Method for roll-forming disk carriers or the like and the associated profile roller set

Abstract

A method for roll-forming disk carriers or the like, which are designed as a pot-shaped sheet metal part having inner and outer teeth, wherein a multitude of cassettes is equidistantly arranged on the circumference of a roll-forming tool, said cassettes having profile rollers arranged in their interior, which roll out the disk carrier to be formed with their outer circumference and thus impart toothing on the disk carrier to be formed, wherein the forming depth of the profile rollers at the disk carrier to be formed is designed in such a way that a narrow, peripheral, self-contained, unformed bridge remains between the inner diameter and the outer diameter of the toothing, wherein the bridge increases the engine-speed strength of the disk carrier as a hoop band cylinder that is integrated into the toothing.

Claims

1. A method for roll-forming a disk carrier from a sheet metal part to form toothing having inner and outer teeth are created in the sheet metal part, the method comprising: arranging a plurality of cassettes spaced equidistantly from one another around a circumference of a roll-forming tool, each of said plurality of cassettes having an interior in which profile rollers are arranged, setting a forming depth of the profile rollers at a given position to create a narrow, peripheral, self-contained, unformed bridge that remains between an inner diameter and an outer diameter of the toothing of the disk carrier, said bridge defining a hoop band cylinder that is integrated into the toothing to increase engine-speed strength of the disk carrier, said hoop band cylinder having an axial length approximately equal to an axial length of the disk carrier, and rolling an outer circumference of the profile rollers relative to the sheet metal part to form the toothing and the hoop band cylinder on the disk carrier, wherein the toothing comprises an outer profile of the disk carrier which is formed by radially inward-facing profile sections, which steadily transition to radially outward-facing, profile sections, wherein the toothing comprises an inner profile of the disk carrier, the inner profile comprising radially inward-facing teeth, which steadily and repeatedly transition to teeth heads with larger diameters at equidistantly arranged locations around an entire circumference of the disk carrier, wherein the hoop band cylinder is defined between the two profile sections of the outer profile and the inner profile, and the two profile sections of the radially outward-facing profile section and the teeth heads, and wherein said hoop band cylinder extends around the entire circumference of the disk carrier.

2. A profile roller tool for roll-forming a disk carrier from a sheet metal part having toothing comprising inner and outer teeth, comprising: a plurality of cassettes spaced equidistantly on a circumference of a roll-forming tool, each of said plurality of cassettes having a plurality of profile rollers arranged in an interior of each of the plurality of cassettes, an outer circumference of the plurality of profile rollers positioned within the plurality of cassettes so as to roll relative to the sheet metal part to form the toothing on the disk carrier, wherein the plurality of profile rollers have a given forming depth with respect to the sheet metal part to create a narrow, peripheral, self-contained, unformed bridge remaining between an inner diameter and an outer diameter of the toothing, said bridge defining a hoop band cylinder that is integrated into the toothing to increase engine-speed strength of the disk carrier, said hoop band cylinder having an axial length approximately equals an axial length of the disk carrier, wherein the plurality of profile rollers are configured to form the toothing so as to comprise an outer profile which is formed by radially inward-facing profile sections, which steadily transitions to a radially outward-facing profile sections, wherein the plurality of profile rollers are further configured to form the toothing so as to comprise an inner profile of the disk carrier, the inner profile comprising radially inward-facing teeth, which steadily and repeatedly transitions to teeth heads with larger diameters at equidistantly arranged locations around an entire circumference of the disk carrier, wherein the plurality of profile rollers are further configured to form the hoop band cylinder defined between the outer profile and the inner profile so as to extend around the entire circumference of the disk carrier.

3. The profile roller tool according to claim 2, wherein the plurality of profile rollers comprise: at least one first profile roller to produce the radially inward-facing profile sections of the toothing, at least one second profile roller to produce the radially outward-facing profile sections, and at least one third profile roller to finely machine the radially inward-facing and radially outward-facing profile sections.

4. The profile roller tool according to claim 3, wherein the at least one second and third profile rollers each comprise a single profile roller.

5. The profile roller tool of claim 2, wherein the plurality of cassettes comprise a replaceable adjustment panel disposed on a rear wall of each of the plurality of cassettes, wherein a thickness of said adjustment panel determines the forming depth of the toothing in the disk carrier.

6. The profile roller tool according to claim 5, further comprising a machine housing, wherein at least a part of the adjustment panel of the plurality of cassettes is leveraged against the machine housing spaced at an adjustable radial distance.

7. The profile roller tool according to claim 5, wherein the thickness of said adjustment panel determines the forming depth of the toothing in the disk carrier.

8. The profile roller tool in accordance with claim 2, wherein each of the plurality of profile rollers comprise a plurality of radially inward-facing profile rollers that form a central opening for inserting the sheet metal part and a radially inward-facing distance of at least some of the radially inward-facing profile rollers is adjustable.

9. The profile roller tool in accordance with claim 2, further comprising a machine housing, wherein each of the plurality of cassettes comprise adjustment panels, and at least a part of the adjustment panels of the plurality of cassettes is leveraged against the machine housing spaced at an adjustable radial distance.

10. The profile roller tool according to claim 2, further comprising a machine housing, wherein a radial distance between the plurality of cassettes and the machine housing surrounding the plurality of cassettes is adjustable.

11. A method for spin-forming a disk carrier from a sheet metal part to form toothing having inner and outer teeth, comprising: arranging a plurality of cassettes equidistantly on a circumference of a tool, each of said plurality of cassettes having an interior in which spinning tools are arranged and profile elements disposed at a front surface of the spinning tools, setting a forming depth of the profile elements at a given position to create, in accordance with the given position, a narrow, peripheral, self-contained, unformed bridge that remains between an inner diameter and an outer diameter of the toothing of the disk carrier, said bridge defines a hoop band cylinder that is integrated into the toothing to increase engine-speed strength of the disk carriers, and said hoop band cylinder having an axial length approximately equals an axial length of the disk carrier, and shaping the disk carrier to be formed with an outer circumference of the profile elements to form the toothing and the hoop band cylinder on the disk carrier, the shaping comprising: forming radially inward-facing profile sections, which steadily transition to radially outward-facing profile sections, to form an outer profile of the disk carrier comprising the toothing, forming the toothing comprising an inner profile of the disk carrier, the toothing comprising radially inward-facing teeth, which steadily and repeatedly transition to teeth heads with larger diameters at equidistantly arranged locations around an entire circumference of the disk carrier, forming the hoop band cylinder between the two profile sections of the outer profile and the inner profile, and the two profile sections of the radially outward-facing profile section and the tooth head so as to extend around the entire circumference of the disk carrier.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The following section explains the invention in greater detail, using drawings that represent only one embodiment. The drawings and their description disclose further features and advantages of the invention.

(2) The illustrations show the following:

(3) FIG. 1 shows a sectional detail of a disk carrier according to the prior art.

(4) FIG. 2 shows a disk carrier according to prior art in accordance with DE 10 2013 216 747 A1.

(5) FIG. 3 shows a front view of a disk carrier in the manner of an external disk carrier in accordance with the invention.

(6) FIG. 4 shows an enlarged sectional detail of the external disk carrier of the section X from FIG. 3.

(7) FIG. 5 shows a front view of the hoop band cylinder according to the invention with integrated toothing according to FIG. 4.

(8) FIG. 6 shows a top view of internal disk carrier according to the invention.

(9) FIG. 7 shows and enlarged sectional view of a the section X from FIG. 6.

(10) FIG. 8 shows toothing according to the prior art.

(11) FIG. 9 shows toothing according to the invention in an external disk carrier according to the invention.

(12) FIG. 10 shows toothing according to the invention in an internal disk carrier.

(13) FIG. 11 shows a schematic representation of a roller set for the manufacture of an external disk carrier.

(14) FIG. 12 shows an enlarged representation of a roller set according to FIG. 11.

(15) FIG. 13 shows a roller set for producing the toothing at an external disk carrier.

(16) FIG. 14 shows an enlarged detail according to representation in FIG. 13.

(17) FIG. 15 shows an additional roller set for producing an external disk carrier.

(18) FIG. 16 shows an enlarged representation of the roller set according to FIG. 15.

(19) FIG. 17 shows a prospective view of a cassette with a profile roller arranged therein in a rotatable manner.

(20) FIG. 18 shows a lateral view of the cassette of FIG. 17.

(21) FIG. 19 shows a perspective view of an alternative tool shape compared to FIGS. 17 and 18 showing a spinning tool.

(22) FIG. 20 shows a schematic view of the interior structure of the spinning tool according to FIG. 19.

(23) FIG. 21 shows a perspective view of a roll-forming tool according to the design of FIGS. 17 to 18 or according to the design of FIG. 19-20.

DETAILED DESCRIPTION

(24) FIG. 1 shows a disk carrier 1 according to the prior art, which essentially comprises a cover 2, on the inside of which toothing 3 is arranged.

(25) FIG. 1 shows a sectional detail of a complete disk carrier from the prior art that is shown in FIG. 2. It is evident that disk carrier 1 has an undesirably thick wall 4, which consists of a double corrugated sheet metal profile, namely comprising the inner toothing 3, superseded by the larger wave-like toothing 3a, which results in the modulated corrugated sheet metal profile mentioned in the description and seen as a disadvantage.

(26) The task of the invention is to balance such a wave-shaped toothing 3a with the toothing 3 so that the engine-speed strength of such a disk carrier can be significantly increased while decreasing or maintaining the same wall thickness.

(27) As shown in FIGS. 3 to 5, the invention features an external disk carrier (FIG. 3), which defines two different diameters X and Y from a rotation center 20.

(28) Diameter X is the tooth diameter 15 according to FIG. 4, which shows the outside diameter of a valley-like profile section 10 of the toothing that is axially constricted inwardly.

(29) The toothing according to the invention comprises an outer profile 7 according to FIGS. 3 and 4. The outer profile 7 is formed by the valley-like radially inward-facing profile section 10, which steadily transitions to a radially outward-facing, peak-like profile section 9.

(30) Accordingly, this is an evenly unmodulated peak-valley profile of the outside profile 7, which means that the previous, modulated corrugated sheet metal profile can be eliminated.

(31) The inner profile 8 of the outer disk carrier 5 in turn comprises a radially inward-facing tooth 11, which steadily and repeatedly transitions to a tooth head 12 with a larger diameter at equidistantly arranged locations around the circumference.

(32) Accordingly, an unformed bridge 13 results between the two profile sections of the outer profile 7 and the inner profile 8, wherein said bridge surrounds the entire inner and outer toothing in the manner of a hoop band cylinder 16, thereby forming a closed cylinder as can be seen in FIG. 5.

(33) Accordingly, the component according to the invention comprises an unformed hoop band cylinder 16 between the inner tooth head diameter 14 (parameter y) and the outer tooth diameter 15 (parameter x), which in the embodiment of the drawing has a hoop band thickness 17.

(34) This hoop band thickness 17 in the area of the hoop band cylinder 16 significantly increases the engine-speed strength of the entire toothing, including at high rotational speeds because it is a closed hoop band, which holds the toothing together in radial and circumferential direction and protects and braces it against outward-facing centrifugal forces.

(35) FIG. 5 is a schematic front view of such a hoop band cylinder 16. Hoop band cylinder 16 thus has an unformed rotationally symmetrical profile in the manner of a cylinder with an outer diameter 18 and an inner diameter 19. Since the hoop band cylinder 16 is completely shaped as a rotationally symmetrical cylinder component, it meets the requirement to optimally brace and capture centrifugal forces directed from the inside out.

(36) The same conditions also apply to an internal disk carrier 25, as shown in FIGS. 6 and 7, which is shaped in the same manner as the external disk carrier 5 in accordance with FIGS. 3 to 5.

(37) Again, there is an unformed hoop band cylinder as a rotationally symmetrical cylinder component, which extends over the entire axial length of the internal disk carrier 25 and thus absorbs the centrifugal forces generated by the rotation.

(38) The modulated corrugated sheet metal profile, which was seen as a disadvantage, is therefore eliminated in the invention, for the internal and the external disk carrier.

(39) A component of a disk carrier produced in this manner is therefore able to absorb significantly higher rotational speeds with the same or reduced wall thicknesscompared to equivalent components of the prior artthan the disk carriers of the prior art, as shown for example in FIGS. 1 and 2.

(40) FIGS. 8 to 10 show the contrast of the different tooth formations, wherein FIG. 8 shows the conventional toothing 3 of a conventional disk carrier 1, while FIG. 9 shows the formation of a continuous rotationally symmetrical cylinder area between the internal and external toothing, which is shown as hoop band cylinder 16.

(41) The same conditions apply to the internal disk carrier 15 of FIG. 10, in which hoop band cylinder is radially offset inwards from the external disk carrier.

(42) FIGS. 11 to 18 then display preferred tools that are suitable for producing the toothing according to the invention.

(43) FIG. 11 initially shows the toothing of an external disk carrier 5 as an example, wherein three different profile roller sets are used, namely profile roller set 31 for producing the valley-like profile section 10 (see FIG. 12), profile roller set 32 for producing the peak-like profile section 9 in the area of the external toothing, and profile roller set 33 for fine-machining (calibration) of peak and valley profile sections 9, 10 according to FIGS. 15 and 16.

(44) It goes without saying that the respective processing of the external profile 7 in accordance with FIGS. 11 to 16 involves a counter-piece not represented in greater detail, having an identical profile, which is arranged in the interior space of external disk carrier 5, into the profile of which the component profile according to the invention is formed.

(45) The same applies to the production of the internal disk carrier 25 in an analog manner.

(46) The first step is to describe the profile roller set 31, which in accordance with FIG. 11 consists of two profile rollers 21, 22, positioned at an inclination angle 26, which form a pair of rollers, wherein each profile roller 21 comprises a rotation axis 23 and 24.

(47) As will be explained below, the profile rollers mentioned here are contained in a cassette, wherein a multitude of cassettes is equidistantly arranged over the circumference and arranged so that a complete processing set consists of a multitude of profile rollers 21, which are arranged equidistantly at the circumference of the outer profile 7 of the external disk carrier 5.

(48) The arrangement of the profile rollers in cassettes on the inner circumference of a support tool has the advantage that each cassette can take up a profile roller set that is adapted to the groove tooth of the disk carrier in each case, which allows for allocating an individual profile roller set to each groove tooth of the disk carrier.

(49) The profile rollers can either be arranged in a rotatable manner on a bearing axis within the corresponding cassette or can be contained in the cassette without an axis.

(50) The valley-shaped profile sections 10 are rolled out using the profile rollers 21, 22, which are positioned toward another in inclination angle 26, as shown in FIG. 12.

(51) As shown in FIGS. 13 and 14, an additional profile roller 27 is used, which is suitable for roll-forming the small profiled profile sections 9 (peak areas), as shown in FIG. 14.

(52) This type of profile roller 27 is also contained in a cassette and all cassettes are arranged equidistantly at the circumference, thus forming a roll-forming tool that is, for example, the subject of the separate DE 10 2010 053 547 A1.

(53) Again, the corresponding profile roller 27 is kept in the range of a rotary axis 28 within a cassette that is not further specified.

(54) The same applies to FIGS. 15 and 16, wherein a profile roller 29 is designated for fine machining of the peak-like profile sections 9 and the valley-like profile sections 10. This roller is designed in such a way that the corresponding profile forms roll out the valley-like profile sections 10 as well as the peak-like profile sections 9, using a profile mandrel not further specified, which is positively connected to the inner circumference.

(55) It goes without saying that an internal disk carrier 25 is produced in the same manner.

(56) As in the case of the profile roller set shown here, the radially outward-facing section, which is labeled interior profile 8 in FIG. 7, is produced for the internal disk carrier 25.

(57) In relation to the profile designated as exterior profile 7 in FIG. 7, it is therefore a counter-piece, which provides leverage against the radially inward-facing profile roller sets arranged on the outer circumference.

(58) FIGS. 17 and 18 therefore show a suitable forming tool, which in the displayed embodiment comprises two cassette halves 38, 39 arranged in mirror symmetry, between which the profile roller 29, 31, 32, 33 is held, respectively.

(59) Profile roller 29 is shown as an example, wherein the other profile rollers are held by the corresponding cassettes in accordance with the drawings of FIGS. 11, 13 and 15 in the same way as shown.

(60) The profile roller 29 attached there has a rotatable bearing in the directions of rotation 35 and is arranged on a bearing bolt 41 having a rotatable bearing in the associated recess in the cassette.

(61) Accordingly, a circumferential space 42 forms in the cassette as an open space so that the profile roller held there is freely rotatable.

(62) Of course, the invention is not limited to a profile roller 29, 31, 32, 33 with a rotatable bearing in a bearing bolt 41.

(63) The corresponding profile section 36 corresponds to the profile section that was described for profile rollers 29, 31, 32, 33.

(64) The corresponding profile roller therefore protrudes from a section 37 of cassette 34 with part of its outer circumference.

(65) The rear wall of cassette 34 comprises an adjustment panel 40, which essentially consists of a plug-in attachment 43, which extends over the clearance of the cassette and which is used to insert the cassette into a recess not further specified.

(66) It is important that the adjustment panel 40, which adjoins the plug-in attachment 43 from the inside, is replaceable and has a variable adjustment thickness 44.

(67) In this manner, the profile depth of a toothing can be determined by replacing an adjustment panel 40 with different adjustment thickness.

(68) The larger the adjustment thickness 44 of adjustment panel 40, the deeper the toothing of the profile rollers braced against the outer circumference of a disk carrier.

(69) FIGS. 19 and 20 show that the invention is not limited to a roll-forming tool. In another embodiment the design may include a spinning tool instead of a roll-forming tool. Such a spinning tool 48 is shown in FIGS. 19 and 20.

(70) The same explanations as for the profile roller set described above regarding the production of an external or internal disk carrier 5, 25 apply to this spinning tool.

(71) Instead of roll-forming the profile, this embodiment uses a spinning tool, wherein a workpiece holder 45 has a spinning tool 48 arranged on its front side 47, wherein the front part of the spinning tool is formed by a profile element 49 which matches the profile shape of one of the profile rollers described above.

(72) In this manner, each profile roller can be replaced by a corresponding spinning tool 48.

(73) Workpiece holder 45 on its underside has a radially inward-facing cam tab 50, which causes one upward movement per stroke. The entire workpiece holder is moved back and forth in the manner of a pendulum in the direction of the arrows 46. The connecting rods 51 have a rotatable attachment in the corresponding bearing bolt 41 in the area of cassette 34.

(74) The other end of connecting rods 51 meshes with the associated, unilaterally open bearing shells at workpiece holder 45 in such a way that it executes a back and forth pendulum movement in the direction of the arrows 46 and accordingly, generates a profile at an external disk carrier 5 or an internal disk carrier 25, in the exterior area.

(75) Again, the spinning tool 48 has a counter-piece on the opposite side, which is shaped as a profile mandrel.

(76) The component according to the invention in the form of a disk carrier 1, 5, 25 preferably consists of a metal part in fine-grain quality with suitable ductility for roll-forming and/or spin-forming. The material thicknesses suitable for this purpose are listed above.

(77) A suitable set for tools for roll-forming provides that each of the cassettes holding the roll-forming tools are sequentially arranged in axial direction of the disk carrier 1, 5, 25 in a processing machine in such a way that the disk carrier to be formed initially moves to the area of the first cassette for forming the first profile section. After leaving the first cassette, it moves in axial direction to reach the work area of the second cassette axially adjoining in the conveyor direction of the disk carrier, where the second profile section is formed. After leaving this second cassette, it moves in axial direction to reach the work area of the third cassette adjoining in the conveyor direction of the disk carrier, where calibration takes place.

(78) In a further embodiment, the roll-forming tools for roll-forming in the second and third cassette may be combined in a single cassette. In that case, calibration takes place during roll-forming in the second cassette and the third cassette is omitted.

(79) The embodiment according to FIG. 21 shows a roll-forming tool 52 comprising a multitude of cassettes 34 equidistantly arranged on the outer circumference, wherein each cassette 34 holds one or more profile rollers 21, 22, 27, 29. Cassette 34 can either be designed according to FIG. 17-18 or FIG. 19-20.

(80) Accordingly, the roll-forming tool 52 comprises a multitude of cassettes 34 equidistantly arranged on the circumference, wherein the cassettes 34 with their radially inward-facing profile rollers 21, 22, 27, 29 form a central opening 53 for inserting the workpiece to be formed and wherein the radially inward-facing distance 55 of at least part of the profile rollers 21, 27, 29 is adjustable.

(81) At least a part of all adjustment panels 43 of the cassettes 34 is leveraged against a fixed machine housing 56 with an adjustable radial distance 55. Thus, a part or all of the cassettes 34 can be designed to be adjustable.

(82) It was described above that the radial distance of the adjustment panels 40 on the sides of the cassettes can be adjusted by arranging adjustment panels 40 in different thicknesses. However, the direction of the arrow at number 55 shows that the distance can be adjusted by way of arranging set screws that are not shown. The relevant set screw is, e.g., inserted in a threaded hole of the adjustment panel 40 and braces its head against the inside of a fixed machine housing 56 from which a ring, which is either closed or divided into segments surrounds the roll-forming tool 52 at its outer circumference as shown in FIG. 20. In a reversal of this adjustment principle, the setting screw can also be adjustably inserted in a threaded hole of the machine housing 56 and brace its head on the adjustment panel 40.

(83) Instead of setting the radial distance 55 with threaded means, other adjustment methods, such as eccentric bolts, eccentric washers or similar can be used as well.

DRAWING LEGEND

(84) 1 Disk carrier 2 Cover 3 Toothing 3a Toothing 4 Wall 5 External disk carrier 6 Internal toothing 7 External profile 8 Internal profile 9 Profile section (peak) 10 Profile section (valley) 11 Tooth 12 Tooth head 13 Bridge 14 Tooth head diameter Y (of 12) 15 Tooth diameter X (of 11) 16 Hoop band cylinder 17 Hoop band thickness 18 Outer circumference (of 16) 19 Inner circumference (of 16) 20 Rotation center 21 Profile roller (21+22=roller pair for 16) 22 Profile roller (21+22=roller pair for 16) 23 Rotation axis (of 21) 24 Rotation axis (of 22) 25 Internal disk carrier 26 Inclination angle 27 Profile roller (for 9) 28 Rotation axis 30 Profile roller (for 9+10) 31 Roller set (for 21+22) 32 Roller set (for 27) 33 Roller set (for 29) 34 Cassette 35 Rotational direction 36 Profile section 37 Recess 38 Cassette half 39 Cassette half 40 Adjustment panel 41 Bearing bolt 42 Circumferential space 43 Plug-in attachment 44 Adjustment thickness 45 Workpiece holder 46 Direction of arrow 47 Front side 48 Spinning tool 49 Profile element 50 Cam tab 51 Connection rod 52 Roll-forming tool 53 Opening 54 Counter-piece 55 Radial distance 56 Machine housing