Abstract:
Roller profiling machine includes several forming stations which progressively shape a given material until obtaining a pre-designed profile with a section variable along the length of the profile. Each forming station is placed over a head ( 2 ) that includes a first device arranged for a translation movement, horizontal and perpendicular to the direction in which the profile is advanced; and a second device arranged for a rotation movement; wherein, the head ( 2 ) is also inclined in a certain angle (α) with respect to the horizontal; the angle being configured to avoid a collision between the forming material and the rollers.

Description:
[0001]    The present invention relates to a roller profiling machine which comprises several roller stations arranged in mobile heads and which allows the production of metal profiles with variable sections. 
       BACKGROUND OF THE INVENTION 
       [0002]    Profiling machines base their operation on the formation of metal sheets by means of several roller shaping stations. These stations are normally constituted by pairs of rollers mounted over horizontal axles, although they can have other layouts. The sheet undergoes a deformation as it passes between different rollers, deformation which gradually, when passing through several roller stations, gives shape to the material until the profile with the desired section is obtained. 
         [0003]    This type of machines is conceived for large scale production since they have the capacity to produce a big quantity of profiles with constant section. The versatility of profiling machines is based on the possibility of mounting several roller sets on the same machine. Another method for achieving flexibility is to use fast changeable structures of the “cassette” type, where the roller stations are mounted. Other machine structures such as the “turret” type or those that offer automated changes are less used. 
         [0004]    Profiling machines allow for the inclusion, in the same productive line, of other tools that impact the metal to perform operations such as die-cutting, stamping, punching, bending, welding, cutting, marking, etc. Thus, it is possible to obtain finished pieces, in a continuous process, in accordance to requirements. 
         [0005]    Mainly from the automotive sector, there is an increasing demand of profiles with variable section along the whole length of said profiles. These types of pieces are obtained by means of other metal deformation processes, mainly press stamping using a mould and die. Despite this system being very well-known and used by industries, it has very low versatility since any change in the final piece demands the use of a different tool. The advantage of the constant production of the same profile also entails greater limitation of the profiling machines. 
       DESCRIPTION OF THE INVENTION 
       [0006]    The roller profiling machine which is the object of the present invention is intended to solve the technical problem posed by the fabrication of metal profiles with variable section along the entire length of said profile. 
         [0000]    It is an object of the present invention to obtain the profiles through profiling with rollers, wherein the section of said profiles has a variable length. A profiling machine of this kind comprises several heads fitted with servo-controlled movement in at least two directions, rotation and translation that is horizontal and perpendicular to the direction in which the profile is advanced. Furthermore, over each head, a forming station is also installed provided with two parallel axles to house a pair of shaping rollers. A reduction motor provides rotation movement to the inferior axle, and it is transmitted to the superior axle by a simple gear system. 
         [0007]    Every forming station can optionally use an independent structure that houses the superior axle. This structure is symmetrically built to allow for two mountings, one at 180° from the other. It is therefore possible to install an axle with a two-way outlet, and in each one of them a superior roller can be installed, which, for example, can make it possible to process material of two different thicknesses. This system avoids using processes of adjustment or mounting of new pieces. The head is placed with a certain inclination to the horizontal to avoid collisions between the rollers and the profiled material when a rotation is made. The whole set of servo-motors is lead by a numerical control that defines and controls the position and movements of each head. 
         [0008]    Furthermore, the machine also has a multiple counting wheels system; whereby upon making contact, the wheels record the movement of the material as it is profiled. The synchronization through movement belts of all these wheels makes it possible for the machine to process cut formats. In the case that the elaboration started from a continuous tread from a coil, a single counting wheel would be enough. In either case, the movement of the counting wheel or wheels is transmitted to an encoder that sends the information to the numeric control. 
         [0009]    A piece start detection system is used in the case of profiling pre-cut formats which establishes the point of origin of the variable path. 
         [0000]    Throughout the description and the claims the word “comprises” and its variants do not exclude other technical characteristics, additional elements, components or steps. For experts on the subject matter, other objects, advantages and characteristics of the invention will be derived partly by the description and partly by the application of the present invention. The following set of accompanying examples and drawings are presented by way of example and are not to limit the present invention. Furthermore, the present invention covers all possible combinations of specific and preferred embodiments hereby set forth. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]      FIG. 1  shows a perspective view of a profiling machine unit to make variable section profiles. 
           [0011]      FIG. 2  shows an elevation view of a profiling head, from the entrance of the piece. 
           [0012]      FIG. 3  shows a perspective and detailed view of the counting wheels used in the pre-cut format process. 
       
    
    
     PREFERRED EMBODIMENT OF THE INVENTION 
       [0013]    The perspective representation of  FIG. 1  shows a roller profiling machine according to the present invention; wherein said machine comprises at least a main bedplate ( 1 ) which consists of a platform, several legs and several base plates, over which various heads ( 2 ) are placed, which support the different forming stations. 
         [0014]    In the example represented in this figure, the roller profiling machine comprises eleven independent heads ( 2 ) coupled to the bedplate ( 1 ) on their lower side. The material to be profiled circulates, according to  FIG. 1 , from left to right, and the finished piece exits at the right end. 
         [0015]    The servo-motors are located in the lower area of each head ( 2 ) and they provide rotation movement ( 3 ) and translation ( 4 ) movement, the latter being horizontal and perpendicular to the direction in which the profile is advanced. Each one of these servo-motors comprises an internal encoder so that the position of the head ( 2 ) is known at all times. On the upper side of said heads ( 2 ) there is reduction motor ( 5 ) that transmits the rotation movement to the rollers. 
         [0016]      FIG. 2  shows the head ( 2 ) mounted on the main bedplate ( 1 ) where the translation servo-motor ( 4 ) is fixed to the base plate of the main bedplate and, by means of a spindle, transmits the lineal translation movement (from left to right according to  FIG. 2 ) to the plate that supports the head ( 14 ). This plate ( 14 ) is in turn settled on some linear rails ( 10 ). On the other hand, the support plate ( 14 ) also houses the rotation trunnion ( 9 ) which has a worm wheel on its lower part, activated by the rotation servo-motor ( 3 ). The spinning plate ( 15 ) is fixed to the trunnion ( 9 ) and is responsible for supporting the forming station. This forming station is placed with a certain inclination to the horizontal, such as to avoid a collision between the forming rollers and the material to be profiled. This possible collision would take place when making the necessary turn to profile in a perpendicular direction to the defined path. 
         [0017]    The forming station is divided in two structures. The first one supports the axle of the inferior roller ( 8 ). This axle is the one that receives the necessary rotation movement, from the reduction motor ( 5 ), to make the profiled material circulate through the rollers. Each reduction motor is in turn directed by a frequency converter. The second structure, located over the first one, supports the superior roller axle. The inferior axle rotation movement is transmitted to the superior one by gears ( 11 ). 
         [0018]    The higher structure shown in  FIG. 2  has the special feature of being built in a symmetrical way with respect to the position of the gear ( 11 ) and the seats. This allows for two mounting possibilities, one at  180 ° from the other. Thereby, and by mounting a superior axle with a double side outlet, it is possible to mount both superior rollers ( 6 ,  7 ). Then, it would be possible to provide the machine with the capacity for profiling materials with two different thicknesses by mounting a superior roller or another according to the specific needs. The joint of both the upper and lower structure, is carried out by several fast clamping flanges. 
         [0019]      FIG. 3  shows a view of the initial part of the profiling machine. In such view the counting wheel system ( 13 ) can be appreciated; in this case three of them are visible. The first forming head is represented with a discrete trace, resembling transparency. The layout of several counting wheels is necessary to profile pre-cut formats in their length. 
         [0020]    These wheels have a double function, since on the one hand, they support the forming material that protrudes from the profiling rollers, and on the other hand, they record the forming material movement through the machine. This material is adjusted with one or several rollers to ensure that there is no skid between it and the counting wheels. There is the possibility of placing as many wheels as deemed necessary to obtain a reliable reading of the piece from the point where its head gets in the first forming station until the tail goes out of the last one. The counting wheels are supported by a side structure ( 16 ) facing the forming stations. On the rear side of the figure, in the side structure, there is a system of pulleys integral to each wheel, synchronized by belts. At the same time, this belt system transmits the movement to an encoder that sends the speed and position signal to the numerical control. The accuracy of this gauging is essential to accurately adjust the path that defines each head according to the requirements. 
         [0021]    In the case that the forming material is continuously profiled from a coil, for example, a single counting wheel with direct transmission to the encoder would be enough. 
         [0022]    The machine object of the present invention can be used independently or incorporated to a production line that adds other operations onto the forming material. Additionally, it can function as a feeder that performs material forwarding and stop operations so that other tools—located before or after the forming—can perform other operations.