A CYLINDER BENDING MACHINE WITH A FLATNESS DECREASING MECHANISM AND CORRESPONDING BENDING FLATNESS DECREASING METHOD

TECHNICAL FIELD

The present invention relates to a bending flatness decreasing method which is utilized in decreasing the pre-bending flatness occurring in the sheet plate bending process in cylinder bending machines used in bending and shaping sheet plates; and relates to a flatness decreasing mechanism decreasing the bending flatness and providing the desired form to the sheet plate. PRIOR ART

For bending and forming sheet plates, cylinder bending machines are frequently used. The sheet plates, which are fed to the cylinder bending machines by the feeding units, can be bent in desired forms by providing position control. In cylinder bending machines, the bending process is carried out as the sheet plate is passed through the rollers. The number of rollers is changing depending on the usage area of cylinder bending machines in systems.

The sheet plates, which are brought to the operation region in order to be processed, are fed to the machine by the driving mechanism provided on the sheet support unit existing in the inlet part belonging to the cylinder bending machine. After the sheet plate is taken into the machine, four rollers, defined as bottom roller, upper roller, left lateral roller and right lateral roller, apply pressure on the sheet plate. By means of this, the desired form is obtained on the sheet plate. The processed sheet plates are taken to the region, where the completed products are provided, through the sheet support unit provided in the outlet part belonging to the cylinder bending machine.

In the present cylinder bending process, some problems are encountered on the sheet plate particularly while form is applied to hard sheet plates. While the desired form can be applied to the middle region of the sheet plate, flatness, called pre-bending flatness and which is at undesired amount (at a region which can be up to 8 - 10 times of the sheet thickness), are formed on the two edges provided in the end parts. The reason of this is that the end parts do not completely contact with the roller surfaces while the sheet plate performs movement between the rollers. Since the end parts cannot completely contact to the roller surfaces, a desired amount of pressure force cannot be provided in these parts and this leads to production error. In the present conditions, in order to prevent the bending flatness formed on the sheet plate, there are two methods, in one of the methods, after the process, an extra operation is carried out as follows: the end parts are cut from the two edges of the sheet plate; and in the second method, before the sheet plate is being formed in the cylinder bending machine, the sheet plate is pre-processed in a different metal processing bench (press brake, etc.), and, the desired form is obtained on the edges.

In the case where the edges are cut afterwards, material loss occurs. If an additional pre- process is applied, there occurs the cost of transportation of materials between different benches, additional labor is needed, etc. and as a result of these, excessive additional cost and time loss occur.

As a result, because of the abovementioned problems, an improvement is required in the related technical field. BRIEF DESCRIPTION OF THE INVENTION

The present invention relates to a novel method which decreases bending flatness occurring on sheet plate in cylinder bending machines and a novel mechanism which facilitates application of said method, in order to eliminate the abovementioned problems and to bring new advantages to the related technical field.

The main object of the present invention is to provide a flatness decreasing method which decreases undesired bending flatness occurring at certain regions of the sheet plate processed in cylinder bending machines and which provides the bending flatness to be brought to the desired form.

Another object of the present invention is to provide a flatness decreasing mechanism which decreases undesired bending flatness occurring in the bending process of the sheet plate and which brings the sheet plate to the desired form.

Another object of the present invention is to provide a flatness decreasing mechanism which performs the processes of undesired flatness, formed on the sheet plate, on the same cylinder bending machine in an automatic process, and which provides saving from the labor and time consumed during the carrying of the materials.

Another object of the present invention is to provide a flatness decreasing mechanism which will prevent material loss which will occur as the undesired parts of the sheet plate are cut after the cylinder bending process as the undesired bending flatness is decreased and as the undesired bending flatness is brought to the desired form.

In order to realize all of the abovementioned objects and the objects which are to be obtained from the detailed description below, the present invention relates to a cylinder bending machine having sheet support units connected to the inlet and outlet edges extending between the feet and the rollers having an arrangement which will perform bending in the desired form on a sheet plate with at least one first edge and at least one second edge extending at certain axes; and which support the sheet plate from below during the bending process. Said cylinder bending machine is characterized by comprising at least one flatness decreasing mechanism having at least one form mold which is adapted to said sheet support units and which provides the desired form by applying pressure to the first and second edges by pressing said edges between the rollers during the bending process and which is provided at a certain inclination angle in the direction of the form desired to be formed on the sheet plate beforehand; and at least one drive unit which will transmit the drive required for the process of forming and shaping of said form mold.

In a preferred embodiment of the subject matter invention, there are essentially at least two symmetrical flatness decreasing mechanisms where one flatness decreasing mechanism is adapted to the inlet sheet support unit extending along the inlet edge and where one flatness decreasing mechanism is adapted to the outlet sheet support unit extending along the outlet edge.

In another preferred embodiment of the subject matter invention, said form mold comprises at least one bottom mold and at least one upper mold provided in male and female forms and which will provide the desired inclination on the sheet plate.

In another preferred embodiment of the subject matter invention, there is at least one positioning opening where the sheet plate is positioned during the bending process between the bottom and the upper molds.

In another preferred embodiment of the subject matter invention, the form mold comprises at least one connection surface on the side thereof facing towards the sheet support units. In another preferred embodiment of the subject matter invention, there are at least two of said drive units in order to drive each form mold provided on each one of the flatness decreasing mechanisms. In another preferred embodiment of the subject matter invention, there is at least one drive arm which will advance the form mold in the drive unit in the desired position, in the desired moment and in the desired amount.

In another preferred embodiment of the subject matter invention, there is at least one drive element which will provide the required drive to said drive arm in order to provide the movement of said drive arm.

In another preferred embodiment of the subject matter invention, there is at least one connection unit adapted to the connection surface, in order to connect the drive unit to the form mold.

In another preferred embodiment of the subject matter invention, said connection unit comprises at least one connection plate fixed to the connection surface. In another preferred embodiment of the subject matter invention, there is at least one connection element which will fix said connection plate.

In another preferred embodiment of the subject matter invention, the connection unit is provided in a hinged manner which is able to eliminate any problem in the connections and which does not delimit the movement of the form mold.

In another preferred embodiment of the subject matter invention, there is at least one axis adjustment pin which is adapted to the housings provided inside the bottom mold and which provides positioning of the sheet plate in the positioning opening in a flat axis prior to the process and which provides the bottom and the upper molds to be at a separate position from each other in a continuous manner.

In another preferred embodiment of the subject matter invention, said axis adjustment pin comprises at least one springy body which is positioned in the housing provided inside the bottom mold and which provides the bottom and the upper molds to be separate from each other in a continuous manner by providing a springing movement in Y axis. In another preferred embodiment of the subject matter invention, there is at least one stop end which extends towards the positioning opening at the continuation of said springy body and thereby which provides axis adjustment of the sheet plate. In another preferred embodiment of the subject matter invention, there is at least one stopper fixed to the connection surface in order to delimit the movement of the upper mold in Y axis for delimiting the opening position, provided between the bottom and the upper molds in the desired dimensions. In another preferred embodiment of the subject matter invention, there are pluralities of axis adjustment pins which are positioned at different points from each other in order to be able to provide the required axis adjustment along the form mold.

In another preferred embodiment of the subject matter invention, the form mold is provided at different inclination angles and the form mold is changeable according to the radius of the bending angles which are desired to be applied and according to the thickness of the sheet plate.

In another preferred embodiment of the subject matter invention, the form mold essentially has a structure which is made of metal material or made of metal and plastic material mixture or made of metal and elastomer (rubber) material mixture.

The present invention also relates to a bending flatness decreasing method applied to a cylinder bending machine with sheet support units which will support the sheet plate from the bottom during the bending process by being connected to the inlet and outlet edges extending between the feet and the rollers with the arrangement which will perform bending in the desired form on a sheet plate with at least one first edge and with at least one second edge extending at certain axes; said method is characterized by comprising the steps of: a. Positioning the sheet plate on the positioning surface belonging to the inlet sheet support unit,

b. Taking the sheet plate to the main body by means of the transfer mechanism and positioning the sheet plate between the rollers so that one surface of the sheet plate is in contact with the left lateral, bottom and right lateral rollers and so that the other surface of the sheet plate is in contact with the upper roller,

c. Rotating the rollers in the related directions, d. Advancing the flatness decreasing mechanism belonging to the inlet sheet support unit by means of the drive obtained from the drive unit and capturing the first edge, e. Positioning the first edge to the positioning opening provided between the bottom and the upper molds belonging to the form mold provided in the flatness decreasing mechanism,

f. Positioning the form mold between the bottom and the upper rollers together with the first edge positioned in the form mold,

g. Advancing the bottom roller towards the upper roller in Y axis and pressing the form mold between the bottom and the upper rollers,

h. Providing the desired form by applying pressure like press to the first edge existing between the form mold,

i. Advancing the bottom roller in Y axis in the inverse direction and diverging from the upper roller,

j. Releasing the first edge by the form mold,

k. Bending the second edge in the desired form.

In another embodiment of the present invention, the bending flatness decreasing method is characterized by comprising the steps of: a. Advancing the flatness decreasing mechanism, connected to the outlet sheet support unit, towards the sheet plate by means of the drive obtained from the drive unit, b. Positioning the second edge to the positioning opening provided in the form mold, c. Advancing the bottom roller towards the upper roller in Y axis and pressing the second edge positioned inside the form mold and bending the second edge in the desired form,

d. Advancing the bottom roller in Y axis in the inverse direction and diverging from the upper roller and releasing the second edge by the form mold.

In order for the embodiment and the advantages of the subject matter invention to be understood in the best manner with the additional elements, it has to be evaluated with the detailed description and with the figures explained below.

BRIEF DESCRIPTION OF THE FIGURES

In Figure 1 , the general view of the cylinder bending machine is given.

In Figure 2, a general view of the flatness decreasing mechanisms is given. In Figure 3a and 3b, the lateral view of the form mold wherein the sheet plate is positioned and a representative view of the pressure application step of the form mold onto the sheet plate are given. In Figure 4, the general view of the drive units is given.

In Figure 5a and 5b, the detailed view of the form mold is given.

REFERENCE NUMBERS

10 Cylinder Bending Machine

1 1 Main Body

1 11 Upper Roller

1 12 Bottom Roller

1 13 Left Lateral Roller

1 14 Right Lateral Roller

12 Feet

13 Inlet Edge

14 Outlet Edge

20 Sheet Support Units

20a Inlet Sheet Support Unit

20b Outlet Sheet Support Unit

21 Connection Edge

22 Positioning Surface

221 Transfer Mechanism

30 Flatness Decreasing Mechanism

31 Form Mold

311 Bottom Mold

312 Upper Mold

313 Connection Surface

314 Positioning Opening

32 Drive Unit

321 Drive Element

322 Drive Arm

33 Connection Unit

331 Connection Plate 332 Connection Element

34 Axis Adjustment Pin

341 Springy Body

342 Stop End

343 Stopper

40 Sheet Plate

41 a First Edge

41 b Second Edge

X: Depth Axis

Y: Vertical Axis

Z: Horizontal Axis

THE DETAILED DESCRIPTION OF THE INVENTION In this detailed description, the subject matter flatness decreasing method and the flatness decreasing mechanism (30) which decreases flatness are explained with references to examples without forming any restrictive effect in order to make the subject more understandable. Accordingly, in the detailed description and in the figures below, said flatness decreasing mechanism (30) is described to be adapted to the sheet support units (20) of a cylinder bending machine (10). However, the subject matter invention can also be applied to different metal processing benches with minor revisions.

With reference to Figure 1 and 2, the cylinder bending machine (10) essentially comprises a main body (1 1 ) extending between two mutual feet (12). At least one upper roller (11 1 ), at least one bottom roller (1 12), at least one left lateral roller (1 13) and at least one right lateral roller (1 14) are connected to said main body (1 1 ) in order to carry out the bending process on the sheet plate (40). The sheet plate (40) is taken by the left lateral roller (1 13) along the whole length of the cylinder bending machine (10) between the feet (12) in order for the sheet plate (40) to be processed; and this part is defined as the inlet edge (13). When the sheet plate (40) completes the operation thereof, the sheet plate (40) exits from the edge on the side of the right lateral roller (114) exactly opposite to said inlet edge (13), and this part is defined as the outlet edge (14). The width of the cylinder bending machine (10) is defined as the X axis, the length thereof is defined as the Z axis, and the height thereof is defined as the Y axis.

One each sheet support units (20), which support the sheet plate (40) along the inlet and outlet edges (13, 14) during the input of the sheet plate (40) into operation and during the output of the sheet plate (40) from operation, are adapted to the cylinder bending machine (10). Said sheet support unit (20), extending along the inlet edge (13), provides the sheet plate (40) to be fed to the cylinder bending machine (10) for the operation, and said sheet support unit (20) is defined as the inlet sheet support unit (20a). The sheet support unit (20), extending along the outlet edge (14), is defined as the outlet sheet support unit (20b).

The edges of the sheet support units (20), which extend along the inlet and outlet edges (13, 14) and which are connected to the cylinder bending machine (10), are defined as the connection edge (21 ). One each positioning surfaces (22), where the sheet plate (40) will be positioned in the X axis after and before operation, are extending from said connection edge (21 ). On said positioning surface (22), the transfer mechanism (221 ) is provided which will drive the sheet plate (40) to the operation region or to the region where the finished products are stacked. Both sheet support units (20) have movement capability in the Y axis by referencing the connection edge (21 ) as the center. Thus, the sheet plate (40) advances to the desired region in a position-controlled manner by means of synchronized movements provided both in X and Y axes by the sheet support units (20).

With reference to Figure 2, one each flatness decreasing mechanism (30) is adapted to each sheet support unit (20). Said flatness decreasing mechanism (30) comprises sufficient number of drive units (32) which are connected onto the positioning surface (22) and at least one form mold (31 ) which is connected to said drive unit (32) at an orthogonal angle and which extends along the connection edge (21 ). There are preferably two drive units (32) used in each of the flatness decreasing mechanisms (30) and the number of drive units (32) may change optionally and may change depending on the structure of the system. There is one each connection unit (33) provided in a hinged structure so as to be able to compensate any kind of mismatch at every connection point in order to connect said form mold (31 ) to the drive units (32). In addition, sufficient number of axis adjustment pins (34) is adapted to the form mold (31 ) in order to adjust the axis of the sheet plate (40) inside the form mold (31 ) and in order to keep the form mold (31 ) permanently in open form.

With reference to Figure 3a and Figure 3b, the form mold (31 ) comprises at least one bottom mold (31 1 ) and at least one upper mold (312) where at least one positioning opening (314) is provided between said bottom mold (31 1 ) and said upper mold (312). The edges of the sheet plate (40), which extend parallel in certain axes so as to be placed to said positioning opening (314), are the end parts which have a flat form in an undesired manner, and they are defined as the first and second edge (41a, 41 b). In said bottom and upper molds (31 1 , 312), external surfaces are provided in forms with radius which are compliant with the rollers (1 1 1 , 1 12, 1 13, 114) whereto the molds (31 1 , 312) will contact during the process. On the inner surfaces of the bottom and the upper molds (311 , 312) facing each other, the female form is provided on the bottom mold (311 ) and the male form is provided on the upper mold (312) in order to apply the required pressure for providing the desired form on the sheet plate (40). The surface, which extends so as to remain on the side of the connection edge (21 ) where the form mold (31 ) is connected to the drive units (32), is defined as the connection surface (313).

With reference to Figure 4, each drive unit (32) is connected to the form mold (31 ) at a vertical angle along the X axis. The drive unit (32) comprises at least one drive element (321 ) extending along the X axis, and at least one drive arm (322) which transfers the drive, received from said drive element (321 ), to the form mold (31 ) and which will provide the movement of the form mold (31 ). Said drive element (321 ) is preferably a hydraulic cylinder, and a structure (pneumatic, electric motor, etc.) can be used which will produce the required drive using different systems. In the present invention, the drive arm (322), which functions using the hydraulic system, drives the form mold (31 ) in the desired moment, in the desired position and in the desired amount by means of the synchronized movements provided in the X axis in a position controlled manner. The movement, required in the Y axis, is provided by means of the left and right lateral rollers.

With reference to Figure 5a and Figure 5b, the connection unit (33) provides the required movement flexibility for the form mold (31 ) by means of the hinged structure thereof. The connection unit (33) comprises at least one connection plate (331 ) in order to provide connection to the connection surface (313) at points where the drive arm (322) is connected to the form mold (31 ). The desired connection is provided by a connection element (332), which is preferably in bolt form, by engaging thereof into the housings provided on the connection plate (331 ).

With reference Figure 3a, one each axis adjustment pin (34) is placed to the housings provided inside the bottom mold (31 1 ) belonging to the form mold (31 ). Said axis adjustment pin (34) comprises at least one springy body (341 ) which provides movement in Y axis remaining inside the housing and at least one stop end (342) which extends towards the positioning opening (314) at the continuation of said springy body (341 ). In addition, in order to delimit the movement of said axis adjustment pin (34) in Y axis, stopping mechanisms, which are defined in stopper (343) form, are connected to the form mold (31 ) from the connection surface (313). After the next sheet plate (40), which will be processed in the cylinder bending machine (10), is positioned onto the positioning surface (22) of the inlet sheet support unit (20a), it is taken to the main body (1 1 ) by means of the transfer mechanism (221 ). The sheet plate (40) in the main body (1 1 ) is taken between the rollers (11 1 , 1 12, 1 13, 114) so that one surface thereof is in contact to the left lateral roller (113), to the right lateral roller (114) and so that the other surface is in contact to the upper roller (1 1 1 ). The three rollers (113, 1 12, 1 14), which are in contact with one surface of the sheet plate (40), are rotating in the same direction and the other roller (1 1 1 ) is rotating in an inverse direction to the three rollers (1 13, 1 12, 1 14). Meanwhile, the first edge (41 a) of the sheet plate (40) is captured by the flatness decreasing mechanism (30) adapted to the sheet support unit (20a).

The first edge (41 a) is positioned to the positioning opening (314) between the bottom and the upper molds (31 1 , 312) of the form mold (31 ). The first edge (41 a) advances up to the stop end (342) and it stops here. In order for the placement of the first edge (41 a) to the positioning opening (314), the bottom and the upper molds (31 1 , 312) should be separate from each other and the positioning opening (314) should be continuously open. Since, as the sheet plate (40) is taken between the rollers (1 11 , 112, 1 13, 114), the form mold (31 ) advances as a result of the drive obtained from the drive unit (32) and it takes the edges (41 a, 41 b) of the sheet plate (40) to the positioning opening (314). Since the sheet plate (40) applies no stress and since the form mold (31 ) grabs the edges (41 a, 41 b) of the sheet plate (40) as a result of advancing thereof, it waits in open form so that the sheet plate (40) is able to be placed to the positioning opening (314). However, in order for this positioning opening (314) to be at a predetermined dimension, the stopper (343) belonging to each axis adjustment pin (34) is used. When the upper mold (312) begins separating from the bottom mold (311 ) upwardly in the Y axis, the stopper (343) advances in Y axis in inverse direction, and the upper mold (312) is stopped when it is rested onto the connection surface (313).

The form mold (31 ), which takes the first edge (41 a) to the positioning opening (314), is positioned between the rollers (1 11 , 1 12, 1 13, 114) together with the sheet plate (40). The bottom roller (1 12) presses the form mold (31 ) between the upper roller (1 11 ) and itself by pushing from below, and provides the tightening process. Thus, by means of the force obtained from the pressure applied on the form mold (31 ) by means of the male form provided in the upper mold (312) and by means of the female form provided in the bottom mold (31 1 ), it brings the first edge (41 a) to the desired form for instance, like press.

After the first edge (41 a) is brought to the desired form, the sheet plate (40) becomes idle as the rollers (1 11 , 1 12, 113, 114) are released. In the next step, the sheet plate (40) is advanced in the X axis again, however, the sheet plate (40) is advanced from the outlet edge (14) towards the inlet edge (14) by means of the transfer mechanism belonging to the outlet sheet support unit (20b). The symmetric of the flatness decreasing mechanism (30) connected to the inlet sheet support unit (20a) is also ready in the outlet sheet support unit (20b). This time, the form mold (31 ) belonging to the outlet sheet support unit (20b) advances in the desired manner by means of the drive arms (322) by means of the drive obtained from the drive units (32) connected to the form mold (31 ) and in the direction of the information obtained from the position control provided in the system. The second edge (41 b) of the sheet plate (40) is taken to the positioning opening (314) between the bottom and the upper molds (311 , 312) of the form mold (31 ) on its own side, and said second edge (41 b) is positioned in a flat axis with the help of the axis adjustment pins (34). Afterwards, by means of the force obtained from the pressure applied onto the form mold (31 ) pressed between the rollers (1 1 1 , 1 12, 113, 114), the desired form is also applied to the second edge (41 b). As described above, by means of a bending flatness decreasing method, the undesired bending flatness at both edges (41 a, 41 b) of the sheet plate (40) is substantially decreased without the need for any additional bench. The pre-bending flatness, which can be equal to approximately 8-10 times the thickness of the sheet plate (40) at maximum, is decreased to 1-1.5 times of the sheet plate by means of the bending flatness decreasing method. On both edges (41a, 41 b) of the sheet plate (40), bending process is carried out with the desired radius and with the desired form. Afterwards, the sheet plate (40) is driven to the main body (1 1 ) and between the rollers (1 11 , 1 12, 1 13, 1 14) from the inlet edge (13) and the standard cylindrical pre-bending and bending processes are begun. By means of the flatness decreasing mechanisms (30) adapted to the cylindrical bending machine (10), the need for any additional process is eliminated. Moreover, by means of the position control provided in the cylindrical bending machine (10), the pre-bending process and the standard cylindrical bending process are carried out in the form of steps, which follow each other, without the need for any additional process. Manually, the control of the pre- bending process is possible, however, it is not preferred since it is a very time-consuming and difficult process. In this case, material loss is prevented since there is no need for cutting the ends of the sheet plate (40) afterwards.

It is possible to adapt the flatness decreasing mechanism (30) to the cylinder bending machine (10) from one side, however, this is not preferred. Since when the flatness decreasing mechanism (30) carries out the process from one side, the turning process, which is to be applied to the sheet plate (40), requires a time-consuming and difficult manual intervention. As the flatness decreasing mechanism (30) is adapted to the inlet sheet support unit (20a) and to the outlet sheet support unit (20b) so that said support units (20a, 20b) are the symmetric of each other, all of the processes, which necessitate manual intervention, are eliminated and all of the disadvantages thereof are prevented. Thus, since the bending flatness decreasing process is carried out on the same bench and in an automated manner, the cost of carrying between the benches and the time loss resulting from carrying and the work power loss are prevented. After the operators load the sheet plate (40) to the cylinder bending machine (10), the whole process advances in regular consecutive steps and the process errors are prevented without the need for any additional process.

The form mold (31 ) is changeable, and this property provides an additional important advantage to the system. If a sheet plate (40) having dimensions (thickness, length, etc.) with different properties is taken to the operation region in order to be processed, a different form mold (31 ), which has different dimensioned positioning openings (314), radius, etc. compliant to the dimensions of said sheet plate (40), is connected to the drive arms (322). The form mold (31 ) changing process can be easily carried out by the operator.

Another important property of the form mold (31 ) is that the form mold (31 ) can be provided from different materials. In the present invention, said form mold (31 ) is made of metal material, however, by taking the conditions of production into consideration when required, the metal and the elastomer (rubber) can also be provided from material which is a mixture of metal and plastic.

The protection scope of the present invention is set forth in the annexed Claims and cannot be restricted to the illustrative disclosures given above, under the detailed description. It is because a person skilled in the relevant art can obviously produce similar embodiments under the light of the foregoing disclosures, without departing from the main principles of the present invention.