Patent Application
20220362827
The invention relates to a stretch-rolling device and a stretch-rolling method for pressure-forming workpieces by rolling. For this purpose, the stretch-rolling device has a pair of work rolls with two rolls, which implement a plurality of stages in the axial direction, and which are configured for the stepwise deformation of the workpieces, in that the workpieces successively pass through the stages.
The stretch rolling process is a type of longitudinal rolling process in which the rolling stock is transported through the roll gap perpendicularly to the rolling axes and thereby deformed. The stretch rolling process is characterized by the fact that a blank to be rolled, for example a round or square material, is fed to the rolls by a manipulator and is formed in individual stages, which are arranged in the axial direction of the rolls and are also referred to as “passes”, “calibers” or “sectors”. The stages of the rolls therefore usually have different rolling profiles and the blank to be rolled passes through one after the other, resulting in a stepwise change of the profile cross-section of the blank.
Stretch rolling is particularly suitable for the production of intermediate forms, such as semi-finished products or preforms, and in rarer cases also of finished parts. In the production of intermediate shapes, stretch rolling allows simplifying downstream processing steps such as drop forging. For example, the use of materials and the process forces in drop forging can be reduced and the surface quality of the components can be increased. Specifically, stretch rolling is used, for example, to produce intermediate forms for components such as crankshafts, axles and link components.
DE 10 2014 101 150 A1 describes a stretch-rolling device which has a roll pair with two rolls whose direction of rotation can be reversed and two gripping devices for handling the workpieces to be rolled. The two gripping devices are arranged on opposite sides of the roll pair. Furthermore, the rolls have at least two rolling tools, i.e., stages, in the axial direction, the stages being configured for the stepwise forming of the workpiece.
According to the technology described in DE 10 2014 101 150 A1, the output of the workpieces is limited in that the handling of the workpieces by the two gripping devices always only takes up part of the pair of rolls, i.e., not all stages are used at the same time.
An increase in output is achieved with a stretch rolling device according to DE 10 2016 112 946 A1. For this purpose, a plurality of gripping devices are installed on the opposite sides of the pair of rolls, wherein two opposing gripping devices, which form a pair of gripping devices, are assigned to one step and grip the corresponding workpiece. In addition, the stretch-rolling device has a transfer device for transporting the workpieces from one pair of gripping devices to another pair of gripping devices in the working cycle of the device.
The increase in output according to DE 10 2016 112 946 A1 comes at the expense of a considerable construction effort, since two gripping devices are used per stage for parallel occupation of the stages in order to grip the workpiece at both ends. In addition, the parallel rolling of a plurality of workpieces is associated with a technical problem resulting from the fact that the workpieces have different lengths due to the deformation at different stages along the axial direction of the rolls. For this purpose, length compensation between the individual gripping devices must be ensured in order to ensure a reliable and high-quality rolling process.
It is an object of the invention is to provide an improved stretch-rolling device and an improved stretch-rolling method, in particular to realize a high output of workpieces with reduced structural complexity.
The object is achieved with a stretch rolling device with the features of claim 1 and a stretch rolling method with the features of claim 9. Advantageous developments follow from the dependent claims, the following description of the invention and the description of preferred embodiments.
The stretch-rolling device according to the invention is used for the pressure forming of workpieces, preferably metallic workpieces, by rolling.
The stretch-rolling device has a pair of work rolls with two rolls, which can each be rotated about their roll axes and form a roll gap between them. The rolls are configured to realize several stages in the axial direction, for the stepwise deforming the workpieces, by the workpieces successively passing through the stages. When deforming the workpieces, the work rolls rotate in opposite directions. The direction of rotation of the work rolls can be reversed. However, this is not strictly required. Normally, the rolled profiles differ at the different stages to achieve a gradual deformation of the workpieces. Preferably, each workpiece passes through all stages, from the lowest stage to the highest stage. However, in special cases it may also be possible that not all stages act on the workpieces, i.e., stages are omitted or skipped. The terms “successive”, “stepwise” etc. do not necessarily limit the processing to a complete run through of all available stages.
The stretch-rolling device also has a manipulator, preferably precisely one manipulator with a plurality of gripping devices. Preferably, the number of gripping devices is equal to the number of stages. The gripping devices, preferably the entire or substantially entire manipulator, are arranged on a working side of the pair of work rolls and are adapted to grip the workpieces and guide them through the roll gap at an associated stage in a feed/retraction direction. The working side is defined by the position of the pair of working rolls and the gripping devices. The side opposite the working side (relative to the pair of working rolls) can be designed as a tool changing side, via which maintenance work, such as a roll change, can be carried out.
The stretch rolling apparatus further comprises a support arranged to temporarily support workpieces and transfer them in cooperation with the manipulator to another gripping device, preferably the adjacent gripping device of the next higher stage. In other words, the workpieces are transferred from one gripping device to another gripping device, preferably a gripping device of a higher stage, for example the next higher stage. This transfer of the workpieces normally takes place once per work cycle of the stretch rolling device. The workpiece that has completed processing, preferably the workpiece of the highest level, is ejected. Furthermore, a new workpiece, which is also referred to herein as a blank, is fed to the lowest processing stage. Thus, when the workpieces are handed over, normally only the first workpiece (the blank) to the penultimate workpiece are gripped and picked up by a gripping device. It should be noted that the term “finished part” refers only to the stretch rolling process, i.e., it does not necessarily indicate an end product or finished part. Rather, the finished workpiece that has passed through all the intended stages of the stretch rolling device is preferably an intermediate form, such as a semi-finished product or preform.
The support is not a manipulator because the support does not have gripping devices configured to grip the workpieces and feed them through the roll gap in a feed/retraction direction. In particular, the support does not have any gripping devices that enter or pass or are capable of passing through the roll gap. The support can be configured passive in that the workpieces are placed thereon for transfer or the support supports the workpieces without actively gripping or clamping them. Alternatively, the support can have retaining means configured to temporarily retain or stabilize, for example to grip or clamp, the workpieces.
The thusly constructed stretch-rolling device allows several workpieces to be processed at the same time by a parallel occupation of all or at least several stages, for example every second stage. The parallel occupation allows increasing the output of the workpieces, and thus productivity. This is achieved without installing two or more manipulators on opposite sides of the pair of work rolls. If necessary, the manipulator only has to include further gripping devices, such as tongs, on the working side, which achieves the improved functionality without a significant increase in the structural and procedural complexity of the stretch rolling device. The transfer of the workpieces to gripping devices during the process in subsequent stages is realized in connection with a support. This achieves a high output with a comparatively small number of assemblies, which also improves the reliability and maintainability of the stretch rolling device.
Preferably, one or more gripping devices are designed to be rotatable about their own axis to enable the corresponding workpieces to be rotated between the individual stages. This means a rotation of the workpieces about their longitudinal axis by a certain angle, for example 90°. The rotation can take place before or after the deforming at the respective stage.
Preferably, the gripping devices are configured to grip the workpieces at one end and feed them through the roll gap at an assigned stage, while the workpieces are not gripped at the other end. Gripping of the “second” end of the workpiece by an additional gripping device of a manipulator is not required, which not only reduces the structural complexity but also the process control.
Preferably, the support can be moved in the axial direction and/or in the feed/retraction direction. In particular, the movability of the support can be used to implement or at least support the transfer of the workpieces by transporting the workpieces transversely by the support. As an alternative or in addition, the support can be configured so that it can be moved in the up/down direction, for example to descend during rolling and not to impede the rolling process.
The support is preferably arranged on the working side. Thus, the support does not obstruct or limit access to the side opposite the working side, which is advantageously designed as a tool changing side. This improves the maintainability of the stretch rolling device.
Preferably, the number of gripping devices is equal to the number of stages, the assignment of gripping device to the stage being a one-to-one correspondence. In this way, the pair of work rolls can be optimally used along the axial direction, with the configuration and control of the individual gripping devices being able to be designed in the best possible way for the associated stage.
Preferably, the gripping devices can be moved by the manipulator in the axial direction and/or the feed/retraction direction, with the manipulator itself being particularly preferably moveable for this purpose in the axial direction and/or the feed/retraction direction relative to the pair of work rolls. In particular, the movability of the gripping devices or the manipulator can be used to realize the transverse transport, i.e., transport of the workpieces for transfer in the axial direction, either in connection with a stationary support or in combination with a support that can also be moved.
At the end of the rolling process, the workpieces of the different stages usually have different lengths. In order to compensate for these different lengths, at least one gripping device can preferably be adjusted relative to the manipulator in the feed/retraction direction. This can be realized by means of a length compensation section, which can adjust the gripping device, such as the clamps, of the corresponding gripping device for length compensation in the feed/retraction direction. Preferably, at least N−1 (where N denotes the number of stages) gripping devices have such a length compensation section. The increase in length and/or the rate of increase in length may vary from stage to stage. Thus, the gripping devices are preferably individually movable. For this purpose, the individual mobility or movability in the feed/retraction direction can be implemented passively, for example spring-loaded, or actively, for example pneumatically, by an electric motor, etc.
Preferably, the support has holding means configured to temporarily hold, preferably clamp the workpieces for transfer to the respective adjacent gripping device of the next higher stage, while the gripping devices grip. In this way, the reliability of the handover can be improved. In this case, the holding means are preferably essentially stationary relative to the support, i.e., apart for example from a clamping movement.
The object is also achieved by a stretch-rolling method for pressure-forming workpieces using a stretch-rolling device according to the above description. The method includes: gripping a plurality of workpieces by a respective gripping device of the manipulator; passing the workpieces through the roll gap formed by the pair of work rolls at an associated stage in the feed/retraction direction; rotating the rolls, preferably in opposite directions, and applying pressure to the workpieces through the rolls, thereby deforming the workpieces according to their stage; transporting the workpieces to a transfer position and supporting the workpieces by the support, preferably placing the workpieces onto the support; releasing the workpieces from the gripping devices; and gripping the workpieces by another gripping device, preferably the adjacent gripping device of the next higher stage.
The features, technical effects, advantages and exemplary embodiments that have been described in relation to the stretch-rolling device apply analogously to the stretch-rolling method.
One or more workpieces are thus preferably rotated between the individual stages about their longitudinal axes, for example by 90°. The rotation can take place before or after the forming at the respective stage.
Furthermore, it is particularly preferred that the gripping devices of the manipulator grip the workpieces at one end and guide them through the roll gap at the assigned stage, while the workpieces are not gripped at the other end.
In order to transfer the workpieces to another gripping device, the support preferably moves in the axial direction and/or in the feed/retraction direction and/or up/down in order to effect or at least support the transfer. Alternatively, or additionally, the gripping devices are moved by the manipulator in the axial direction and/or in the feed/retraction direction to transfer the workpieces to another gripping device. For this purpose, it is particularly preferred that essentially only the manipulator itself moves relative to the pair of work rolls in the axial direction and/or in the feed/retraction direction.
In order to compensate for different lengths of the workpieces at the various stages, at least one gripping device is preferably adjusted relative to the manipulator in the feed/retraction direction according to the length of the associated workpiece. Preferably, the gripping devices are moved individually during rolling, since the increase in length and/or the rate of increase in length can vary from stage to stage. This can be done passively, for example with a spring, or actively, for example pneumatically, with an electric motor, etc.
The number of workpieces to be rolled is preferably smaller than the number of stages available, for example approximately half as large. A reduced occupancy of the stages may be favorable or necessary to comply with machine limits with regard to force or energy consumption.
Further advantages and features of the present invention are evident from the following description of preferred embodiments. The features described there can be implemented individually or in combination with one or more of the features described above, insofar as the features are not inconsistent with one another. The following description of the preferred embodiments is made with reference to the accompanying drawings.
In the following, preferred embodiments are described with reference to the Figures. Same, similar or functionally equivalent elements are provided with the same reference symbols in the Figures, and a repeated description of these elements is in some instances dispensed with to avoid redundancies.
First, the components of the stretch-rolling device 1 will be explained and then a stretch-rolling method that can be carried out with these components.
The stretch rolling device 1 has a pair of work rolls with a top and a bottom roll 10. The top roll is omitted from the figures for better visibility of the manipulation and transport of the workpieces W. The rolls 10 are rotatable in opposite directions. Their direction of rotation can be reversible, but this is not strictly required. In the axial direction, the rolls 10 include a plurality of stages S1 to S4, which are also referred to as passes, calibers or segments. Preferably, the rolling profile of the work rolls differs at the different stages S1 to S4. The stages S1 to S4 are used for the stepwise deforming of the workpieces W, wherein for this purpose such a workpiece W passes through the stages S1 to S4 successively. Four stages S1 to S4 are shown as examples in the Figures.
Between the stages S1 to S4, the workpieces W are preferably rotated by an angle, for example 90°, as indicated by arrows in
The stretch-rolling device 1 also has a manipulator 20 with a plurality of gripping devices 21. The gripping devices 21 are assigned according to the stages S1 to S4, wherein a one-to-one correspondence is not necessarily required. For example, a gripping device 21 can be configured to serve several stages. However, the number of gripping devices 21 is preferably equal to the number of stages S1 to S4 as shown in the Figures, in which case the correspondence is one-to-one. The side on which the manipulator 20 with the gripping devices 21 is located relative to the pair of work rolls is referred to herein as the working side AS. The gripping devices 21 have adjustable clamping jaws, for example, in order to be able to securely grip the workpieces W and release them for transfer.
According to the embodiment of
The stretch-rolling device 1 also has a support 30 which, according to the embodiment of
Since the support 30 and/or the manipulator 20 or its gripping devices 21 are designed to be movable in the axial direction, a separate transfer device for transferring the workpieces W to adjacent gripping devices 21 is not required.
The stretch-rolling device 1 according to
Then the manipulator 20 moves the workpieces W into the fully advanced position, shown in
During or after the transfer to the fully advanced position, a new workpiece/blank Wn is fed to the first stage S1 by a feeder (not shown in the figures) by positioning it on the corresponding position of the support 30. The feeding of a new workpiece Wn is shown in
After the transfer into the completely advanced position, the finished workpiece Wf, which has completely passed through the rolling process, is also gripped by a discharge device (not shown in the figures) and discharged or removed from the process. This method step is shown in
With the workpieces W held in the fully advanced position by the support 30, the gripping devices 21 can release their associated workpieces W, and the manipulator 20 drives the gripping devices 21 substantially axially toward the first stage S1 (downward in the Figures) where the first gripping device 21 grips the newly supplied workpiece Wn and the other gripping devices 21 grip the adjacent workpiece W of the preceding stage S2 to S4, respectively. The transfer of the workpieces W can be seen from a comparison of
After the finished workpiece Wf has been discharged and all workpieces W, including the new workpiece/blank Wn, have been gripped by the gripping devices 21—this process stage can be regarded as the start of a work cycle—the workpieces W are rolled. For this purpose, the workpieces W are gripped by the roll profiles of the corresponding stages S1 to S4 of the rolls 10, transported by rotating the rolls 10 (in the direction of rotation opposite to the transfer into the advanced position) and plastically deformed. The direction of rolling (to the left in the Figures) is denoted herein by the reference symbol WR. The stretch-rolling device then returns to the position shown in
The stretch-rolling device according to
In addition to the technical effects that apply to all of the embodiments presented herein and are described below, an advantage of the present embodiment of
The two embodiments of
For this purpose, the support 30 is designed to be movable at least in the axial direction. It can be configured passive, so that the workpieces W are placed on it or the support 30 supports the workpieces W without actively gripping or clamping them. Alternatively, the support 30 can have retaining means 31 which are set up to temporarily retain, for example to grip or clamp, the workpieces W.
The support 30 can be installed on the working side AS as shown in
The tray 30 can alternatively or additionally be configured to be movable in the feed/retraction direction between the two sides, i.e., the working side AS and the side opposite to the working side AS. Furthermore, several supports 30 can be provided, as can be seen in
At the end of the rolling process, the workpieces W of stages S1 to S4 usually have slightly different lengths. In order to compensate for these differences in length, at least some, preferably at least N−1 (here N designates the number of stages), gripping devices 21 have a length-compensating section 22. The length compensation sections 22 can be implemented, for example, by a spring system that can deflect to different extents for the length compensation of the gripping devices 21.
In the herein described embodiments, the workpieces W are rolled on the “return” i.e., the transfer from the advanced position to the starting position of
The herein described stretch-rolling concept allows simultaneous occupation of all or at least several stages S1 to S4, for example every second stage. A reduced occupation of stages S1 to S4 may be necessary to comply with machine limits with regard to force or energy consumption. Nevertheless, the stretch-rolling device 1 enables the output of the workpieces W to be optimized due to the parallel configuration. This is achieved without the need for two manipulators on opposite sides of the pair of work rolls. The manipulator on the working side AS is only expanded by further gripping devices 21, such as tongs, which achieves the improved functionality without a significant increase in the structural and procedural complexity. The transverse transport, i.e., transport of the workpieces W in the axial direction, is implemented, for example, either by an additional transverse transport axis in the manipulator 20 in conjunction with a stationary support 30 or by combining a manipulator 20 that is stationary in the axial direction with a support 30 that can be moved in the axial direction. In this case, it is not necessary for the “second” end of the workpieces W to be gripped by another manipulator. In this way, a high output is achieved with a comparatively small number of assemblies, which also improves the reliability and maintainability of the stretch rolling device.
As far as applicable, all individual features that are presented in the embodiments can be combined with one another and/or exchanged without departing from the scope of the invention.
| Number | Date | Country | Kind |
|---|---|---|---|
| 10 2019 213 833.0 | Sep 2019 | DE | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2020/075271 | 9/10/2020 | WO |
