STRAIGHTENING MACHINE WITH A MODULAR INTERCHANGEABLE CASETTE SYSTEM

Abstract

A straightening machine having an allocated straightening roll drive including a top bearing frame and a bottom bearing frame, in which a plurality of straightening rolls and supporting rolls are held in a cassette-like manner and arranged in an interchangeable manner. An improved adaptability of a straightening machine to different straightening requirements and straightening areas is achieved in that all the straightening rolls and supporting roils respectively arranged in the top and/or bottom bearing frame are distributed into several straightening roll segments that are modularly adapted to one another and each configured in the form of an interchangeable cassette. Each straightening roll segment includes at least one layer of supporting rolls and at least one allocated straightening roll.

Description

The invention focuses on a straightening machine having an associated straightening roll drive, including an upper bearing frame and a lower bearing frame, in which a plurality of straightening rolls and supporting rollers are held in a cassette-like manner and are arranged so as to be replaceable.

When processing flat material, such as flat steel or flat material produced from non-ferrous metal, the necessary production steps usually also include the straightening process in order to produce level plane (steel) bands or plates that are free of residual stress. During the straightening process, the respective material is bent repeatedly in straightening machines, with or without tension, by means of straightening rolls in order to produce the desired straightening effect. When straightening flat products, the respective product is usually guided through between a group of upper and lower straightening rollers and, at the same time, is deformed plastically as a result of a corresponding setting of the upper and lower straightening rollers. In order to achieve the plastics deformation required in each case in this connection, there is a need for a bending radius which is or can be various depending on the band thickness or plate thickness and yield strength of the product to be straightened and which is realized in each case by means of suitable roller diameters, roller divisions and roller penetration depths. The possible plastic deformation of the product or of the material is all the greater, in this connection, the smaller the roller diameter. However, arbitrarily small rollers cannot be used in a straightening machine as, on the one hand, the bending forces arising, where applicable, cannot be absorbed and, on the other hand, the required process moments for representing the shaping work, where applicable, cannot be made available by means of the small straightening rollers on account of the mechanical stress being too great. This is the reason why, in the case of a given roller diameter, a given roller division, being the distance between centers of two adjacent rollers, and a given penetration depth and given or desired plastic deformation, in each case only one defined product spectrum or material spectrum, which depends on the respective product thickness and the yield strength thereof, is able to be straightened. The use of straightening machines with interchangeable cassettes and different roller diameters is disclosed in the prior art in order, then, to configure straightening machines here in a relatively flexible manner and so as to be adaptable to different products.

Such a generic straightening machine is disclosed in EP 1 584 384 B1. Said document discloses a straightening machine which includes a motor-fitted drive unit and a main transmission which is drivingly connected thereto, wherein all the interchangeable cassettes, which are replaceable one for another, are connectable in each case to the main transmission, which interchangeable cassettes each comprise straightening rollers with a variously sized diameter and a different number of straightening rollers. In addition, the replaceable interchangeable cassette with straightening rollers, which comprise a small straightening roller diameter, comprises a single intermediate transmission which is integrated in the interchangeable cassette and is couplable to the main transmission of the straightening machine. Interchangeable cassettes, which are each fitted with a fixedly predetermined tool set, which consists of straightening and supporting roller combinations, are used in this connection. All the straightening rolls and supporting rollers which are present on an upper bearing frame or a lower bearing frame are replaced in each case. In this respect, it is known from the prior art to replace each complete set of straightening rolls and supporting rollers by means of an interchangeable cassette.

An alternative to replacing a complete set by means of an interchangeable cassette is described in WO 2008/145355 A1. Said document discloses the replacement in each case of individual straightening rolls of a straightening machine. Where required, upper and lower pairs are able to be replaced together.

In addition, the metal sheet producers are nowadays faced with the requirement that a large spectrum of metal sheets or bands of the most varied dimensions and strengths have to be produced in small as well as in large batch sizes. This results in the straightening machines required for this having to cover a large straightening range. In order to be able to cover a large straightening range, variously sized straightening roll diameters and/or variously sized divisions have to be used in the straightening machines in order to obtain optimum straightening results. This can be achieved, in principle, with the interchangeable cassette straightening machines, as are described, for example, in EP 1 584 384 A1, which are fitted in each case with fixedly predetermined tool sets, i.e. with fixedly predetermined combinations of straightening rolls and supporting rollers, however without the flexibility appropriate to today's production conditions. However, in order to be able to straighten a large spectrum of dimensions and strengths with one straightening machine, a plurality of different interchangeable cassette sets have to be held on standby. Where applicable, even multiple straightening machines have to be provided in order to be able to adapt the requirements in an optimum manner to a product to be straightened in each case, i.e. to thin, middling or even thick metal sheets.

Consequently, there is a need additionally to expand existing straightening machines with reference to the straightening range which is realizable therewith, i.e. the product dimensions to be processed therewith, and in particular also to enable a cost-efficient and rapid machine retrofit.

The object underlying the invention, consequently, is to create a solution which provides improved adaptability of a straightening machine to different straightening requirements and straightening ranges.

In the case of a straightening machine of the type designated in more detail in the introduction, said object is achieved according to the invention in that all the straightening rolls and supporting rollers, which are arranged respectively in the upper and/or lower bearing frame, are divided into multiple straightening roll segments, which are coordinated with one another in a modular manner and are realized in each case in the manner of a replaceable interchangeable cassette, wherein each straightening roll segment includes at least one layer of supporting rollers and at least one associated straightening roll.

Advantageous further developments and expedient configurations of the invention are the object of the subclaims.

The invention therefore proposes providing a modular straightening tool (modular straightening roll segment) inside a lower and/or upper cassette or a lower and/or upper bearing frame in order to ensure cost-efficient and rapid machine retrofitting for expanding or adapting the straightening range of the straightening machine. In this connection, the respective modular straightening tool or the respective tool module consists of a modular segment which is realized in the manner of a replaceable interchangeable cassette, each straightening roll segment comprising at least one layer of supporting rollers and at least one associated straightening roll. The respective straightening roll segments therefore form modular segments which each realize a tool module, the upper and/or the lower bearing frame providing the tool carrier. It is consequently possible to configure the upper and/or the lower bearing frame with a variable number of modular straightening roll segments or tool modules so as to be interchangeable and replaceable, each of which consist of straightening roll and supporting roller combinations with different diameters, divisions and roll materials and each of which are selected for the optimum adaptation to the straightening job to be carried out in each case, in particular the material to be straightened in each case. It is possible to replace only individual modular straightening roll segments or, however, also all straightening roll segments of a bearing frame and, as a result, to retrofit the straightening machine in a corresponding manner.

On account of the modular design, it is additionally possible to realize a large variety of different straightening roll segment combinations in one straightening machine and, as a result, to create clearly improved adaptability of the straightening machine to different straightening requirements and straightening ranges. In this connection, as a result of selecting the respective straightening roll segments suitably with respect to the related selection of the grading of straightening roll diameters and of the division realized therewith, it is also possible to expand the entire straightening range of the straightening machine in a significant manner. It is also possible, by means of skillful selection of the straightening rolls actively participating in the straightening process, to fit out a straightening machine so that it is adapted to the respectively desired technological requirements of the straightening processes and, as a result, to improve the straightening quality. In cases where simply one straightening roll of the equipment of a straightening machine is worn, it is also possible for only the module which comprises said straightening roll to be replaced. It is no longer necessary then to replace the complete set of the straightening machine which includes all the straightening rolls.

The fitting out of a straightening machine can, consequently, be effected in dependence on the metal sheet parameters and tool load history, i.e. on the straightening roll load history. Individual straightening rolls of a straightening machine are stressed to varying degrees during the straightening process such that the operating service lives thereof are different. The particularly heavily stressed tool can then be replaced here. However, within the framework of a replacement routine, a cyclical exchange of different, identically designed modules is able to be performed at a certain position inside the upper and/or lower bearing frame of the straightening machine.

A further advantage of the invention consists in that now just smaller units, also from a weight point of view, will have to be replaced in a straightening machine. This makes it possible to work with crane capacities which have a smaller carrying capacity than those which would be necessary should a complete set of a straightening machine have had to be replaced as a whole. The necessary space required for one single module-like straightening roll segment is also less than for a complete set of straightening rolls. The lighter weight and the smaller dimension of a module-like straightening roll segment in relation to a complete set of straightening rolls and/or supporting rollers also makes it possible then additionally to set up tool centers or processing centers, where applicable, in the vicinity of the straightening machine.

The following advantages can be obtained overall with the invention:

• • reduction in the transport weights and in the dimensions of the tool modules;
  • optimum configuration of the straightening tool with respect to the product to be straightened;
  • expandable straightening roll/supporting roller combinations which are adaptable to changes in the production program which is to be processed with the straightening machine;
  • reduction in the investment costs of a cassette solution compared to replacing complete sets;
  • reduction in fitting times as a result of the modular design of the straightening/supporting roller units;
  • as a result of the cyclical replacement of straightening/supporting roller units inside the cassette, the service life/lifetime of the tools is able to be standardized.

In one configuration, the invention provides that the straightening roll segments, which are coordinated with one another in a modular manner, are realized so as to be replaceable individually or in groups and are arranged in the upper and/or the lower bearing frame. The achievement here is that total, almost complete flexibility with regard to the positioning of individual straightening roll segments is ensured.

In order to be able to provide the straightening machine with straightening rolls at different positions in a particularly flexible and interchangeable manner, it is advantageous according to a further development of the invention when both all the straightening rolls and supporting rollers which are arranged in the upper bearing frame and all the straightening rolls and supporting rollers which are arranged in the lower bearing frame are arranged in multiple straightening roll segments which are each coordinated with one another in a modular manner and are realized in the manner of a replaceable interchangeable cassette.

In order to be able to provide good adaptation to different straightening requirements and straightening regions, it is additionally expedient for all the straightening rolls and supporting rollers, which are arranged respectively in the upper and/or lower bearing frame, to be divided into identical or variously dimensioned types of modular straightening roll segments and/or interchangeable cassettes, which is also provided by the invention.

It is additionally expedient to use different types of modular straightening roll segments such that the invention additionally provides that all the straightening rolls and supporting rollers, which are arranged respectively in the upper and/or lower bearing frame, are divided, with reference to the respective straightening roll diameter and/or supporting roller diameter and/or with reference to the respective number of straightening rolls and/or of supporting rollers, into types of modular straightening roll segments and/or interchangeable cassettes which are fitted variously with straightening rolls and/or supporting rollers.

It is particularly advantageous when the individual modular straightening roll segments each realize an interchangeable cassette and are in each case coordinated with one another such that, as a whole, they realize an interchangeable cassette system which is formed from interchangeable cassettes which can be exchanged for one another. The invention is consequently distinguished additionally in that the individual modular straightening roll segments realize interchangeable cassettes of an interchangeable cassette system which can be exchanged for one another individually or in groups.

Such an interchangeable cassette system can include variously dimensioned types of modular straightening roll segments and/or interchangeable cassettes, which is also provided by the invention.

In this connection, the interchangeable cassette system can include types of modular straightening roll segments and/or interchangeable cassettes which are fitted variously with straightening rolls and/or supporting rollers with reference to the respective straightening roll diameter and/or supporting roller diameter and/or with reference to the respective number of straightening rolls and/or of supporting rollers, as a result of which the invention is additionally distinguished.

In order to be able to detect operating data and wear states and to be able to determine and identify service lives and necessary cycles for interchanging straightening rolls, the invention also provides finally that said straightening machine comprises means for detecting and/or storing material parameters of the material to be straightened and/or means for detecting and/or storing method parameters which act on each and every modular straightening roll segment during a straightening operation and/or status parameters which are automatically adjusted on each and every modular straightening roll segment after a straightening operation.

The straightening roll segments, which are coordinated with one another in a modular manner, are in each case replaceable, complex elements of the straightening machine which each form per se a closed operating unit and in this respect a “modular straightening roll segment”.

The invention is explained in more detail below as an example by way of the drawing, in which:

FIG. 1 shows a schematic side view of the design of a straightening machine according to the invention produced from modular straightening roll segments,

FIG. 1a shows a schematic side view of a modular straightening roll segment when seen in side view in the processing direction of the straightening machine,

FIG. 2 shows exemplary embodiments of possible tool retrofits as a result of replacing modular straightening roll segments,

FIG. 3 shows a schematic representation of various arrangements of different combinations of straightening roll segments in the lower bearing frame,

FIG. 4 shows a schematic representation of various combinations of modular straightening roll segments in the upper bearing frame,

FIG. 5 shows a flow chart for detecting and using identified method parameters and/or status parameters and

FIG. 6 shows a schematic representation of the arrangement of a straightening machine according to the invention with an associated tool processing station.

FIG. 1 shows a straightening machine which is designated overall by the reference 1 and includes an upper bearing frame 2 and a lower bearing frame 3. Three straightening roll segments 4, 5 and 6, which are coordinated with one another in a modular manner, are each realized in the manner of a replaceable interchangeable cassette and between which all the straightening rolls 7 and supporting rollers 8 which are arranged in the upper bearing frame 2 are divided, are arranged in the upper bearing frame 2. The three modular straightening roll segments 4, 5, 6 are realized uniformly in this exemplary embodiment and each comprise both the same number of straightening rolls 7 and supporting rollers 8 and such with identical diameters. The straightening roll 2′ is arranged in the modular straightening roll 4, the straightening roll 4′ is arranged in the modular straightening roll 5 and the straightening roll 6′ is arranged in the modular straightening roll 6.

Four straightening roll segments 9, 10, 11 and 12, which are coordinated with one another in a modular manner and are each realized in the manner of a replaceable interchangeable cassette, are arranged in the lower bearing frame 3. All the straightening rolls 7 and supporting rollers 8 arranged in the lower bearing frame 3 are once again divided between said straightening roll segments. In this case too, the straightening rolls 7 of the respective modular straightening roll segments 9-12 comprise the same diameter and are realized with the identical number in a respective modular straightening roll segment 9-12. In the same way, the modular straightening roll segments 9-12 are fitted with supporting rollers 8, each with identical diameters and with the identical number. If a changeover with reference to individual or multiple straightening rolls 7 and supporting rollers 8 is then to be effected, the individual modules 4-6 and 9-12 are able to be replaced and interchanged independently of one another. As a result, the straightening machine 1 is able to be adapted to different straightening requirements.

FIG. 1a shows a schematic side view of a modular lower straightening roll segment 9 when viewed in a side view in the processing direction 40. It can be seen how each straightening roll 7 is supported by multiple supporting rollers 8.

FIG. 2 shows a lower bearing frame 3 where the modular straightening roll segments 10 and 11 according to the exemplary embodiment according to FIG. 1 have been replaced by four straightening roll segments 13-16 which are half as wide. The modular straightening roll segments 13-16 are also designed identically to one another, but clearly comprise smaller roller diameters and roll diameters compared to the straightening roll segments 9 and 12.

In the left-hand part of FIG. 2, it is shown by the dot dash line that individual modules, here as an example the modules 12 and 15, can be replaced within the framework of a tool retrofit. However, it is also possible for multiple straightening roll segments to be replaced in groups, as is shown in the middle image of FIG. 2 in the dot-dash representation. The removed straightening roll segments 13-16 are replaced by straightening roll segments 17-19 which are to be installed. The right-hand part of FIG. 2 shows a cyclical changing of individual modular straightening roll segments 13-16. Here, the straightening roll segment 13 is removed, the straightening roll segments 14-16 then slip to the straightening roll segment 9 in the lower bearing frame 3 to close the gap created by the removed straightening roll segment 13. The straightening roll segment 13 is then inserted, in turn, into the gap created on the side of the straightening roll segment 12. In this way, the individual straightening roll segments 13-16 can be moved to positions which are exposed to different mechanical stresses during the straightening a sheet metal material that is guided by the straightening machine.

As a result, uniform wear can be achieved on the straightening rolls of the straightening roll segments 13-16.

FIG. 3 shows multiple combination options of various modular straightening roll segments 9-21 in their arrangement in the lower bearing frame 3. In an analogous manner, FIG. 4 shows a schematic representation of different arrangements and combinations of modular straightening roll segments 4-6 and 22-30 in the upper bearing frame 2.

It can be seen from FIGS. 3 and 4 that not only can variously sized rollers and/or rolls be combined in an arbitrary manner, but also the divisions (distance between centers) are variable in dependence on the pairing.

In a manner not shown, the individual straightening roll segments can also be moved vertically up or down, with reference to the sheet metal material traversing the straightening machine, by such an amount that they are not continuously in contact with the sheet metal material to be processed, as is known, in principle, from sheet metal forming by means of straightening machines. In this respect, the number of straightening rolls 7 that are active in each case is able to vary without individual modular straightening roll segments having to be replaced.

FIG. 5 shows schematically how the processing of the detected status parameter “straightening roll—actual diameter” and the detected method parameter “sheet metal data acquisition: temperature, strength, thickness” can be utilized in order, by means of filed data and a computer and a storage unit, to obtain automated support and indication as to whether, on the one hand, the correct tool combination, i.e. the combination of modular straightening roll segments that is necessary in the current case for achieving the desired straightening result, is set and present and whether they still comprise the necessary status parameters, i.e. for example, a sufficient straightening roll diameter. This is then checked prior to the start of the sheet metal straightening process, and in the case where the present combination of modular straightening roll segments is ascertained as not sufficient or applicable, a tool change or a replacement of individual modular straightening roll segments is performed. The sheet metal straightening process cannot start until this has been effected.

FIG. 6 shows a schematic representation of the arrangement of a straightening machine 1 according to the invention with an associated straightening roll drive 31, which includes a main drive 32 and a master drive 33 as well as drive trains 34. A tool processing station 35, which includes a grinding machine 36, a reserve of modular straightening roll segments with straightening roll sets 37 and a tool manufacturing unit with a crane track 38, is arranged on the side located opposite the straightening roll drive 31.

The modular straightening roll segments 4-6 and 9-30, with reference to the frame width 41 of the lower bearing frame 3 or to the frame width 42 of the upper bearing frame 2, measured in the processing direction 40 of a metal sheet to be processed, are coordinated with one another in a modular manner, in dependence on their operation site in the upper bearing frame 2 or in the lower bearing frame 3 with reference to their respective width 43, 44, in such a manner that in each case a modular straightening roll segment or multiple modular straightening roll segments are able to be placed at a position which is defined by the respective width 43, 44 or by a multiple of a respective width 43, 44. In this connection, it is naturally also possible for the case where a certain position is to be left free, to insert corresponding blocks there which are not fitted with straightening rolls 7.

LIST OF REFERENCES

1 Straightening machine

2 Bearing frame

3 Bearing frame

4-6 Straightening roll segment

7 Straightening roll

8 Supporting roller

9-30 Straightening roll segment

31 Straightening roll drive

Claims

1-9. (canceled)

10. A straightening machine having an associated straightening roll drive, comprising: an upper bearing frame; a lower bearing frame; and a plurality of straightening rolls and supporting rollers held in the upper bearing frame and the lower bearing frame in a cassette-like manner and arranged so as to be replaceable, wherein all the straightening rolls and supporting rollers, which are arranged respectively in the upper and/or lower bearing frame, are divided into multiple straightening roll segments, which are coordinated with one another in a modular manner and are realized in each case as a replaceable interchangeable cassette, wherein each straightening roll segment includes at least one layer of supporting rollers and at least one associated straightening roil,

11. The straightening machine according to claim 10, wherein the straightening roil segments, which are coordinated with one another in a modular manner, are configured so as to be replaceable individually or in groups and are arranged in the upper bearing frame and/or the lower bearing frame.

12. The straightening machine according to claim 10, wherein ail the straightening rolls and all the supporting rollers arranged in the upper bearing frame and all the straightening rolls and all the supporting rollers arranged in the lower bearing frame are arranged in multiple straightening roll segments that are each coordinated with one another in a modular manner and are configured as a replaceable interchangeable cassette.

13. The straightening machine according to claim 10, wherein all the straightening rolls and the supporting rollers, which are arranged respectively in the upper bearing frame and/or the lower bearing frame, are divided into identical or variously dimensioned types of modular straightening roll segments and/or replacement cassettes.

14. The straightening machine according to claim 10, wherein all the straightening rolls and the supporting rollers, which are arranged respectively in the upper bearing frame and/or the lower bearing frame, are divided, with reference to a respective straightening roll diameter and/or supporting roller diameter and/or with reference to a respective number of straightening rolls and/or number of supporting rollers, into types of modular straightening roll segments and/or interchangeable cassettes which are fitted variously with straightening rolls and/or supporting rollers.

15. The straightening machine according to claim 10, wherein the individual modular straightening roll segments form interchangeable cassettes of an interchangeable cassette system that are replaceable for one another individually or in groups.

16. The straightening machine according to claim 15, wherein the interchangeable cassette system includes variously dimensioned types of modular straightening roll segments and/or interchangeable cassettes.

17. The straightening machine according to claim 15, wherein the interchangeable cassette system includes types of modular straightening roll segments and/or interchangeable cassettes that are fitted variously with straightening rolls and/or supporting rollers with reference to a respective straightening roll diameter and/or supporting roller diameter and/or with reference to a respective number of straightening rolls and/or number of supporting rollers,

18. The straightening machine according to claim 10, further comprising at least one of: means for detecting and/or storing material parameters of a material to be straightened; and means for detecting and/or storing method parameters which act on each and every modular straightening roll segment during a straightening operation and/or status parameters which are automatically adjusted on each and every modular straightening roll segment after a straightening operation.