, 7) using motorized adjustment drives (11.sub.x, 11.sub.y, 11.sub.z) of the profile straightening apparatus, wherein the adjustment drives (11.sub.x, 11.sub.y, 11.sub.z) are operatively connected to the controller (10) which is operatively connected to the force measuring sensors.

9. The method according to claim 2, wherein the correction rollers (6, 7) are adjustable while maintaining positions thereof assumed relative to one another.

10. The method according to claim 2, wherein the correction rollers (6, 7) are adjustable in two radial directions orthogonal to each other, and also in the direction of rotation.

11. The method according to claim 2, further comprising guiding the metal profile (4) through the frame (8) using guide rollers mounted in the frame (8), the guide rollers being mounted at least one of upstream or downstream of the correction rollers (6, 7) in relation to a direction of movement of the metal profile (4).

12. The method according to claim 11, wherein the force measuring sensors are at least partially arranged in a region of the guide rollers.

13. The method according to claim 2, wherein the force measuring sensors are at least partially arranged on at least one of the correction rollers (6, 7), axles (12) of the correction rollers, bearings of the correction rollers in the frame (8), or on an adjustment mechanism for the correction rollers (6, 7).

14. The method according to claim 8, wherein the profile straightening apparatus (5) includes a measuring station (16) arranged downstream of the correction rollers (6, 7) with respect to the direction of movement of the metal profile (4), the measuring station being configured for geometric measurement of the metal profile (4) and being operatively connected to the controller (10), and the method includes checking the calculated adjustment value based on geometric measurement data of the measuring station (16) and upon detecting deviations providing corresponding correction values for calculation of the adjustment values.

15. The method according to claim 14, further comprising combining, by the controller (10), the geometric measurement data obtained by the measuring station (16) with magnitudes of at least one of the forces (F.sub.y, F.sub.z) or the torques (M.sub.x) ascertained by the force measuring sensors in order to identify relationships between the ascertained magnitudes of the forces (F.sub.y, F.sub.z) and torques (M.sub.x) and the geometric measurement data of a same profile portion, and also relationships between changes in the ascertained magnitudes of the forces (F.sub.y, F.sub.z) and the torques (M.sub.x) and changes in the geometric measurement data of the same profile portion, and utilizing said relationships for control of the adjustment drives (11.sub.x, 11.sub.y, 11.sub.z).

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) One exemplary embodiment of a profile straightening apparatus configured according to the invention and the correction method carried out therewith is described and explained in greater detail below with reference to the attached drawings, in which:

(2) FIG. 1 shows one exemplary embodiment of a profile straightening apparatus configured according to the invention in the installed state in a profiling system;

(3) FIG. 2 shows an enlarged and lateral view of the removed profile straightening apparatus from FIG. 1;

(4) FIG. 3 shows the profile straightening apparatus from FIG. 2 in a view rotated through 90° about the horizontal axis;

(5) FIG. 4 shows a second exemplary embodiment of a profile straightening apparatus installed in a profiling system.

DETAILED DESCRIPTION

(6) FIG. 1 shows a schematic illustration of a detail from a profiling system with a multiplicity of forming stations 1 (of which only one is illustrated for reasons of better clarity) with roll forming tools 2, which are mounted in a framework 3 and which act on a metal profile 4 passing through—or at first a metal strip. A profile straightening apparatus 5 integrated in said profiling system is arranged directly downstream of the forming station 1 illustrated here and comprises a frame 8 with an upper 6 and a lower correction roller 7, said rollers receiving between them the metal profile 4 passing through the frame 8. As indicated by means of arrows F.sub.z, F.sub.y and M.sub.x, in the frame 8 of the profile straightening apparatus 5 there are arranged force measuring sensors (not directly visible) with which any forces and torques can be measured, specifically, in relation to a longitudinal axis 9 of the metal profile 4, radial forces, that is to say forces acting transversely with respect to the longitudinal axis 9, in the horizontal direction (F.sub.y) and in the vertical direction (F.sub.z) and also torques (M.sub.x) which act about the longitudinal axis 9. The force measuring sensors input the measurement values into a controller 10, which, for its part, actuates adjustment drives 11.sub.x, 11.sub.y and 11.sub.z which are symbolized here by hand cranks. By means of the adjustment drives 11.sub.x, 11.sub.y, 11.sub.z, the correction rollers 6, 7 can be adjusted, with their position assumed relative to one another remaining unchanged, in the vertical and/or horizontal direction transversely with respect to the longitudinal axis 9 of the metal profile 4, and/or in a direction of rotation about the longitudinal axis 9 of the metal profile 4.

(7) FIGS. 2 and 3 illustrate the profile straightening apparatus 5 from FIG. 1 as such in an enlarged view, specifically in a lateral view (FIG. 2) and in a front view (FIG. 3) as seen in the direction of the longitudinal axis 9 of the metal profile 4.

(8) The upper correction roller 6 and the lower correction roller 7 are configured in a profile-specific manner and therefore in the present case are only indicated by dash-dotted lines. In this way, correction roller axles 12 are visible, which are mounted with a mount 13 in the frame 8 in such a way that the relative position thereof to one another always remains constant. The adjustment drives 11 are symbolized by hand cranks, since the present invention is not limited to a motorized adjustment of the correction rollers, for example using a motor driven actuating screw. The adjustment drive 11.sub.z makes it possible to displace the mount 13 and thus the correction roller axles 12 collectively upward and downward; this is therefore a vertical adjustment. The adjustment drive 11.sub.y displaces the mount 13 or the correction roller axles 12 perpendicularly with respect to the longitudinal axis 9 of the metal profile 4 in a horizontal manner, and this is therefore a horizontal adjustment. With the adjustment drive 11.sub.x, the mount 13 of the correction roller axles 12 is finally rotated as a whole about the longitudinal axis 9 in a clockwise or counter-clockwise direction, as a result of which a torsional adjustment is made.

(9) By virtue of the fact that the profile straightening apparatus 5 is fixedly attached with fastening screws 14 to a substructure 15 (FIG. 1), and the metal profile 4 in the upstream forming station 1 is fixedly clamped in, a radial adjustment of the correction rollers 6, 7 by means of the vertical and/or horizontal adjustment drives 11.sub.z, 11.sub.y makes it possible to introduce an axially proceeding bend into the metal profile 4 in order to compensate for any stresses which are present in the material and which would lead to an opposing bend and thus to an axial deviation from the prescribed profile geometry. In a corresponding manner, the adjustment drive 11.sub.x makes possible, in a direction of rotation, a torsion of the metal profile 4 in relation to the zero position defined in the forming station 1, as a result of which any twists of the metal profile 4 or internal stresses, which would lead to such twists, can be corrected.

(10) FIG. 4 shows a second exemplary embodiment of a profile straightening apparatus 5 according to the invention, with this exemplary embodiment differing from the exemplary embodiment according to FIG. 1 only by a measuring station 16 for the geometric measurement of the metal profile 4, said station being arranged downstream of the profile straightening apparatus 5. The measuring station 16 is expediently arranged at the output of the profiling system and is only indicated here, since there are already corresponding measuring devices for measuring the straightness of a profile. As is also indicated in FIG. 4, the measurement data of the measuring station 16 are also input into the controller 10 and taken into account by said controller during actuation of the adjustment drives 11.

(11) The present exemplary embodiments are firstly intended to detect any forces F.sub.z, F.sub.y acting in the two directions orthogonal to the longitudinal axis 9 of the metal profile 4 (vertically and horizontally), and also any torques M.sub.x about the longitudinal axis 9, and to output a warning in the case of changes during ongoing operation, since such changes in the forces or torques may be indicative of undesired axial deviations of the metal profile 4 from the prescribed profile geometry. Secondly, the exemplary embodiments implement a preferred configuration of the present invention, according to which the correction rollers 6, 7 or their correction roller axles 12 are adjustable in a motorized manner by means of adjustment drives 11 and can preferably be used already during set-up operation of the profiling system. To this end, as is illustrated in particular with reference to FIG. 1, the metal profile 4 is moved into the profile straightening apparatus 5 and possibly stopped there before it reaches downstream a separating machine (not illustrated here) for separating profile pieces. For the sake of completeness, it should be mentioned at this point that further machining stations right through to a feed of a second metal strip, a welding station or a number of further forming stations could also be connected downstream of the profile straightening apparatus 5.

(12) By means of the force measuring sensors, it is then possible to ascertain any vertical and horizontal forces F.sub.z, F.sub.y, which are indicative of internal stresses which can lead to axial bowing. Said forces are expediently measured in the bearings of the correction roller axles 12, which are in line with the roll forming tools 2 of the forming station 1 which is last in the upstream direction. In a corresponding manner, a torque M.sub.x acting for instance on the correction rollers 6, 7 is also measured in the metal profile 4, said torque acting in a direction of rotation about the longitudinal axis 9 of the metal profile 4 and possibly leading to a torsion of the manufactured metal profile 4.

(13) Any measured forces F.sub.z, F.sub.y or torques M.sub.x are transmitted to the controller 10, in which a suitable algorithm is used to calculate from said measurement values how the correction rollers 6, 7 need to be adjusted vertically and/or horizontally and/or rotated about the longitudinal axis 9 of the metal profile 4 in order to neutralize the internal stresses acting in the metal profile 4 or counteract them such that undesired axial deviations from a prescribed profile geometry are corrected. The controller 10 uses the corresponding results to actuate the adjustment drives 11 of the profile straightening apparatus 5 and to adjust the correction rollers 6, 7 or their mount 13 correspondingly.

(14) Even if, during set-up operation of the profiling system, the profile straightening apparatus 5 is conventionally set by hand in order to manufacture profile pieces without axial deviations from the intended profile geometry, the motorized adjustability of the correction rollers 6, 7 improves the further operation of the profiling system. In this case, changes in the measured forces F.sub.y, F.sub.z or torques M.sub.x are transmitted to the controller 10, in which a suitable algorithm is used to calculate how the correction rollers 6, 7 need to be further adjusted vertically and/or horizontally and/or rotated about the longitudinal axis 9 of the metal profile 4 in order to neutralize the changed internal stresses acting in the metal profile 4 or counteract them such that undesired axial deviations from a prescribed profile geometry are corrected. The controller 10 uses the corresponding results to actuate the adjustment drives 11 of the profile straightening apparatus 5 and to adjust the correction rollers 6, 7 or their mount 13 correspondingly.

(15) In both exemplary embodiments, axial deviations of the metal profile 4 from the prescribed profile geometry are thus already corrected at the output of the forming station 1, with there being no dead time between the identification of causes for axial shape deviations and the correction of same; therefore no waste is produced.

(16) The modified exemplary embodiment according to FIG. 4 can optimize the method just described in that the profile geometry is measured downstream of the profile straightening apparatus 5 by means of the measuring station 16, which is merely indicated. Expediently, this happens at the very end of the profiling system, after the metal profile 4 has been separated into individual profile pieces. In this way, it is possible to identify, if, in spite of correction, axial deviations of the metal profile 4 from the prescribed profile geometry are still present, therefore the algorithm of the controller 10 has not led to the optimal correction result. The measurement values of the measuring station 16 are likewise fed back into the controller 10 and taken into account there by the algorithm, in that either the calculation is corrected in a case-specific manner or the algorithm is continually optimized.