Device for producing at least one undercut in a slotted or closed profiled sheet section

Abstract

A device for manufacturing at least one undercut in a sheet-metal profile that is slotted or closed may include an inner core portion and an outer core portion, which together can be inserted within the sheet-metal profile and/or may support a semi-finished sheet-metal product from which the sheet-metal profile is formed. The inner core portion and the outer core portion may have faces that mate with one another such that when the inner core portion rotates or translates relative to the outer core portion, the outer core portion is forced away from the inner core portion. To cause this behavior, the faces may be undulating, inclined, or cam-like, for example. In effect, a cross-sectional profile of the device may be reduced at least for purposes of extracting the device from the sheet-metal profile after the undercuts have been formed.

Claims

1. A device for manufacturing at least one undercut in a sheet-metal profile that is slotted or closed, the device comprising: a core that either supports a semi-finished sheet-metal product from which the sheet-metal profile is formed or is insertable within the sheet-metal profile, wherein the core comprises: a first core outer portion, a second core outer portion, wherein at least one of the first core outer portion or the second core outer portion includes a depression or a protrusion for shaping an undercut in the sheet-metal profile, and an inner core portion that is disposed between and movable relative to the first and second core outer portions, the inner core portion having at least one active face that is either inclined or cam-shaped, wherein moving the inner core portion in a first direction relative to the first and second outer core portions causes the first and second outer core portions to diverge, wherein moving the inner core portion in a second direction opposite the first direction relative to the first and second outer core portions causes the first and second outer core portions to converge; and a mounting on which the first and second outer core portions are movably positioned, the mounting defining an opening there through that is penetrated by the inner core portion, and having at least one guide bar extending therefrom; a compression spring into which the guide bar is inserted so as to be radially supported on the guide bar; a compression body coupled to the inner core portion, and defining at least one through bore that is penetrated by the at least one guide bar extending from the mounting.

2. The device of claim 1 wherein the mounting comprises a guide for holding the first and second outer core portions in a manner that prevents movement in the first direction and the second direction but permits the first and second outer core portions to diverge and converge.

3. The device of claim 1, wherein the compression spring is supported on the mounting, wherein moving the inner core portion in the first direction and relative to the first and second outer core portions requires overcoming a force of the compression spring.

4. A device for manufacturing at least one undercut in a sheet-metal profile that is slotted or closed, the device comprising: a core that either supports a semi-finished sheet-metal product from which the sheet-metal profile is formed or is insertable within the sheet-metal profile, wherein the core comprises: a first outer core portion having a first clearance defined in a side thereof, a second outer core portion having a second clearance defined in a side thereof, wherein at least one of the first outer core portion or the second outer core portion includes a depression or a protrusion for shaping an undercut in the sheet-metal profile, and an inner core portion having a third clearance defined in a side thereof and having at least one active face that is either inclined or cam-shaped, the inner core portion being disposed between and movable relative to the first and second outer core portions, wherein moving the inner core portion in a first direction relative to the first and second outer core portions causes the first and second outer core portions to diverge, wherein moving the inner core portion in a second direction opposite the first direction relative to the first and second outer core portions causes the first and second outer core portions to converge; and an end stop having a guide configured to receive the first and second outer core portions in a manner that permits the first and second outer core portions to converge and diverge depending on the positioning of the inner core portion, the guide of the end stop comprising a web-shaped guide element having a cross-sectional profile that tapers in a direction of the first and second outer core portions, wherein each of the first, second, and third clearances respectively defined in the side of the first outer core portion, the second outer core portion, and the inner core portion are configured to receive the web-shaped guide element, wherein the first and second outer core portions are moveable in a substantially linear manner together with the inner core portion, wherein the first and second outer core portions selectively mate with the end stop, with the inner core portion being moveable in the first direction relative to the first and second outer core portions when the first and second outer core portions are positioned against the end stop.

5. The device of claim 4 wherein the end stop includes mutually facing stop faces that delimit the divergence of the first and second outer core portions.

Description

BRIEF DESCRIPTION OF THE FIGURES

(1) FIG. 1 is a perspective view of an example core unit in a starting position with coils that are largely relaxed.

(2) FIG. 2 is a perspective view of the example core unit of FIG. 1 in an intermediate position, after the core unit has been displaced in a linear manner.

(3) FIG. 3 is a perspective view of the example core unit of FIG. 1 in an end position.

(4) FIG. 4 is a perspective view of an example core unit during a retracting movement, wherein the core unit is being pulled away from an end stop in a linear manner.

(5) FIG. 5 is a perspective view of an example core unit at the end of an operational cycle, wherein the core unit has been moved away and retracted from an end stop.

(6) FIG. 6 is partial perspective view of the example core unit of FIG. 1 showing a core mounting plate on which an outer core portions are guided.

(7) FIG. 7 is an enlarged partial perspective view of a portion of an end of the example core unit of FIG. 1 that is connectable to a terminal stop.

(8) FIG. 8 is a perspective view of an example piece of closed-profile sheet metal into which inwardly oriented undercuts have been manufactured.

(9) FIG. 9 is a perspective view of an example piece of closed-profile sheet metal into which undercuts have been manufactured.

DETAILED DESCRIPTION

(10) Although certain example methods and apparatus have been described herein, the scope of coverage of this patent is not limited thereto. On the contrary, this patent covers all methods, apparatus, and articles of manufacture fairly falling within the scope of the appended claims either literally or under the doctrine of equivalents.

(11) The device illustrated in the drawing serves for manufacturing undercuts in a slotted or closed hollow profile which is made from sheet metal. The device comprises a threepart core 1 which may also be referred to as a core unit or as a collapsible core.

(12) The core unit 1 is configured so as to be elongate and comprises two outer core portions 1.1, 1.2 which have in each case a plurality of depressions 2, 3 for shaping inwardly oriented undercuts in a closed sheet-metal profile, for example. An inner core portion 1.3 which is displaceable in a linear manner in relation to the outer core portions 1.1, 1.2 and has undulated active faces 1.31, 1.32 is disposed between the two outer core portions 1.1, 1.2. Those inner faces 1.11, 1.21 of the outer core portions 1.1, 1.2 that face the active faces 1.31, 1.32 of the inner core portion 1.3 are likewise configured so as to be undulated. The undulated active faces 1.31, 1.32 of the inner core portion 1.3, and the inner faces 1.11, 1.21 of the outer core portions 1.1, 1.2 are preferably configured so as to be mutually substantially complementary. The three core portions 1.1, 1.2, 1.3 have substantially identical widths or depths, respectively, such that the lateral faces of the collapsible core 1, which run parallel with one another, have lateral part faces 1.12, 1.22, 1.33 which are in each case disposed so as to and be mutually flush.

(13) By displacing the inner core portion 1.3 in a linear manner in the movement direction which is indicated by the arrow P1 in FIG. 1 in relation to the outer core portions 1.1, 1.2, the core unit 1 is spread, as a result account of which the outer core portions 1.1, 1.2 are made to diverge.

(14) The depressions 2, 3 for shaping inwardly oriented undercuts in the slotted or closed sheet-metal profile are disposed on that outer side of the respective outer core portion 1.1, 1.2 that faces away from the inner core portion 1.3. The depressions 2, 3 are configured so as to be channel-shaped, for example, and run transversely to the longitudinal axis of the collapsible core (core unit) 1. The depressions 2, 3 may furthermore also be configured in the shape of dents or calottes.

(15) The outer core portions 1.1, 1.2 by way of one of the ends thereof are held on a plate-shaped mounting 4 so as to be movable. The mounting (core mounting plate) 4 has a through opening 4.1 which is penetrated by a substantially straight portion 1.34 of the inner core portion 1.3. The straight portion 1.34 of the inner core portion has a substantially rectangular cross section, for example, wherein the through opening 4.1 of the core mounting plate 4 has a corresponding cross-sectional profile and serves as a guide. The core mounting plate 4 on that side which faces the outer core portions 1.1, 1.2 is provided with a guide 4.2 for the outer core portions 1.1, 1.2 (see FIG. 6). The guide 4.2 is configured so as to be groove-shaped and intersects the through opening 4.1.

(16) Guide bolts (guide bars) 5 which run parallel with one another are attached on that side of the core mounting plate 4 that faces away from the outer core portions 1.1, 1.2. The guide bolts 5 extend parallel with respect to the longitudinal axis of the collapsible core (core unit) 1 and are guided (through bore 6.1) in a plate-shaped compression body (compression plate) 6. The compression plate 6 is fixedly connected, for example welded or screwed, to the end of the straight portion of the inner core portion 1.3. The guide bolts 5 are provided with compression springs (coil springs) 7 which are disposed between the core mounting plate 4 and the compression plate 6 and which are push-fitted onto the guide bolts 5.

(17) The outer core portions 1.1, 1.2 are moveable in a substantially linear manner together with the inner core portion 1.3, wherein the core portions 1.1, 1.2, 1.3 are assigned an end stop 8. In the position of the collapsible core 1 illustrated in FIG. 2, the outer core portions 1.1, 1.2 by way of the end thereof that faces away from the core mounting plate 4 abut the end stop 8, wherein that end of the inner core portion 1.3 that faces away from the core mounting plate 4 is (initially) located so as to be considerably spaced apart from the end stop 8. If the inner core portion 1.3 is now moved onward in the direction of the end stop 8 by further displacement of the compression plate 6, while compressing the compression springs 7, in relation to the outer core portions 1.1, 1.2, the outer core portions 1.1, 1.2, on account of the undulated inner faces 1.11, 1.21 thereof and of the undulated active faces 1.31. 1.32 of the inner core portion 1.3, are made to diverge. In FIG. 3 this is indicated by the mutually opposed arrows P2, P3.

(18) The end stop 8 is provided with a guide 8.1 for the outer core portions 1.1, 1.2. The guide 8.1 is configured as a web-shaped guide element which has a cross-sectional profile, for example a trapezoidal profile, which tapers off in the direction of the outer core portions 1.1, 1.2. Clearances 1.13, 1.23, 1.35 for receiving the guide element 8.1 are configured in those end sides of the outer core portions 1.1, 1.2 and of the inner core portion 1.3 that face the guide element 8.1. The guide element 8.1 at the same time serves for locking the core portions 1.1, 1.2, 1.3. The end stop 8 furthermore has mutually facing stop faces 8.2, 8.3 which delimit the diverging movement of the outer core portions 1.1, 1.2.

(19) The functional concept of the collapsible core according to the invention will be briefly explained again by means of FIGS. 1 to 5.

(20) A starting position in which the compression springs 7 are largely relaxed and the threepart core unit (collapsible core) 1 is not spread is illustrated in FIG. 1.

(21) FIG. 2 shows an intermediate position, after the core unit 1 has been displaced in a linear manner in the direction of the end stop 8 and the two outer core portions 1.1, 1.2 by way of that end thereof that faces away from the core mounting plate 4 touch the end stop 8.

(22) An end position which follows on from the intermediate position according to FIG. 2 is illustrated in FIG. 3. In this end position, the compression plate 6 has previously been displaced in a linear manner onward in the direction of the arrow P1, counter to the spring force of the compression springs 7. As a result, displacement of the inner core portion 1.3 has been caused, as a result which the two outer core portions 1.1, 1.2 have been urged to the outside and thus perform a lifting or spreading motion, respectively. The end stop 8 which here is configured in a fork-shaped or U-shaped manner, for example, here likewise serves as a limiter of the lifting or spreading motion, respectively, of the two outer core portions.

(23) A situation during the retracting movement of the core unit 1 is illustrated in FIG. 4. It can be seen that the core unit 1 is being pulled away from the end stop 8 in a linear manner in the direction of the arrow P4, wherein, on account of the previously compressed compression springs 7, the compression plate 6 is first moved together with the inner core portion 1.3, and the two outer core portions 1.1, 1.2 initially remain engaged with the end stop 8. As a result, the inner core portion 1.3 is pulled, and at the same time the total height of the threepart collapsible core 1, or the spacing of the outer core portions 1.1, 1.2, respectively, is reduced, this being additionally indicated in FIG. 4 by the arrows P5 and P6. As a result, the manufacture of closed hollow profiles and slotted profiles having undercuts is possible in a transfer or line process.

(24) The situation at the end of an operational cycle is illustrated in FIG. 5. After having pulled the inner core portion 1.3, the entire core unit 1 has been moved away and retracted from the end stop 8 (cf. arrow P4). The core unit 1 thus releases the sheet-metal profile which is provided with undercuts for onward conveying in the transfer or line process. The situation according to FIG. 5 corresponds to the starting position illustrated in FIG. 1.

(25) An example of a closed sheet-metal profile B, which has inwardly oriented undercuts 9.1, 9.2 and which can be manufactured by means of the core unit 1 according to FIGS. 1 to 7, is illustrated in FIG. 8. The undercuts 9.1 are configured in a channel shape or pleat shape, while the undercuts 9.2 are configured in a dent shape. Of course, other geometrical shapes are possible for the hollow profile to be manufactured. In particular, closed sheet-metal profiles B having outwardly oriented undercuts 10 may also be manufactured using a device according to the invention, as is shown in an exemplary manner in FIG. 9.

(26) The embodiment of the device according to the invention is not restricted to the exemplary embodiments illustrated in the drawing. Rather, numerous variants which also make use of the invention as stated in the appended claims in a design which is modified with respect to the exemplary embodiments are conceivable. For example, it is also conceivable for the diverging (spreading) of the outer core portions 1.1, 1.2 to be performed by means of a rotatable inner core portion (not shown), wherein the latter then has at least one active face which in a predefined rotation direction, namely the rotation direction in relation to the outer core portions 1.1, 1.2, is configured so as to be cam-shaped. The cam-shaped active face, or the cam of the rotatable inner core portion (not shown), respectively, in the non-spread position of the outer core portions here is received with play in a hollow chamber in one of the outer core portions, for example, from where said cam, on account of rotation of the inner core portion, may be pivoted outward and passed against an inner face of the other outer core portion, such that diverging (spreading) of the outer core portions 1.1, 1.2 results from a continuation of this rotation or pivoting movement, respectively.