U.S. patent application number 13/154502 was filed with the patent office on 2011-10-13 for cold roll forming apparatus.
This patent application is currently assigned to SMORGON STEEL LITESTEEL PRODUCTS PTY LTD. Invention is credited to Ross John Bartlett, Alexander Noller.
Application Number | 20110247384 13/154502 |
Document ID | / |
Family ID | 35781496 |
Filed Date | 2011-10-13 |
United States Patent
Application |
20110247384 |
Kind Code |
A1 |
Bartlett; Ross John ; et
al. |
October 13, 2011 |
COLD ROLL FORMING APPARATUS
Abstract
A cold roll forming mill for the manufacture of hollow flange
seam welded beams from a single strip of metal comprises a forming
station (1), a seam guide and welding station (2) and a shaping
station (3). Either or both of the forming and shaping stations
(1,3) comprise independently supported side engaging roll
combinations (7,12) adapted, in use, to roll either or both of
opposite sides of the strip. Adjacent transverse pairs of side
engaging roll (7,12) combinations are selectively movable relative
to each other in a transverse direction perpendicular to a
direction of travel of said strip through said mill. At least some
of the side engaging roll combinations (7,12) are driven. Drive
rolls (6) spaced within the forming and shaping stations (1,3)
engage the strip between opposite edges thereof.
Inventors: |
Bartlett; Ross John;
(Mundoolun via Beaudesert, AU) ; Noller; Alexander;
(Springwood, AU) |
Assignee: |
SMORGON STEEL LITESTEEL PRODUCTS
PTY LTD
Port Melbourne
AU
|
Family ID: |
35781496 |
Appl. No.: |
13/154502 |
Filed: |
June 7, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12750016 |
Mar 30, 2010 |
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13154502 |
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11570937 |
Dec 19, 2006 |
7721579 |
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PCT/AU2005/000898 |
Jun 22, 2005 |
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12750016 |
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Current U.S.
Class: |
72/181 |
Current CPC
Class: |
B21D 19/04 20130101;
B21D 5/08 20130101; B23K 11/0873 20130101 |
Class at
Publication: |
72/181 |
International
Class: |
B21D 5/08 20060101
B21D005/08 |
Foreign Application Data
Date |
Code |
Application Number |
Jun 23, 2004 |
AU |
2004903390 |
Claims
1. A cold roll forming mill for the manufacture of hollow flange
seam welded beams from a single strip of metal, said mill
comprising: a forming station; a seam guide and welding station;
and, a shaping station; wherein either or both of said forming
station and said shaping station comprises independently supported
side engaging roll combinations adapted, in use, to roll either or
both of opposite sides of said strip, adjacent transverse pairs of
said side engaging roll combinations being selectively movable
relative to each other in a transverse direction perpendicular to a
direction of travel of said strip through said mill, and all
forming and shaping rolls of either or both of said forming station
and said shaping station consist of said side engaging roll
combinations; and wherein each of said roll stand frames is
independently and selectively movable transversely of a mill
bed.
2. A mill as claimed in claim 1 wherein some or all of said side
engaging roll combinations are idler rolls.
3. A mill as claimed in claim 1 wherein some or all of said side
engaging roll combinations are drive rolls.
4. A mill as claimed in claim 1 wherein drive rolls, spaced within
said forming station and spaced within said shaping station engage
a central region of said strip between formed edge regions
thereof.
5. A mill as claimed in claim 4 wherein some or all of said drive
rolls engage said strip over a substantial portion thereof between
formed edge regions of said strip.
6. A mill as claimed in claim 4 wherein some or all of said drive
rolls engage said strip adjacent a central portion spaced from said
formed edges.
7. A mill as claimed in claim 4 wherein some or all of said drive
rolls engage said strip adjacent opposed formed edges thereof.
8. A mill as claimed in claim 1 wherein transverse pairs of side
engaging roll combinations are mounted on respective roll stand
frames.
9. A mill as claimed in claim 1 wherein transverse pairs of said
side engaging roll combinations are movably mounted on a common
roll stand frame.
10. A mill as claimed in claim 1 wherein at least one side engaging
roll of a side engaging roll combination is rotatably mounted on an
inclined axis lying in a transverse plane perpendicular to a
direction of travel of a strip of metal through said side engaging
roll combination.
11. A method of cold roll forming a hollow flange member from a
single strip of metal, said method comprising: driving a metal
strip through a cold rolling mill by driven rolls engaging a planar
central region of said strip; forming a contour along at least one
edge region of said strip by forming rolls; continuously seam
welding by an ERW process a free edge of said at least one edge
region to a surface of said strip along a predetermined weld region
to form a hollow flange; and, shaping said hollow flange by shaping
rolls to form a shaped hollow flange of desired cross-sectional
configuration; wherein said forming rolls and said shaping rolls
consist of side engaging roll combinations each being independently
and selectively movable relative to each other in a transverse
direction perpendicular to a direction of travel of said strip
through said mill.
12. A method as claimed in claim 11 wherein one or more of said
forming rolls are driven to assist in driving said strip through
said mill.
13. A method as claimed in claim 11 wherein one or more of said
shaping rolls are driven.
14. A method as claimed in claim 11 wherein prior to continuous
seam welding, said free edge is aligned linearly with a
predetermined weld axis on said surface of said strip and said at
least one free edge is guided through a predetermined linear
trajectory along an incidence axis of a subsequent weld junction
between said at least free one free edge and said surface wherein
energy imparted to said hollow flange member is focussed by a
proximity effect along said predetermined weld axis on said surface
prior to fusing said at least one free edge thereto.
15. A method as claimed in claim 11 wherein said at least one free
edge is aligned with said weld region by one or more seam rolls
each having a circumferential shoulder providing an abutment for
said at least one free edge.
16. A method as claimed in claim 15 wherein at least one free edge
of said metal strip is urged into abutment with said
circumferential shoulder by a contoured guide roll.
17. A method as claimed in claim 15 wherein said metal strip is
supported centrally by opposed cylindrical roll surfaces adjacent
said weld region as said at least one free edge is urged into
abutment with said circumferential shoulder.
18. A method as claimed in claim 15 wherein at least one free edge
is guided toward said closure region at a predetermined angle
relative to strip surface by adjustably mounted seam rolls.
19. A method as claimed in claim 11 wherein said at least one free
edge of said metal strip is guided through said predetermined
trajectory by a contoured squeeze roll extending over said
contoured surface of said metal strip between spaced substantially
parallel contact faces of said contoured squeeze roll.
20. A method as claimed in claim 11 wherein weld energy is imparted
to said free edge and said predetermined weld region by an
electrical induction coil, said coil extending substantially around
said metal strip in a plane substantially perpendicular to a
longitudinal axis thereof.
Description
FIELD OF THE INVENTION
[0001] This invention is concerned with improvements in cold roll
forming mills.
[0002] The invention is concerned particularly, although not
exclusively, with aspects of a cold roll forming mill for hollow
flange members.
[0003] More particularly, the invention is concerned with aspects
of a cold roll forming mill for the continuous production of dual
welded hollow flange beams.
BACKGROUND OF THE INVENTION
[0004] It is known to produce hollow flange members by cold forming
light gauge steel strip to form a section having a planar web and
hollow triangular cross-section flanges extending along opposite
sides of the web. U.S. Pat. Nos. 991,603 and 3,342,007 describe the
manufacture of such beams by a cold forming process wherein the
free edge of the hollow flange lies adjacent the edge of the web
but is not secured thereto. These hollow flanges are known as
"open" flanges and lack torsional resistance.
[0005] U.S. Pat. No. 3,698,224 describes the manufacture of hollow
flange beams by a cold forming process wherein seam welded steel
tubing is subjected to a shaping process which flattens the tube to
form a hollow flange beam with a pair of juxtaposed webs.
[0006] In order to improve the section efficiency of "open" flange
beams, it has been proposed to secure the edges of the hollow
flanges to the web to improve torsional stiffness in the flanges.
U.S. Pat. Nos. 6,436,552, 6,115,986, 6,397,550 and 5,692,353
describe cold formed thin gauge hollow flange beams wherein a lip
formed along the edge of the hollow flange is secured to the web
intermediate its edges by fasteners, clinch perforations, spot
welding or the like.
[0007] Russian Inventor's Certificate 827723 describes a cold
formed thin gauge hollow flange beam wherein the free edges of the
hollow flanges are formed as internally folded lips or formations
to support the hollow flanges against localized crushing under
load. A side wall of the hollow flange is welded by a fillet weld
to the edge of the web to form a "closed" flange.
[0008] In order to reduce the costs of manufacture of cold formed
"closed" hollow flange beams, an in-line dual welding process was
devised and described in U.S. Pat. No. 5,163,225, in respect of
which, the assignee of the present invention is the successor in
title. The dual welding process described for the first time an
in-line high frequency induction or resistance welding process
wherein a free edge of a hollow flange was welded to the face of
the strip of metal to form a weld seam adjacent the edge of the web
of the hollow flange beam so formed. In that process, a
conventional tube rolling mill was adapted to produce hollow flange
beams having circular cross-section flanges at the weld station,
the circular cross-section flanges subsequently being shaped to
triangular cross-section to form "Dogbone" (Registered Trade Mark)
beams.
[0009] While generally satisfactory for a relatively narrow range
of web and flange widths and a narrow range of metal strip gauges,
an adaptation to a conventional mill structure was considered to be
not only limiting in the scope of beam sizes but also inefficient
and capital intensive in terms of requiring a large number of roll
sets of large diameter which caused considerable unproductive
downtime each time a roll change was required for a different beam
size. Moreover, difficulties in maintaining weld seam stability
imposed severe limitations on yield due to a high reject rate.
[0010] One proposal to address some of the shortcomings in the
original "Dogbone" process was described in U.S. Pat. No.
5,403,986. This document proposed a tandem mill structure with
separate spaced cold forming mills inclined to a longitudinal axis
in a forming section of the mill. Shaped flanges, independently
produced from separate strips of metal were brought together with a
third planar web strip such that the edges of the web protruded
between the free edges of the flanges prior to welding. The welding
and forming stations were substantially the same as those described
in U.S. Pat. No. 5,163,225.
[0011] As used herein, the expression "ERW" refers to electrical
resistance or induction welding using either contacts or induction
coils/impeders to create a current in the member and other forms of
electrical resistance welding.
[0012] It is an aim of the present invention to overcome or
alleviate at least some of the disadvantages of prior art methods
and apparatus for the production of hollow flange seam welded
beams.
SUMMARY OF THE INVENTION
[0013] According to one aspect of the invention there is provided a
cold roll forming mill for the manufacture of hollow flange seam
welded beams from a single strip of metal, said mill
comprising:
[0014] a forming station;
[0015] a seam guide and welding station; and,
[0016] a shaping station, said mill characterized in that either or
both of said forming station and said shaping station comprises
independently supported side engaging roll combinations adapted, in
use, to roll opposite sides of said strip, adjacent transverse
pairs of said side engaging roll combinations being selectively
movable relative to each other in a transverse direction
perpendicular to a direction of travel of said strip.
[0017] Suitably, some or all of said side engaging roll
combinations are idler rolls.
[0018] If required, some or all of said side engaging roll
combinations are drive rolls.
[0019] Preferably, drive rolls, spaced within said forming station
and spaced within said shaping station engage a central region of
said strip between formed edges thereof.
[0020] If required, some or all of said drive rolls may engage said
strip over a substantial portion thereof between formed edges of
said strip.
[0021] Alternatively, some or all of said drive rolls may engage
said strip adjacent a central portion spaced from said formed
edges.
[0022] In a still further alternative, some or all of said drive
rolls may engage said strip adjacent opposed formed edges
thereof.
[0023] The transverse pairs of side engaging roll combinations may
be mounted on respective roll stand frames.
[0024] If required, transverse pairs of said side engaging roll
combinations may be movably mounted on a common roll stand
frame.
[0025] Suitably, said roll stand frames are selectively movable
transversely of a mill bed.
[0026] The transverse pairs of side engaging roll combinations may
be aligned in a transverse plane perpendicular to a direction of
travel of a strip of metal between said side engaging roll
combinations.
[0027] Preferably, each of said transverse pair of side engaging
roll combinations is located in a respective longitudinally spaced
transverse plane perpendicular to a direction of travel of a strip
of metal between said side engaging roll combinations.
[0028] If required, at least one of a side engaging roll of a side
engaging roll combination is rotatably mounted on an inclined axis
lying in a transverse plane perpendicular to a direction of travel
of a strip of metal through said side engaging roll
combination.
[0029] At least one side engaging roll of a side engaging roll
combination may be rotatably mounted on a horizontal axis lying in
a transverse plane perpendicular to a direction of travel of a
strip of metal through said side engaging roll combination.
[0030] Suitably, at least one side engaging roll of a side engaging
roll combination is rotatably mounted on a vertical axis.
[0031] If required, said drive rolls may alternate with said side
engaging roll combinations along a mill bed.
[0032] Suitably, any or all of said at least one of a side engaging
roll of a side engaging roll combination is rotatable on an axis
selectively angularly adjustable in a plane lying perpendicular to
a direction of travel of a metal strip in said mill.
[0033] Preferably, said drive rolls are located between pairs of
longitudinally spaced side engaging roll combinations along said
mill bed.
[0034] Suitably, said seam guide and welding station includes a
seam guide roll stand having at least one seam guide roll having a
circumferential shoulder pivotally mounted on an inclined
rotational axis lying in a transverse plane perpendicular to a
direction of travel of said strip.
[0035] If required, said at least one seam guide roll may be
selectively movable along said inclined axis.
[0036] The rotational axis of said seam guide roll may be
selectively angularly adjustable in said transverse plane.
[0037] Preferably, the seam guide and welding station includes a
weld box stand having at least one squeeze roll pivotally mounted
on an inclined rotational axis lying in a transverse plane
perpendicular to a direction of travel of said strip.
[0038] Suitably, said at least one squeeze roll may be selectively
movable along said inclined axis.
[0039] If required, the rotational axis of said at least one
squeeze roll may be selectively angularly adjustable in said
transverse plane.
[0040] Preferably, one or more of said forming rolls and/or said
shaping rolls may be rotatably journalled in a mounting frame
releasably securable to a respective forming roll stand and/or a
shaping roll stand.
[0041] If required, one or more sets of said forming rolls and/or
said shaping rolls may be rotatably journalled in a mounting frame
releasably securable to a respective forming roll stand and/or a
shaping roll stand.
[0042] Suitably, said mounting frame is adjustable in a transverse
plane perpendicular to a direction of travel of said strip through
said mounting frame.
[0043] Preferably, said seam guide and welding station
comprises:
[0044] a seam roll stand rotatably supporting at least one seam
roll adapted, in use, to guide a free edge of a contoured edge
region of said metal strip into linear alignment with a
predetermined weld axis spaced from said free edge on a surface of
said metal strip; and,
[0045] a weld box stand rotatably supporting at least one pair of
squeeze rolls, in use, to urge said free edge when heated to a
predetermined temperature into fused engagement with a
correspondingly heated said weld axis on said surface, said pair of
squeeze rolls co-operating, in use, to guide said free edge through
a predetermined linear trajectory substantially along an incidence
axis of a subsequent weld junction between said free edge and said
surface of said metal strip whereby energy imparted to said cold
formed member is focussed by a proximity effect along said
predetermined weld axis of said surface.
[0046] Suitably, said electrical current is induced in said free
edge and said weld region by electrical contractors slidably
engaging said metal strip adjacent said free edge and said weld
region.
[0047] Preferably, said electrical current is induced in said free
edge and said weld region by an induction coil transversely
surrounding said metal strip in a plane perpendicular to a
direction of travel of said metal strip therethrough.
[0048] Preferably, at least one of said pair of squeeze rolls is
angularly adjustable in a plane perpendicular to a direction of
travel of said metal strip therebetween.
[0049] At least one of said pair of squeeze rolls may be adjustable
relative to the other of said pair in a direction perpendicular to
a rotational axis of said at least one of said pair of squeeze
rolls.
[0050] Suitably, said weld box includes web support rolls rotatable
about parallel respective axes perpendicular to a direction of
travel of a metal strip member therebetween.
[0051] If required, a web support roll may have a contoured outer
edge to function as one of said pair of squeeze rolls.
[0052] The apparatus may include more than one seam roll stand.
[0053] If required, at least one of said seam roll stands includes
a seam roll having a circumferential shoulder thereon, said
circumferential shoulder, in use, providing an abutment for said
free edge of said metal strip.
[0054] Suitably, a contoured guide roll is provided, in use, to
urge said free edge of said metal strip into abutment with said
circumferential shoulder.
[0055] If required, a rod-shaped impeder supported at one end
thereof, upstream of said one or more seam roll stands, extends
into a hollow interior of a contoured edge region of said metal
strip.
[0056] According to another aspect of the invention there is
provided a method of cold roll forming a hollow flange member from
a single strip of metal, said method comprising the steps of:
[0057] driving a metal strip through a cold rolling mill by driven
rolls engaging a planar central region of said strip;
[0058] forming a contour along at least one edge region of said
strip by forming rolls;
[0059] continuously seam welding by an ERW process a free edge of
said at least one edge region to a surface of said strip along a
predetermined weld region to form a hollow flange; and,
[0060] shaping said hollow flange by shaping rolls to form a shaped
hollow flange of desired cross-sectional configuration.
[0061] If required, one or more of said forming rolls may be
driven.
[0062] In addition, or alternatively, one or more of said shaping
rolls may be driven.
[0063] Suitably, forming of said hollow flange is effected by one
or more forming rolls rotatably supported about a pivotal axis
inclined at an angle between vertical and horizontal in a
transverse plane perpendicular to a direction of travel of said
strip of metal.
[0064] If required, shaping may be effected by one or more shaping
rolls rotatably supported about a pivotal axis inclined at an angle
between vertical and horizontal in a transverse plane perpendicular
to a direction of travel of said strip of metal.
[0065] Forming of said hollow flange may be effected by forming
rolls mounted in longitudinally spaced transverse operating planes,
said spaced operating planes being parallel to each other and
perpendicular to a direction of travel of said strip of metal.
[0066] Suitably, shaping of said hollow flange may be effected by
shaping rolls mounted in longitudinally spaced transverse operating
planes, said spaced operating planes being parallel to each other
and perpendicular to a direction of travel of said strip of
metal.
[0067] Preferably prior to said step of continuous seam welding,
said free edge is aligned linearly with a predetermined weld axis
on said surface of said strip and said at least one free edge is
guided through a predetermined linear trajectory along an incidence
axis of a subsequent weld junction between said at least free one
free edge and said surface whereby energy imparted to said hollow
flange member is focussed by a proximity effect along said
predetermined weld axis on said surface prior to fusing said at
least one free edge thereto.
[0068] If required, said at least one free edge is aligned with
said weld region by one or more seam rolls each having a
circumferential shoulder providing an abutment for said at least
one free edge.
[0069] Said at least one free edge of said metal strip may be urged
into abutment with said circumferential shoulder by a contoured
guide roll.
[0070] Suitably, said metal strip is supported centrally by opposed
cylindrical roll surfaces adjacent said weld region as said at
least one free edge is urged into abutment with said
circumferential shoulder.
[0071] Said at least one free edge may be guided toward said
closure region at a predetermined angle relative to strip surface
by adjustably mounted seam rolls.
[0072] Preferably, said at least one free edge of said metal strip
is guided through said predetermined trajectory by a contoured
squeeze roll extending over said contoured surface of said metal
strip between spaced substantially parallel contact faces of said
contoured squeeze roll.
[0073] Weld energy may be imparted to said free edge and said
predetermined weld region by an electrical induction coil or
contactors, said coil extending substantially around said metal
strip in a plane substantially perpendicular to a longitudinal axis
thereof.
[0074] If required, an elongate rod-like induction impeder
supported at one end may extend within a hollow interior cavity of
said contoured surface to a region adjacent a closure region where
said at least one free edge is fused to said surface of said metal
strip.
BRIEF DESCRIPTION OF THE DRAWINGS
[0075] In order that the various aspects of the invention may be
more fully understood and put into practical effect, reference will
now be made to preferred embodiments illustrated in the
accompanying drawings in which:
[0076] FIG. 1 is a schematic side elevational view of a forming
station and edge preparation and welding station of a cold roll
forming mill;
[0077] FIG. 2 is a schematic side elevational view of a shaping
station of a cold roll forming mill;
[0078] FIG. 3 shows schematically a front elevation of a driven
roll stand fitted with side rolls;
[0079] FIG. 4 shows schematically a rear elevation of a forming
roll stand;
[0080] FIG. 5 shows schematically a rear elevation of a seam guide
roll stand;
[0081] FIG. 6 shows schematically a side elevation of a welding
apparatus;
[0082] FIG. 7 shows schematically a front elevation of a weld box
stand;
[0083] FIG. 8 shows schematically the operation of the squeeze
rolls in the weld box stand;
[0084] FIG. 9 shows schematically front, side and rear elevations
of a shaping roll stand;
[0085] FIG. 10 shows schematically side and front elevations of a
turk's head roll stand.
[0086] As used herein, the expression "front elevation" means a
view in the direction of travel of a strip of metal
therethrough.
[0087] Moreover, like numerals are employed for like features in
the drawings for the sake of clarity.
DETAILED DESCRIPTION OF THE DRAWINGS
[0088] In FIGS. 1 and 2, the cold forming mill comprises a forming
station 1, an edge preparation and welding station 2 and a shaping
station 3. Conventional slit strip roll handling and let off rolls
upstream of the forming station 1 and flying saw and take-off table
assemblies at the downstream end of shaping station 3 are omitted
for the sake of clarity.
[0089] In FIG. 1, mill beds 4 support a conventional entry table 5,
a series of drive roll stands 6, a series of forming roll stands 7,
side roll assemblies 8, a seam guide roll stand 9, a weld coil 10
and a weld box 11.
[0090] FIG. 2 shows a downstream portion of the cold forming mill
wherein mill beds 4 support drive roll stands 6, shaping roll
stands 12 and a turk's head roll stand 13.
[0091] FIG. 3 shows a front elevational view of drive roll stand 6a
of FIG. 1. This roll stand differs from other roll stands 6 only in
that it includes side rolls to steady the formed strip prior to
entry into the seam guide roll stand 9.
[0092] Drive roll stand 6a comprises a pair of spaced frames 20 in
which are journalled roll shafts 21, each supporting a respective
cylindrical drive roll 22. Roll shafts 21 are coupled via universal
joints 23 to drive shafts 24 coupled to a conventional drive train
(not shown). As can be seen, drive rolls 22 engage the central web
25 of a formed hollow flange beam member 26 and because the grip on
the web is so good, it has been found unnecessary to drive any of
the forming or shaping rolls in the mill. A conventional height
adjustment mechanism 27 provides vertical height adjustment to
upper roll shaft 21 to adjust the nip between upper and lower rolls
22 to accommodate differing metal strip feedstock thickness. If
required, selected drive rolls may be contoured to assist in
forming or shaping hollow flanges.
[0093] Mounted on an upstream side of roll stand 6a is a side roll
assembly comprising a pair of side rolls 28 supported on respective
mounting brackets 29. Side rolls 28 engage the hollow flanges 30 of
member 26 for precise lateral location prior to entry into the seam
guide roll stand 9 and are adapted for lateral adjustment by screw
adjuster 31 and for vertical adjustment by screw adjusters 32.
[0094] FIG. 4 illustrates a rear elevational view of a typical
undriven forming roll stand 7 showing a pair of frames 35
adjustably mounted on a base 36 for selective relative lateral
movement by a shaft 37 having threaded portions 38,38a of opposite
hand engaging in respective slide blocks 39,39a. Frames 35 are
slidably adjustable between inner and outer stops 40,41
respectively.
[0095] Upper and lower forming rolls 42,43 are supported on
respective mounting brackets 44,45 and upper mounting brackets 44
are slidably mounted on frames for vertical adjustment by adjusting
screws 46 to accommodate differing thicknesses of the metal strip
feedstock or differing roll set configurations.
[0096] FIG. 5 shows a rear elevational view of a seam guide roll
stand 9 having a base 50 and a support frame 51. On the downstream
side of the frame as viewed are a pair of contoured support rolls
52 which support the hollow flange regions 30 on either side of web
25. Rolls 52 are rotatably journalled in lower roll support
brackets 53 slidably mounted on frame 51 and movable laterally
relative to each other by an oppositely handed threaded screw
adjustment 54. Vertical adjustment of lower roll support brackets
53 is achieved by screw-threaded adjusters 55. Seam guide rolls 56
are mounted on upper roll support brackets 57 which are mounted for
lateral relative movement on frame 51 by adjuster 58 having a shaft
59 with oppositely handed screw-threads and also for vertical
movement by adjuster screws 60.
[0097] Seam guide rolls 56 have a circumferential shoulder 61 which
provides an abutment against with the free edge 62 of hollow flange
30 is urged. Seam guide rolls rotatably journalled in slide blocks
63 which are linearly adjustable along respective rotational axes
64 by adjuster screws 65 and, if required slide blocks 63 may be
pivotally mounted on upper roll support brackets for angular
adjustment in a transverse plane perpendicular to a direction of
travel of the metal strip feedstock therethrough.
[0098] Mounted on a front side of frame 51 is a pair of web support
rolls 66,67, upper support roll 66 having a circumferential rim 68
engaging between the free edge 62 of the flange 30 and the side of
web 25 as shown in the cutaway region 69. The end wall 70 of
support roll 66 also serves as an abutment for free edge 62 of
flange 30. Also shown in cutaway region 69 is a contoured end wall
71 of lower support roll 67 which also supports the hollow flange
30. Relative vertical movement between web support rolls 66 and 67
is achieved by adjuster screw 72.
[0099] FIG. 6 shows a high frequency electrical induction welding
apparatus 10 shown schematically in FIG. 1 between seam guide roll
stand 9 and weld box 11.
[0100] Welding apparatus 10 comprises an induction coil assembly 75
in the form of a sheet copper loop 76 which surrounds a hollow
flange member 77 as it passes therethrough. Loop 76 is supported at
its free ends 78 by respective sheet copper support brackets 79
separated by an electrical insulating medium 80. Coil assembly 75
is cooled by water recirculating in copper tubes 81 secured to
assembly 75.
[0101] Located within each hollow flange 30 in the region of coil
76 is an impedance device 82 comprising a fibreglass tube filled
with ferrite rods (not shown). Each impeder 82 is supported by an
elongate rod 83 supported by a bracket 84 (shown in FIG. 1) which
extends into the hollow interior of a respective web via the gap
between the free edge of the hollow flange and the side of the web
as seen in FIG. 5. Cooling water is recirculated through the
impeder 82 via tubes 85 and a source of compressed air is pumped
through the impeder 82 via tube 86. After the free edges of the
hollow flanges and the weld seam lines along the respective sides
of the web are heated to fusion temperature by the welding
apparatus 10, the heated free edges of the flanges are urged into
contact with respective heated weld seam lines by squeeze roll
sets, shown schematically at 87, in the weld box 11 of FIG. 1.
[0102] FIG. 7 shows the configuration of the four roll weld box 11
in FIG. 1.
[0103] Weld box 11 comprises a cylindrical top roll 90 and a
cylindrical lower roll 91 with contoured edges 91a, each of rolls
90,91 being rotatably journalled about respective rotational axes
92,93. Contoured squeeze rolls 94a,94b rotatable about respective
inclined axes 95a,95b are adapted to urge the heated free edges
62a,62b of hollow flanges 30 into respective heated weld seam line
regions along the opposed boundaries of web 25 to effect fusion
therebetween to create a continuous weld seam. It will be noted
that the cavities defined between squeeze rolls 94a,94b and
respective contoured edges 91a of cylindrical support roll 91 are
ovoid in shape.
[0104] The free edges 62a,62b are urged toward respective weld
lines in a linear fashion perpendicular to the respective
rotational axes 95a,95b of squeeze rolls 94a,94b without a
transverse "sweeping" action thereby maintaining stable induction
"shadows" or pathways on or at the desired position of the weld
seams between respective free edges 64a,64b and the opposed
boundaries of web 25.
[0105] Cylindrical roller 90 is adjustably mounted for movement in
an upright plane by adjustment screw 96, the screw 96 being coupled
to roll carriage 98, slidably mounted in support frame 100.
[0106] Squeeze rolls 94a,94b are slidably mounted in respective
carriages 101,102 of squeeze roll support frames 103,104
respectively for slidable adjustment along respective sliding axes
105,106 means of adjustment screws 107. Squeeze roll support frames
103,104 are, in turn, adjustably mounted for transverse movement by
a screw 108 coupling mountings for support frames 103,104 by a
threaded shaft 109 and for upright movement by screws 110.
Preferably, roll support frames are pivotally mounted on frame 100
for pivotal movement about respective axes parallel to the
direction of movement of a hollow flanged member moving through
weld box stand 11.
[0107] The adjustable roll mounting enables a wide range of hollow
flange members of varying dimensions and cross-sectional
configurations to be welded in the weld box with extremely precise
control over the trajectory through which the free edges of the
hollow flanges travel towards a precisely located weld seam line
adjacent or at the edges of the member web.
[0108] FIG. 8 shows schematically the configuration of the rolls in
weld box 11 of FIG. 7 to more clearly illustrate the guidance of
the free edges of the hollow flanges into the weld seams along the
edges of the web.
[0109] In the drawing a somewhat exaggerated position of the formed
hollow flanges 30 and their respective free edges 62 is shown in
phantom. As the formed section approaches the roll combination,
hollow flanges 30 are urged inwardly towards the contoured ends 91a
of separate rollers 91 which correspond to the movement of rollers
94a,94b along respective sliding axes 105,106 as shown in FIG.
7.
[0110] Importantly, it can be seen that about half of the outer
portion of the hollow flanges which terminate in the free edges 62
is urged in the direction shown by arrows 111 whereby the almost
flat region of the flange adjacent the free edge 62 and a
corresponding portion of the opposite side of the flange are driven
together as a unitary portion towards roll 91 whereby deformation
of the remaining portion of the flange adjacent the boundary 79 of
the web 25 is accommodated in the contoured edges 91a of rolls 91.
Equally, it will be seen that the free edge 62 of the flange 30
travels in a straight line trajectory to the boundary 79 of web 25
where the weld seam is formed.
[0111] FIG. 9 shows a shaping roll stand 12 of FIG. 2 wherein FIG.
9a is a rear elevational view, FIG. 9b is a side elevation and FIG.
9c is a front elevational view.
[0112] Roll stand 12 comprises an arched plate-like frame 120
reinforced by a web 121 attached about an outer edge thereof. Frame
120 is supported on base pads 122 and includes lifting eyes 123 for
ease of handling. Track members 124,125 slidably locate a shaping
roll carriage 126 which is transversely adjustable by adjuster
screw 127. Mounted about a central aperture 128 in frame 120 are
shaping roll support frames 129, each slidably locating a roll
mounting bracket 130 in which is rotatably journalled a shaping
roll 131. Roll mounting brackets 130 are slidably adjustable in
respective support frames 129 by adjuster screws 132 which move the
shaping rolls 131 in a transverse plane perpendicular to the
direction of travel of a hollow flange 133a of a beam 133 moving
therethrough. Shaping rolls 131 are mounted with respective
rotational axes in a common transverse mounting plane represented
at 134 in FIG. 9b and respective adjuster screws 127 move the
shaping rolls 131 in their common mounting plane in a direction
perpendicular to respective rotational axes.
[0113] Just visible via aperture 128 is a set of three shaping
rolls 131a engaged about an opposite hollow flange 133b of beam 133
on the other side of frame 120.
[0114] As can be seen from FIGS. 9b and 9c a front elevational view
of the shaping roll stand is substantially identical except that
roll carriage 126 is displaced to the left to accommodate hollow
flange 133b spaced from hollow flange 133a by the width of the web
therebetween.
[0115] Although like reference numerals have been employed for like
features, the reference numerals for the features on the front face
are distinguished by a prime.
[0116] The particular advantages conferred by this configuration of
roll stand, whether for shaping rolls or forming rolls is its
adaptability to a wide range of sizes of hollow flanged beams with
a wide range of cross-sectional shapes possible in the hollow
flanges. Moreover, location of the roll sets for opposite flanges
in longitudinally spaced planes permits the ruse of multiple roll
combinations such as that illustrated without the interference with
an adjacent set of rolls in the same plane for shaping or forming
of an opposite hollow flange. By using a three roll set of forming
rolls as shown hollow flange beams with closely spaced or otherwise
relatively deep flanges can now be rolled without the limitations
otherwise imposed in conventional mills.
[0117] A still further advantage of a roll stand as illustrated in
FIG. 9 with a three roll shaping set is that by operating one of
the rolls with an inclined rotational axis as shown, a tapered edge
roll of a relatively small diameter can still provide a deep
support face for an upright flange edge without "scrubbing" the
face of the flange as a result of the forming velocity differential
across a planar side wall of a cylindrical roll.
[0118] The roll stand shown in FIG. 9 is considered to permit
substantial cost savings in the cost of roll sets as diameters of
25-30% less than conventional roll diameters may be employed.
Moreover, the adjustability of the rolls allows a large range of
beam sizes can be rolled without having to effect roll changes
simply to accommodate changes in web width. Where roll changes are
required either for a change in hollow flange beam size or
configuration or merely for maintenance purposes, a complete roll
carriage changeover may be effected in minutes and similarly
replacement of a mounting roll bracket also can be effected
rapidly.
[0119] FIG. 10 shows a double sided turk's head roll stand 13
having a configuration similar to shaping roll stands 12 shown in
FIG. 9.
[0120] Referring in particular to FIG. 10b, turk's head roll stand
13 comprises a plate-like frame 140 with top and side reinforcing
webs 141,142 respectively. A mounting base 143 is adapted for
mounting on a mill bed as shown in FIG. 2 and lifting eyes 144 are
provided for handling purposes. Mounted on opposite faces of frame
140 are roll mounting plates 145 with aligned central apertures
146. Mounted about apertures 146 are roll mounting frames 147
slidably locating roll mounting brackets 148 which are axially
adjustable by respective adjuster screws 149. Roll mounting plates
145 are axially adjustable by adjusting screws 150.
[0121] Roll mounting frames 147 are mounted on a face plate 151 in
turn rotatably mounted on roll mounting plates 145 and at least
partial rotation of face plate 151 relative thereto is effected by
adjusting screw 152. Relative rotational adjustment between the
face plates 151 on the front and rear sides of the turk's head
frame 140 permits any twisting or axial deformations in the hollow
flange beam to be removed by idler rolls 153,154,155 and 156 before
the beam progresses to a flying saw or the like to be severed into
predetermined lengths.
[0122] It readily will be apparent to persons skilled in the art
that many modifications and variations may be made to the various
aspects of the invention without departing from the spirit and
scope thereof.
* * * * *