EP4673268A1 - Machine de formage et procédé de fabrication de pièces façonnées pliées de manière complexe - Google Patents

Machine de formage et procédé de fabrication de pièces façonnées pliées de manière complexe

Info

Publication number
EP4673268A1
EP4673268A1 EP24708159.9A EP24708159A EP4673268A1 EP 4673268 A1 EP4673268 A1 EP 4673268A1 EP 24708159 A EP24708159 A EP 24708159A EP 4673268 A1 EP4673268 A1 EP 4673268A1
Authority
EP
European Patent Office
Prior art keywords
forming
tool
workpiece
forming unit
bending
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP24708159.9A
Other languages
German (de)
English (en)
Inventor
Bernd Bahnmüller
Wolfgang Krüger
Oliver Kuhnert
Marcel Sauer
Ralph Schneider
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Wafios AG
Original Assignee
Wafios AG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Wafios AG filed Critical Wafios AG
Publication of EP4673268A1 publication Critical patent/EP4673268A1/fr
Pending legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21F—WORKING OR PROCESSING OF METAL WIRE
    • B21F1/00—Bending wire other than coiling; Straightening wire
    • B21F1/008—Bending wire other than coiling; Straightening wire in 3D with means to rotate the wire about its axis

Definitions

  • the invention relates to a forming machine and a method for producing shaped parts from an elongated workpiece, in particular for producing complex bent parts from wire.
  • Forming machines are computer-numerically controlled machine tools that can produce small or large series of molded parts, some of which have a complex geometry, predominantly by forming, from elongated semi-finished products such as wire, pipe, strip or the like in an automatic production process using suitable tools.
  • a complex bent molded part is a molded part that has more than one bend, with bends being relatively close together and/or merging into one another and/or sometimes even being in different planes. If such molded parts are produced predominantly or exclusively using bending operations, they are occasionally also referred to as bent parts in this application.
  • busbars Insulated and bent copper or aluminum rails, also known as "busbars" are used to electrically connect battery modules and/or as a replacement for cable harnesses. Since the installation spaces available for laying busbars are sometimes relatively narrow and geometrically complex, busbars are often required that have bends in one or more places. Wire materials in the form of insulated and bent copper or aluminum wires with an essentially rectangular or square cross-section are also often used to manufacture coil elements for building stators for electric motors, so-called "hairpins".
  • Computer-numerically controlled forming machines are used today to efficiently produce large numbers of molded parts.
  • the wire is conveyed or transported towards a forming system of the forming machine using suitable equipment under the control of an NC control program.
  • the forming system has several forming units, each of which carries a forming tool that is brought into engagement with the workpiece by a feed movement or, after a Intervention can be withdrawn.
  • different forming tools can be brought into engagement with the workpiece one after the other in order to successively produce several bends and thus possibly complex bending geometries.
  • the bending machine comprises a computer numerical control unit, a transport system for transporting successive wire rods along a transport path and several work stations arranged along the transport path.
  • the transport system has a plurality of workpiece receiving devices, each for receiving a single wire rod.
  • At least two of the work stations are designed as bending stations and are equipped with numerically controlled bending units.
  • the bending units each have a bending tool on their side facing the workpiece, which is optionally brought into engagement with the wire rod or removed from it by means of a feed drive.
  • the feed movements are perpendicular to the course of the transport path in the area of the bending unit. Some of the bending units feed horizontally, others in a vertical direction.
  • the wire processing machine comprises, among other things, a feed device for feeding the flat material from a material supply and for conveying the flat material parallel to a through-feed axis, an integrated stripping device with two milling units for stripping sections of the insulated flat material and a forming system T which comprises a star-shaped arrangement with several forming units with tool heads that can be fed essentially radially to the through-feed axis and on which forming tools can be used to form the flat material by bending.
  • the forming units are mounted on a vertical front wall and lie in a common plane that is oriented perpendicular to the transport direction of the wire.
  • the requirements for the geometry of the finished bent parts are sometimes extremely high.
  • the hairpins are plug-in coil elements in the form of lacquered copper wire brackets with a complex, three-dimensionally bent shape, which are intended to form essential parts of the stator windings. Since the component density in a stator should be as high as possible, there is relatively little space available for a hairpin. Each hairpin must be integrated into its designated space. This requires, among other things, precise dimensioned recesses are provided in the stator, into which a hairpin must fit precisely. In order to achieve high power densities, the sections of immediately adjacent hairpins that lie outside the recesses should also be able to lie as close together as possible. For this reason, for example, there are strict specifications for the target geometry of the finished bent part for hairpins.
  • the invention is based on the object of providing a forming machine of the type mentioned in the introduction, with which complex bent molded parts of the most varied geometries can be produced with high dimensional accuracy.
  • the invention provides a forming machine with the features of claim 1. Furthermore, a method with the features of claim 13 is provided. Advantageous further developments are specified in the dependent claims. The wording of all claims is made part of the content of the description by reference.
  • a forming machine for producing molded parts from an elongated workpiece.
  • the forming machine is suitable and intended for producing complex bent parts from wire.
  • the forming machine has a device for conveying an elongated workpiece to a forming system that has several forming units. These can be controlled in a coordinated manner via a control device.
  • Each of the forming units has a tool carrier that has a tool holder for holding a forming tool.
  • the forming tool can be moved back and forth between a position retracted from the workpiece without engagement with the workpiece and an engagement position with the help of a numerically controlled feed axis (machine axis for the feed) of the forming unit with a feed movement of the tool carrier.
  • the feed into the engagement position does not yet lead to forming.
  • the workpiece can be formed by a working movement of the forming tool, e.g. in a bending operation by bending.
  • the feed movement runs transversely to a local transport direction of the workpiece.
  • the “local transport direction” of the workpiece is In this application, it is also referred to as the "transport direction” for short and describes the direction in which the workpiece is transported to the area of the respective forming unit.
  • the transport can be carried out, for example, by feeding a workpiece in the form of continuous material into the area of the forming unit.
  • the workpiece prefferably in the form of a rod cut to a certain length and to be transported to the forming unit, for example, using a movable workpiece receiving device. Then at least one section of the rod that has not yet been bent extends in the transport direction.
  • the forming system comprises different types of forming units, namely at least one first forming unit and at least one second forming unit.
  • a first forming unit is characterized in that its tool carrier and the forming tool attached to it can be fed in a first feed direction, which lies in an orthogonal plane perpendicular to the local transport direction of the workpiece.
  • the first feed direction can, for example, be oriented radially to the section of the workpiece to be formed, or possibly tangentially to it.
  • a second forming unit is characterized in that, in at least one working configuration of the second forming unit, its tool carrier and the forming tool attached to it can be fed in a second feed direction that is oblique to the local transport direction and oblique to the orthogonal plane.
  • This second feed direction therefore corresponds to an oblique direction that in this working configuration encloses an acute angle with both the orthogonal plane and the local transport direction, i.e. an angle that is between 0° and 90°.
  • the second tool carrier has a tool holder for holding a forming tool in the form of a bending tool, which has at least one tool part that can be rotated about a bending axis.
  • the second forming unit has a rotating mechanism with a rotary drive for rotating the rotatable tool part about the bending axis.
  • the bending axis is aligned parallel to the second feed direction. The bending axis therefore runs parallel to the feed direction of the second forming unit.
  • the feed and the forming operation or bending are then two different work movements.
  • the actual forming can follow the linear feed movement and is carried out using at least one rotary movement.
  • the forming machine is ideally suited to the production of three-dimensionally bent molded parts due to its configuration. If required, only two-dimensionally bent molded parts can of course also be produced. Due to the proposed design, more degrees of freedom in forming are available compared to conventional forming machines, especially those of the type mentioned in the introduction, and certain restrictions in forming can be avoided.
  • several or all forming units i.e. also one or more first forming units, are designed with a rotating mechanism corresponding to the second forming unit in order to be able to use a forming tool in the form of a bending tool with at least one tool part that can be rotated about a bending axis.
  • At least one of the forming units is designed to accommodate a forming tool in the form of a bending tool, which has two tool parts that can be rotated independently of one another about a bending axis, and that the rotating mechanism has two independently controllable drives. This enables two independent rotations of tool parts of a accommodated bending tool.
  • several or all Forming units, including one or more first forming units, are constructed in this way.
  • At least one forming unit also has a machine axis that is designed to move the rotatable tool part in the direction of a bending mold, so that the received workpiece section can be clamped between the bending mold and the tool part by means of the tool part.
  • the workpiece can then be pulled around the bending mold by rotating the tool part. This can rotate with it, so that a rotary draw bending operation is possible.
  • one or more first forming units can only be fed linearly and the forming is achieved by continuing the linear movement of the tool carrier after reaching workpiece contact in order to produce a bend.
  • a forming unit and the associated forming tool can also be designed for other forming operations that change the shape essentially without removing material, such as winding or coiling, and possibly also for pressing or embossing.
  • processing units can be provided for other processing operations, in particular material-removing processing operations such as punching, drilling, thread cutting, milling, chamfering and/or facing.
  • the second forming unit is designed and housed in the forming system in such a way that the second feed direction permanently corresponds to a selected inclined direction that cannot be changed or cannot be changed without extensive assembly work.
  • This inclined direction can, for example, be at a 45° angle to the transport direction and the orthogonal plane.
  • a feed direction adjustment device is provided for variably adjusting the orientation of the second feed direction within a feed direction angle range. This allows different inclinations of the second forming unit to be set in relation to the local transport direction, which can increase the flexibility in using the forming machine. Preferably, continuous adjustment is provided.
  • the feed direction angle range may comprise, in addition to one or more different oblique directions, at least one feed direction which is the above-mentioned orthogonal plane.
  • the second forming device can be fed in the same way as a first forming unit in corresponding working configurations.
  • the feed direction angle range is at least 180°. In some embodiments, it is therefore possible to feed a second forming unit from two opposite directions like a first forming unit perpendicular to the local transport direction and additionally optionally to set an oblique direction as the feed direction.
  • the feed direction adjustment device is designed for manual adjustment, so that the desired inclination of the second forming unit can only be adjusted when setting up or converting the forming machine in accordance with the desired target geometry of the molded part.
  • the feed direction adjustment device is a controllable machine axis, so that the inclination direction can be adjusted and changed in response to control signals from the control unit by means of its own drive, which is also possible during a sequence of bending operations on one and the same molded part if required.
  • a second forming unit can be brought into engagement with the workpiece more than once and, if necessary, from different feed directions in order to introduce one or more bends at different points on the workpiece.
  • a preferably stepless adjustment of the second feed direction is realized in some embodiments in that the feed direction adjustment device has a curved guide on which a carriage is guided, which carries the second forming unit together with a drive of the feed axis for the second feed.
  • the second forming unit can be mounted on a rotary table, in particular such that the second forming unit can be pivoted about a rotation axis that runs perpendicular to the second feed direction. This further increases the flexibility of use.
  • first forming unit is sufficient. In most embodiments, however, several, e.g. two, three, four or more first forming units are provided. This can increase the flexibility for producing different bending geometries. Different first forming units can be equipped with different forming tools, and if necessary, several first forming units can also be equipped with the same type of forming tool.
  • the first forming units can form a substantially coplanar arrangement in which several first feed directions or several first forming units, in particular all first feed directions or all first forming units, are located in a common orthogonal plane or in the vicinity thereof and the feed direction of the second forming unit is oriented obliquely to this orthogonal plane and to the transport direction.
  • the individual forming units do not necessarily have to be arranged exactly in a single common plane. They can be arranged partially offset minimally in the transport direction and/or moved over small travel paths in the transport direction, but remain close to the common orthogonal plane.
  • Some conventional torsion spring machines can be retrofitted with a second forming unit including associated drives and corresponding software components.
  • the devices for conveying the workpiece comprise a feed device for drawing in an elongated workpiece from a material supply and for conveying the workpiece to the forming system, wherein the feed device is preferably designed as a rotatable feed device for numerically controlled workpiece rotation.
  • the feed device is thus designed as a rotatable feed device and has a rotary machine axis for numerically controlled workpiece rotation.
  • the wire material can then be rotated using the feed device to change the orientation of the bending plane.
  • the workpiece can then be rotated about the transport axis, for example, between the creation of a first bend and the creation of a second bend.
  • first feed directions or first forming units may be located in different orthogonal planes that are offset from one another in the transport direction, and for the second forming unit to be arranged downstream of at least one first forming unit in the transport direction. This allows a bend to be subsequently created at a point that has already been bent.
  • a second forming unit can be arranged between an upstream and a downstream first forming unit.
  • a forming tool can be designed as a pin-mandrel tool with or without a rotating mandrel or as a rotary draw bending tool. With a pin-mandrel tool, the mandrel does not usually rotate while the pin rotates around the bending axis during the bending operation.
  • a forming tool can also be designed as a winding tool or as a coiling tool.
  • At least one pin-mandrel tool and at least one rotary draw bending tool are used for a multi-stage bending sequence.
  • At least one of the forming units is configured as a rotary drawing bending unit.
  • a fully equipped forming machine has a multi-part forming tool on at least one forming unit, which has a bending mold with a circumferential groove for receiving a section of the workpiece to be bent and a tool part that can be rotated around the bending mold by rotating about a bending axis for engaging a section of the workpiece to be bent.
  • the bending mold is designed as a split bending mold and has a lower mold part and an upper mold part that is movable relative to the lower mold part. A lower boundary surface of the circumferential groove is formed on the lower mold part and an upper boundary surface of the circumferential groove is formed on the upper mold part.
  • the upper mold part and the lower mold part can be moved relative to one another by means of a drive between a closed configuration with a relatively smaller clear height and an open configuration with a larger clear height in comparison in order to change the clear height of the circumferential groove.
  • the forming tool is first brought into the open configuration and the workpiece is partially inserted into the circumferential groove so that a side of the workpiece facing the tool can be supported on the bending form.
  • the forming tool is then brought into the closed configuration using the drive in such a way that the parts of the workpiece lying within the circumferential groove lie between the boundary surfaces of the circumferential groove without any play.
  • one of the molded parts in particular the lower molded part, has a guide opening for axially guiding a displacement movement of the other molded part
  • the other molded part in particular the upper molded part, has a guide section dimensioned for insertion into the guide opening and a head section that is wider than the guide section, wherein a radial outer surface of the guide section delimits the circumferential groove inwards and one of the boundary surfaces of the circumferential groove is formed on the head section.
  • the guide section has a cylindrical outer contour at least on the side on which the flat material engages in the circumferential groove, such that the radially inner base surface of the circumferential groove is formed by the part of the radial outer surface of the guide section that is exposed between the upper and lower boundary surfaces.
  • the drive is controlled at least during some bending operations in such a way that the section received in the circumferential groove is clamped between the upper and lower boundary surfaces in the closed configuration with a clamping force acting essentially parallel to the bending axis. This makes it possible to achieve even better dimensional accuracy of the workpiece in the area of the bend.
  • the boundary surfaces are aligned parallel to one another and perpendicular to a bending axis of the forming tool. This means that a flat bend without bulging can be achieved in a flat material even when bending over a short side.
  • a forming machine according to the claimed invention can be used in exactly the same way as a conventional forming machine of the type mentioned in the introduction, given a corresponding number of first forming units.
  • methods for producing molded parts are also possible in which at least one first bend is produced in a first section of the workpiece by means of a first forming unit, the first forming unit being fed in a first feed direction running perpendicular to the transport direction, and at least one second bend is produced in a second section by means of a second forming unit, the second forming unit being fed in a second feed direction that is oblique to the transport direction and oblique to the orthogonal plane of the transport direction.
  • a bending tool with at least one rotatable tool part is used, which is rotated about a bending axis oriented parallel to the second feed direction to produce the second bend.
  • first bend to lie in a first bending plane containing the transport axis and the second bend to lie in a second bending plane oriented perpendicular to the second feed direction.
  • the first and second bends can thus lie in different bending planes such that the molded part is a three-dimensionally bent molded part.
  • the at least one second bend can be created after a first bend.
  • the workpiece can have a section running in the transport direction and a section following the first bend, which runs in a direction that is oblique to the transport direction, and that the second bend is created in this oblique section or in the area of the first bend.
  • the possibility of obliquely aligning the second feed direction means that the process can be run in such a way that the second feed direction is oriented essentially perpendicular to the orientation of a workpiece section to be formed with the second forming unit.
  • Some processes are characterized by the fact that two bends with opposite curvature directions are created in immediate succession using the second forming unit, which preferably merge into one another without an intermediate straight section.
  • the so-called S-bend can be created, for example, in the production of hairpins.
  • the workpiece can be moved by a transport distance in the transport direction between the creation of the first bend and the creation of the second bend.
  • the workpiece is moved in a transport direction after the creation of the first bend and then at least one second bend is created in a second section located at a distance from the first section by means of a second forming unit, wherein the second section is oriented in a direction transverse to the transport direction due to the first bend and the second forming unit in a delivery direction that is oblique to the transport direction and oblique to an orthogonal plane of the transport direction.
  • further degrees of freedom of design arise from the fact that the workpiece is rotated about the transport axis between the creation of a first bend and the creation of a second bend in order to change the bending plane.
  • the forming machine has a forming system with several first forming units, the first feed directions of which lie in a common orthogonal plane to the local transport direction or in the vicinity of this common plane.
  • at least one second forming unit is then provided, in which the second feed direction is oriented obliquely to the orthogonal plane and the local transport direction.
  • the workpiece transport in the transport direction is carried out here via a machine axis of the forming machine, referred to as the feed axis, with successive sections of the elongated workpiece material being successively conveyed into the area of the orthogonal plane.
  • the forming machine is designed to produce complex curved molded parts from straight workpiece sections of a predetermined length. These can be straightened in upstream operations and separated from the supplied workpiece material before the first forming operation begins with a forming unit of the forming system.
  • Such embodiments have a transport system for transporting successive straight workpiece sections (rods) along a transport path, wherein the transport system has a plurality of workpiece receiving devices for receiving a single rod-shaped workpiece section each.
  • the forming system of this embodiment comprises several work stations arranged along the transport path, wherein at least two of the work stations are designed as bending stations in that at least one forming unit designed as a bending unit is arranged there.
  • the workpiece transport in the transport direction is realized here by a travel movement of the workpiece receiving device along the transport path.
  • FIG. 1 shows an oblique perspective view of a forming machine designed in the manner of a leg spring machine according to an embodiment
  • Fig. 2A shows a part of the forming area of the forming machine of Fig. 1 from a different perspective
  • Fig. 2B shows an oblique perspective view of a plug-in coil element
  • Fig. 3 shows a schematic side view of a wire processing plant with a forming machine according to another embodiment
  • Fig. 4 shows a bending station with a horizontally adjustable first forming unit
  • Fig. 5 shows a bending station with a vertically adjustable first forming unit
  • Fig. 6 shows a bending station with an inclined second forming unit
  • Fig. 7A to 7F show different phases of a multi-step process for producing a hairpin in oblique perspective
  • Fig. 8A to 8F show different phases of a multi-step process for producing a hairpin in plan view.
  • Fig. 1 shows an oblique perspective view of a forming machine 100 designed in the manner of a leg spring machine according to an embodiment.
  • Fig. 2 shows a part of the forming area of the forming machine from Fig. 1 from a side perspective in a phase of the production of a hairpin.
  • the forming machine 100 is designed to produce complex three-dimensionally bent molded parts in the form of coil elements for electric motors.
  • a starting material also referred to as workpiece W
  • workpiece W which has a wire-shaped electrical conductor material (e.g. copper) with a substantially flat, rectangular, in particular square cross-sectional shape, which is covered by an electrically non-conductive insulation layer made of varnish or the like.
  • the starting material is in the form of a wound material supply (coil).
  • the workpiece is also referred to below as "wire” or "flat material” for short.
  • the computer-numerically controlled, multi-axis forming machine 100 has several machine axes that can be controlled via a control unit 190, a drive system with several electric drives for driving the machine axes and a control device for the coordinated control of working movements of the machine axes in a production process according to a computer-readable control program specific to the production process.
  • the forming machine has a rectangular machine coordinate system MK, marked with lowercase letters x, y and z, with a vertical z-axis and horizontal x and y axes.
  • the coordinate axes x, y and z are to be distinguished from the controlled driven machine axes, whose drives are controlled via the control unit 190 of the forming machine.
  • the forming machine 100 has a machine frame which has a vertically aligned front wall 105 on its front side.
  • the forming system 200 of the forming machine which is accessible from the front, comprises, among other things, a plurality of first forming units 220-1, 220-2, 220-3, and exactly one second forming unit 230.
  • Behind the front wall 105 there are devices that are designed to convey the elongated, straightened workpiece material in the direction of the forming system 200.
  • This includes a feed device 120 for drawing in the elongated workpiece material from a material supply and for pushing or conveying or transporting the workpiece parallel to a transport axis 310 into the area of the forming system 200, as well as a straightening unit upstream of the feed device 120 for straightening the workpiece coming from the workpiece supply before it enters the feed device 120.
  • the structure behind the front wall can correspond to the structure described in DE10 2019 213 976 A1. Reference is made to the corresponding disclosure.
  • the feed device 120 is designed as a belt feed device, but can also be designed as a roller feed device, gripper feed device or caterpillar feed device.
  • the feed device is designed to convey successive workpiece sections of the workpiece material coming from the material supply and straightened by the straightening unit with a numerically controlled feed speed profile in the horizontal transport direction 308 more or less coaxially to the transport axis 310, i.e. parallel to the x-axis of the machine coordinate system MK, through a downstream guide device 110 into the area of the forming system 200.
  • the feed device 120 is rotated by one of the Transport axis 310 corresponding feed rotation axis can be rotated in both directions by a predetermined angle of rotation (e.g. +/- 180°) (see curved double arrow).
  • the guide bush has a guide opening with a rectangular cross-section adapted to the rectangular cross-section of the flat material.
  • the local transport direction 308 of the wire in the area of the forming units 220-x, 230 runs coaxial to the transport axis 310.
  • the wire is formed into a three-dimensionally bent molded part using numerically controlled tools of the forming system 200.
  • the finished or largely finished formed molded part is then separated from the supplied wire using a cutting unit 280 with a scissor cut.
  • the cutting unit 280 which is equipped with a movable cutting blade, is at an angle of 45° to the vertical direction.
  • first forming units 220-1, 220-2, 220-3 of the forming system 200 are mounted in a suitable orientation to the transport axis 310.
  • the only second forming unit 230 is mounted on an NC-controlled carriage 235, which can be moved over 180° on a semicircular curved guide 234 in a horizontal plane and can be fixed at different points on the curved guide.
  • the carriage carries a rotary table 233 that can be rotated by a motor about a vertical axis of rotation under NC control, which in turn carries the second forming unit 230.
  • These components belong to a feed direction setting device 270 for the variable setting of the orientation of the second feed direction within a feed direction angle range. This is slightly more than 180° here and includes all oblique directions as well as an orientation parallel to the transport direction 308 and orientations of the second feed direction parallel to the orthogonal plane OE.
  • Each of the forming units has a tool holder for receiving a forming tool on its side facing the transport axis 310, wherein the forming tools here are usually one-piece bending tools or bending tools composed of several components.
  • Each forming unit has a translationally movable slider that serves as a tool carrier, with which the respective forming tool can be fed into engagement with the workpiece in a linear or straight feed movement along a feed direction. or can be retracted. Furthermore, each forming unit has a rotary mechanism with one or more rotary drives in order to be able to rotate movable components of the forming tool about a rotary axis (bending axis) 225 oriented parallel to the feed direction in response to control signals from the control device 190.
  • All first forming units are located near a common orthogonal plane OE (corresponding to a y-z plane) oriented perpendicular to the transport axis 310.
  • the associated first tool carriers 240-1, 240-2, 240-3 can each be fed in a first feed direction 222-1, 222-1, which lies in the orthogonal plane perpendicular to the local transport direction of the workpiece.
  • the second forming unit has a second tool carrier 242 which, in the illustrated working configuration, can be fed in a second feed direction 222-2 which is at an acute angle W1 oblique to the local transport direction 308 or 310 and at an acute angle W2 oblique to the orthogonal plane OE (y-z plane).
  • the first forming unit 220-1 which can be seen on the right in Fig. 1 and on the left in Fig. 2A, is mounted on the front wall 105 with a horizontal slide axis so that it can be moved vertically and can be fed and retracted in the direction of the workpiece using a feed drive in a first feed direction 222-1 that runs perpendicular to the transport axis and parallel to the orthogonal plane OE.
  • the multi-part forming tool 250-1 which is mounted in a tool holder on the front of the workpiece carrier, is a pin-mandrel tool.
  • the bending tool has a central bending mandrel with a diametrical groove that can be rotated about the horizontal bending axis and a bending pin that can be rotated around the bending mandrel independently of the bending mandrel.
  • the bending tool can be used to create bends whose bending plane is perpendicular to the axis of rotation 225 of the bending tool or in the x-z plane of the machine coordinate system.
  • the position of the bending plane in relation to the transport axis can be specified by rotating the rotatable feed 120.
  • the second forming unit 220-2 arranged diametrically opposite also has a first feed direction 222-1 in the y-direction, i.e. in the orthogonal plane OE.
  • the forming tool attached to the front of the tool carrier is also designed as a pin-mandrel tool analogous to the opposite side.
  • a further first forming unit 220-3 is mounted horizontally on the front wall 105.
  • the slide axis or the feed direction 222-1 of the workpiece carrier runs vertically, i.e. parallel to the z-direction.
  • the multi-part bending tool 250-3 attached to the tool carrier grips the workpiece from above. It can produce flat bends in a horizontal bending plane.
  • the bending tool is specially adapted to bend a wire made of flat material around the short side, i.e. to create a flat bend in which the broad sides of the flat material in front of and behind the bend lie, if possible, in a common plane in which the flat material also lies in the area of the bend.
  • the forming tool 250-3 is designed as a rotary drawing bending tool. It comprises a central bending form 252 that can be rotated about the bending axis and has a circumferential flat groove 253 for receiving a section of the workpiece to be bent. There is also a tool part 254 that can be rotated about the bending axis and the bending form.
  • the rotatable tool part can be moved in the radial direction in the direction of the bending form and in the opposite direction using its own machine axis. The flat material received in the circumferential groove can thus be held in the radial direction between this tool part and the bending form.
  • the bending mold 252 is designed as a split bending mold. It has a stationary mold part 255, which is fixed in relation to the tool holder, and an outer mold part 256 with a widened head that is movable relative to the stationary mold part. One of the boundary surfaces of the circumferential groove is formed on the stationary mold part and the opposite boundary surface on the movable mold part.
  • the movable mold part 256 has a cylindrical guide section formed integrally with the head, which is guided axially movably in a cylindrical guide opening of the stationary mold part 255 and whose outer side forms the radially inner base of the circumferential groove.
  • the clearance height of the circumferential groove can be continuously changed by moving the movable mold part relative to the stationary mold part by means of a drive between a configuration with a relatively smaller clearance height and a configuration with a larger clearance height.
  • a pneumatic drive has the advantage of clamping in a force-controlled manner and being independent of fluctuations in the wire dimension.
  • the clamping can also be realized via a controlled machine axis, then preferably path-controlled.
  • the forming tool When performing a bending operation, the forming tool is first brought into the open configuration and the workpiece is partially introduced into the circumferential groove in such a way that a narrow side of the flat wire can be supported on the bending form in the area of the groove base. The forming tool is then brought into a closed configuration so that the parts lying in the circumferential groove are positioned without play between the boundary surfaces of the The workpiece material can be prevented from bulging in the area of the inner radius when the bend is created, thereby deviating from the desired bend geometry.
  • the split bending tool is therefore used here to create a flat bend with a bending plane that corresponds to an xy plane.
  • the forming tool 250-2 on the horizontally adjustable tool carrier 242 of the second forming unit 230 is also constructed in several parts and has a central mandrel 251 with a diametrically continuous receiving channel for the workpiece and a tool part 253 with a bending pin that can be rotated around the mandrel.
  • the second forming unit 230 can therefore act on a workpiece section that does not run parallel to the transport axis and may already be bent. This makes it possible to implement completely new sequences of bending steps. It has been shown that, for example, in the production of hairpins, this can significantly improve the dimensional accuracy of the finished molded parts.
  • FIG. 2B A typical geometry of a three-dimensional molded part FT or bent part in the form of a hairpin with multiple bends is explained in FIG. 2B.
  • the finished molded part essentially has the shape of a U-shaped bracket made of bent lacquered copper wire and has two legs that should ideally run parallel to one another to enable the plug-in coil to be inserted into the space provided.
  • the target geometry shown is characterized by a straight first section A1 that is connected to a second section A2 via a complexly curved section A3 that, according to the target geometry, should run parallel to the first section A1.
  • the broad sides of the flat material of the legs are usually at an angle to one another, i.e. they are not coplanar.
  • a so-called S-bend S is formed in the area of the roof ridge.
  • the S-bend is a sequence of bends that immediately merge into one another, each with a different sense of curvature.
  • the following example explains the sequence of bending steps that can be used to produce such a molded part using the forming machine from Fig. 1. Depending on the required geometry, a modified process may result.
  • a piece of flat material is advanced parallel to the transport axis 310.
  • the first forming unit 220-1 is brought into engagement with the still straight workpiece material by horizontal advancement radially to the transport axis, in order to then produce a slight inclination of the bent section with a small rotation.
  • first forming unit 220-3 located at the top is brought into engagement with the workpiece material by vertical feed radially to the transport axis.
  • Working movements of the rotary draw bending produce a first bend B1, which forms the transition between the first leg A1 and one side of the roof.
  • a slight torsion can be introduced by rotating the infeed.
  • the rotary draw bending tool 250-3 coming from above is then brought into engagement again to create the bend B2, which forms the roof ridge.
  • the S-bend is now to be introduced by means of opposing bends that merge directly into one another. This is where the advantage of the inclined second forming unit 230 comes into play.
  • the bends to form the S-bend S are to be introduced in a tool section that does not run parallel to the transport axis 310, but at an angle to it. Because the second feed direction is also oriented at an angle to the transport axis 310 and to the orthogonal plane, the pin-mandrel bending tool 250-2 of the second forming unit can be brought into engagement from the side more or less perpendicular to the wire path.
  • the two opposing partial curvatures of the S-bend can then be created by turning the tool components forwards and backwards.
  • the bending operations already applied on the first side follow in reverse order, in order to first create the curves in the other side of the roof using three small bends with the help of the first forming tool.
  • the rotary bending tool which can be fed from above, is brought into action again to form the transition between the other side of the roof and the second leg, etc.
  • the cutting tool 280 is engaged to separate the finished molded part in the form of a hairpin from the supplied wire material.
  • the workpiece By rotating the infeed by a suitable angle, the workpiece is optimally turned or rotated for the engagement of the corresponding forming tool.
  • a first forming unit can be provided from below on the opposite side. This can also be provided in addition to a first forming unit coming from above.
  • Fig. 3 shows a schematic side view of a wire processing system 400, which in most parts can be identical or similar in structure to the wire processing system of the embodiment from the applicant's published application DE 10 2020 212 558 A1. Reference is made to the description there.
  • the wire processing system is also designed to produce complex three-dimensionally bent molded parts in the form of hairpins from an insulated flat wire material.
  • the starting material is in the form of a wound material supply that is wound on a reel 504.
  • the workpiece enters a rod assembly machine 410 with an integrated stripping device and passes through a straightening unit, a length measuring device, a milling device as part of a stripping device, a downstream brushing device and a feed device downstream of this, as well as a downstream cutting device.
  • a rod assembly machine With regard to the structure and function of the rod assembly machine, reference is made to the above-mentioned patent application.
  • the rod assembly machine 410 supplies elongated workpieces W as an intermediate product in the form of straightened wire rods of a predetermined length, which are separated from the supplied wire.
  • the wire rods are transported to a downstream forming machine in the form of a bending machine 500 using a rod transfer device.
  • the longitudinal direction (direction of the longitudinal center axis) of the wire rods runs horizontally and parallel to the transport direction of the wire rods.
  • the bending machine 500 has its own base 505, on the top of which components of a transport system 510 for transporting successive wire rods along a transport path 512 are attached.
  • the transport path runs in a horizontal plane (xy plane).
  • the transport path is shown for illustration purposes in the area of the base 505 in a schematic plan view of the transport plane.
  • the transport path 512 is closed in the circumferential direction and has a substantially rectangular course with straight longitudinal and transverse sides and curved sections in the corner areas.
  • the transport system 510 comprises a plurality of individual transport units 515, for example from three to ten or more transport units.
  • Each transport unit has a workpiece receiving device 525 for receiving a single wire rod W. In the area of the workpiece receiving device, this runs coaxially to its receiving axis and horizontally and parallel to a direction that corresponds to the local transport direction on the transport route.
  • Each movement of a transport unit 515 can be carried out according to an individual movement profile, which can be specified by the control unit based on a computer program.
  • the transport units 515 are moved via linear direct drives.
  • the bending machine 500 has several bending stations 550-1, 550-2, etc. arranged one after the other along the transport path. At each of the bending stations, a forming unit is attached, with which a bending operation can be carried out on the wire rod, possibly also several bending operations.
  • Fig. 4 shows a perspective side view of the first bending station 550-1. It has a first forming unit 520-1, which can be positioned parallel to the transport path and in the vertical direction using suitable drives.
  • the forming unit has a tool holder for holding a forming tool on its side facing the transport axis.
  • this is a multi-part forming tool in the form of a pin-mandrel tool, the rotatable components of which can be rotated about a horizontal axis of rotation.
  • the feed movement runs in an orthogonal plane OE parallel to a horizontal feed direction that is oriented perpendicular to the transport direction. With the help of the feed drive, the forming tool can be brought into engagement with the workpiece in order to then create a bend in the flat material by means of a rotary working movement.
  • Fig. 5 shows a schematic side view of a second bending station 550-2 with a forming unit 520-2 that can be positioned horizontally (parallel to the transport axis).
  • the first forming unit 520-2 can be linearly adjusted in an orthogonal plane OE oriented perpendicular to the transport direction, just like the forming unit of the first bending station.
  • the associated feed direction can be vertical or at an acute angle to the vertical.
  • the possibility of changing the feed direction within the orthogonal plane OE oriented perpendicular to the transport direction is made possible by a curved guide at the base of the bending station.
  • the forming tool of this forming unit corresponds to the forming tool 250-3 with a split bending form, which was explained in connection with Fig. 2 by other embodiments.
  • the wire can be bent by means of rotary draw bending, whereby the bending point can remain clamped in the split bending form and bulges are thus prevented, so that even when bending over the short side of the flat material, no bulges arise from the bending plane.
  • Fig. 6 shows a variant of a second forming unit 530, which is also mounted along the transport path, for example in a third bending station 550-3 between the second bending station 550-2 and a subsequent fourth bending station.
  • the second forming unit 530 is shown in a working position in which the horizontal feed direction of the tool carrier is neither parallel to the transport direction 508 nor in an orthogonal plane (plane perpendicular to the transport direction). Instead, the second forming unit has a second tool carrier which, in the working configuration shown and other working configurations of the second forming unit, can be fed in a second feed direction 522 which is oblique to the local transport direction 508 and oblique to an orthogonal plane.
  • the angle of attack W2 between the direction of feed and the transport direction 508 is continuously adjustable.
  • the base plate 521 which carries the forming unit is mounted on a rotary table 522 which in turn is mounted on a carriage 523 which can be moved parallel to the transport direction.
  • the available feed direction angle range extends over more than 90° in a horizontal plane, so that the second forming unit 530 can also be used as a first forming unit by adjusting the feed direction by rotating the turntable so that it is oriented radially to the transport axis of the wire rod.
  • This forming machine also enables a particularly efficient bending process for producing hairpins with particularly high dimensional accuracy by using at least a second forming unit 530 with the option of inclined feed.
  • Fig. 7A to 7F show an example of a schematic bending sequence for producing a hairpin with a forming machine similar to Fig. 3, whereby the bending units of the first and second bending stations are swapped. Since the sequence of images is self-explanatory, only particularly noteworthy aspects will be briefly discussed.
  • a first larger bend is first created with the vertically adjustable forming unit (Fig. 7A), before A horizontally adjustable forming unit is used to create slight bends that open up the third dimension (Fig. 7B).
  • a vertically adjustable rotary draw bending unit is then brought into engagement to create the bend at the roof ridge (Fig. 7C).
  • Fig. 7D At the next bending station there is then a second forming unit, i.e.
  • a forming unit whose bending tool can be advanced in an inclined direction that is oblique to the transport direction and the orthogonal plane.
  • the forming tool designed as a pin-mandrel bending tool, is then used to create the so-called S-bend in the prefabricated bend by alternating engagement and alternating rotation in opposite directions.
  • the oblique advance allows optimal tool engagement, which results in optimal tool geometry.
  • the next bending operations are then performed sequentially at two subsequent bending stations, with the bend shown in Fig. 7E being created in a vertical bending plane, while the final bend shown in Fig. 7F is created with the top-feed rotary draw bending tool.
  • Fig. 8A to 8G show a corresponding sequence of bending operations in a schematic top view.
  • a curved roof side is created by three small bends in a vertical bending plane (Fig. 8B), before the bend that is to form the roof ridge is created in a subsequent bending operation in a horizontal bending plane (Fig. 8C).
  • the second forming unit comes into action, which is fed at an angle to the transport direction and to the orthogonal plane.
  • Fig. 8D shows the first bending operation in a bending plane that is oriented vertically and at an angle to the transport direction, Fig.
  • FIG. 8E shows the subsequent bending operations, which create a bend with the opposite direction of curvature slightly offset from the first bend in order to form the S-bend.
  • Fig. 8F and 8G then show the last bending operations to the finished hairpin (Fig. 8G).

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Bending Of Plates, Rods, And Pipes (AREA)
  • Wire Processing (AREA)

Abstract

L'invention concerne une machine de formage pour produire des pièces façonnées à partir d'une pièce allongée (W), en particulier pour produire des pièces pliées de manière complexe à partir d'un fil métallique, comprend des moyens pour transporter une pièce allongée (W) vers un système de formage (200) qui comprend une pluralité d'unités de formage (220-x, 230). Chacune des unités de formage comprend un porte-outil (240-x, 242) qui comprend un logement d'outil pour recevoir un outil de formage (250-x) qui peut être déplacé en va-et-vient au moyen d'un axe d'alimentation à commande numérique de l'unité de formage par l'intermédiaire d'un mouvement d'alimentation, dirigé transversalement par rapport à une direction de transport locale (310) de la pièce, du porte-outil entre une position qui est retirée de la pièce (W) et une position de mise en prise. Le système de formage (200) comprend au moins une première unité de formage et au moins une deuxième unité de formage, la première unité de formage (220-x) comprenant un premier porte-outil (240-x) qui peut être introduit dans une première direction d'alimentation (222-1) qui est située dans un plan orthogonal qui est agencé perpendiculairement à la direction de transport locale (308) de la pièce, et la deuxième unité de formage (230) comprend un deuxième porte-outil (242) qui, dans au moins une configuration de travail de la deuxième unité de formage, peut être introduit dans une deuxième direction d'alimentation (222-2) qui est agencée obliquement par rapport à la direction de transport locale (308) et obliquement par rapport au plan orthogonal. Le deuxième porte-outil (242) comprend un logement d'outil destiné à recevoir un outil de formage (250-2) sous la forme d'un outil de cintrage qui comprend au moins une partie d'outil (253) qui peut tourner autour d'un axe de cintrage (225). La deuxième unité de formage comprend une unité rotative avec un entraînement rotatif pour faire tourner la partie d'outil rotative autour de l'axe de cintrage. L'axe de cintrage (225) est orienté parallèlement à la deuxième direction d'alimentation (222).
EP24708159.9A 2023-02-28 2024-02-27 Machine de formage et procédé de fabrication de pièces façonnées pliées de manière complexe Pending EP4673268A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102023201807.1A DE102023201807A1 (de) 2023-02-28 2023-02-28 Umformmaschine und Verfahren zur Herstellung komplex gebogener Formteile
PCT/EP2024/054896 WO2024180029A1 (fr) 2023-02-28 2024-02-27 Machine de formage et procédé de fabrication de pièces façonnées pliées de manière complexe

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DE102024129196A1 (de) * 2024-10-09 2026-04-09 Wafios Aktiengesellschaft Drahtführungseinrichtung, Drahtverarbeitungsmaschine und Verfahren

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ES471370A1 (es) * 1978-07-03 1979-02-01 Buch Batlle Augusto Perfeccionamientos en maquinas dobladoras universales
JP3744910B2 (ja) * 2003-02-10 2006-02-15 オリイメック株式会社 線ばね成形装置
DE102007031514A1 (de) * 2007-07-06 2009-01-08 Wafios Ag Drahtverformungsmaschine
DE102015208350B3 (de) * 2015-05-06 2016-08-25 Wafios Aktiengesellschaft Verfahren zur Herstellung von Formteilen und Umformmaschine zur Durchführung des Verfahrens
DE102016204572A1 (de) * 2016-03-18 2017-09-21 Otto Bihler Handels-Beteiligungs-Gmbh Umformmaschine und Verfahren zur Positionskorrektur des Schlittenaggregates einer solchen Umformmaschine
DE102019213976B4 (de) 2019-09-13 2021-07-15 Wafios Aktiengesellschaft Verfahren und Drahtverarbeitungsmaschine zur Herstellung von Formteilen aus isoliertem Flachmaterial
JP6682171B1 (ja) * 2019-12-06 2020-04-15 旭精機工業株式会社 線材成形機
DE102020212558A1 (de) * 2020-10-05 2022-04-07 Wafios Aktiengesellschaft Biegemaschine und Drahtverarbeitungsanlage mit Biegemaschine

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