EP0381025B1 - Method and apparatus for the cold deformation of ferrous and non-ferrous metal sections by spatial coil roll bending - Google Patents

Method and apparatus for the cold deformation of ferrous and non-ferrous metal sections by spatial coil roll bending Download PDF

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Publication number
EP0381025B1
EP0381025B1 EP90101359A EP90101359A EP0381025B1 EP 0381025 B1 EP0381025 B1 EP 0381025B1 EP 90101359 A EP90101359 A EP 90101359A EP 90101359 A EP90101359 A EP 90101359A EP 0381025 B1 EP0381025 B1 EP 0381025B1
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EP
European Patent Office
Prior art keywords
bending
coil
profile
bent
station
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.)
Expired - Lifetime
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EP90101359A
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German (de)
French (fr)
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EP0381025A1 (en
Inventor
Walter Dipl.-Ing. Späth
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SPAETH, WALTER
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Spath Walter
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Priority to AT9090101359T priority Critical patent/ATE105519T1/en
Publication of EP0381025A1 publication Critical patent/EP0381025A1/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D11/00—Bending not restricted to forms of material mentioned in only one of groups B21D5/00, B21D7/00, B21D9/00; Bending not provided for in groups B21D5/00 - B21D9/00; Twisting
    • B21D11/06—Bending into helical or spiral form; Forming a succession of return bends, e.g. serpentine form
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D53/00—Making other particular articles
    • B21D53/02—Making other particular articles heat exchangers or parts thereof, e.g. radiators, condensers fins, headers
    • B21D53/027—Making other particular articles heat exchangers or parts thereof, e.g. radiators, condensers fins, headers by helically or spirally winding elongated elements

Definitions

  • the present invention relates to a method and a device for the cold forming of profiles made of ferrous and non-ferrous metals, in which the profile continuously passing through a bending tool is bent in all three spatial axes (X, Y, Z) according to the preamble of patent claims 1 and 4 .
  • Spatial bending processes are known. For example, it is known from DE-A1-36 18 701, which goes back to the same applicant, to give profiles of ferrous and non-ferrous metals practically any desired shape by means of spatial bending. In this known device, however, the profile to be deformed is guided over a bending tool, pressed there and bent under deformation work. The deformation work takes place by passing on and by force transmission on the bending tool.
  • stellarator coils are required for use in fusion reactors. These are spatially curved, self-contained bobbins to be wound with highly sensitive coil conductors to be protected against damage.
  • coil conductors are hollow profile rods, for. B. square or rectangular cross-section. They have a paint layer that is sensitive to damage on the outside and a superconducting liquid in the interior, whereby neither damage to the outer skin of these sensitive profiles nor a change in cross-section may occur during the bending process.
  • a device with which bending can be achieved without damaging the outer skin is known, for example, from US-A-4,624,121.
  • This device enables multi-dimensional bending of profiles with horizontal and vertical bending mechanisms, as well as an axial rotating mechanism.
  • a base plate is pivoted on a base plate in such a way that it can be pivoted about a vertical axis, a vertical plate is firmly attached to this base plate at right angles and in the longitudinal direction of the longitudinal axis of the material, to which in turn horizontal bending devices are attached, and through which the material to be bent is carried out and behind which vertical bending devices are arranged.
  • the vertical bending devices can be pivoted with respect to the horizontal axis.
  • the present invention is therefore based on the object of developing an aforementioned method and the associated device so that the described sensitive closed profiles, for. B. bobbin can be bent with high precision without damage.
  • the method provides the features of claim 1.
  • the problem is solved by the technical teaching of claim 4.
  • the bending tool is designed as a bending head, and that the winding profile leaving the bending head has a winding shape at a small distance exactly aligned below the bending line of the bending head in all three spatial axes (X, Y, Z) and can also be rotated so that the finished bent profile is added to the winding form without further deformation work.
  • the profile to be bent (coil conductor) is bent by a bending head that works freely in space, without using a bending tool (bending template), on which the deformation work necessary for the bending is performed only by force-fitting.
  • console arm points freely into the space in the X direction and can also be moved in the Z direction.
  • the profile to be deformed is introduced into the bending space in this preferred direction, that is to say in the X direction, and spatially bent at the bending head.
  • RWRB process spatial winding roll bending process
  • This winding takes place in that the winding form is arranged in a rotatably driven manner below the bending head and the spatially curved one leaving the bending form Profile in the sense of a winding device.
  • a linear drive of the winding form is also conceivable, i.e. the spatially curved profile then leaves the bending head in the direction of its longitudinal axis and is taken up from a winding form which is likewise movable in the direction of the longitudinal axis.
  • the winding form is in this case (in both of the above-described embodiments) arranged directly below and at a short distance from the outlet end of the bending head, so that a further, undesirable deformation work during the transition from the bending head to the winding form is avoided.
  • the profile to be bent is a coil conductor and the winding form is therefore only used to hold and secure the finished bent coil conductor and no further deformation work is carried out in the winding form itself.
  • the rotary drive of the tool table rotates slightly faster than it corresponds to the withdrawal speed of the rolling station of the bending head, so that a slight tension in the longitudinal direction is applied to the finished bent profile, so that "relatively tight", with a slight pre-tension layer by layer, wound on the winding form will.
  • the preload can be set variably from zero to a maximum preload via the rotary drive.
  • the invention provides that the differential speed and the resultant advance between the rotary drive of the tool table and the take-off speed of the roll station of the bending head are made zero and thereby a "tight winding" in these areas not applicable. Rather, the finished molded profile is held in these areas by slides and other position securing means, which are only removed when this critical negative shaping area is secured by the overlying layer.
  • the layer above is then held in turn by the position securing means described above.
  • a device for carrying out the method uses a bending tool that carries out the deformation work, which is designed as a bending head arranged rigidly on the free end of a bracket arm, and with a winding shape at a short distance from the bending head for receiving the finished bent profile in such a way that it can be adjusted three-dimensionally and driven in a rotating manner Tool table is arranged that the finished bent profile can be recorded on the winding form without further deformation work.
  • a profile straightening system which is CNC-controlled, belongs to the introduction of the coil conductor to be unwound from the coil. It consists of various roller sets in tandem design, all of which are motor-driven and are oriented in the X, Y and Z directions and rotating so as to enable clean straightening.
  • This profile straightener straightens the conductor profile of the waveguide when it is unwound from a coil.
  • the coil station on which the waveguide is unwound, consists of a base foundation rail frame in the Y direction to accommodate a chassis.
  • the bearing frame for receiving the coil is arranged on the chassis.
  • the storage frame can be moved via two rail towers in the Z direction and in the Y direction. In order to the profile to be unwound can always be held in exactly the same rolling position for introduction into the profile straightening system.
  • the coil station therefore always has the task of ensuring that the hollow profile to be unwound from this coil is always inserted into the RWR bending station in exactly the same position. This is to prevent impermissible bends and deformations from being generated on the waveguide before they enter the bending machine. Furthermore, this relatively complex coil station is a prerequisite for the conductors always being inserted into the bending station with a precision of a tenth of a millimeter; only in this way can the required accuracy be generated during the bending process itself.
  • a coil transport system which consists of a rail system that leads from the RWR bending station to the coil station. After the first coil has been unwound, the coil frame is released from the warehouse and moved out to the rear on the rail system for removal.
  • the coiled second coil which was previously housed in the storage room of the RWR bending station, is unrolled, driven into the coil station via the rail system, latched and brought into position.
  • the now freely rolled profile section is aligned, threaded into the bending head and into the straightening machine and prepared for the second winding process with the opposite direction of rotation. of technology are new.
  • this winding shape 48 only has the inner wall 7 and the bottom wall 8, so that the coil conductors 2-6 to be bent are inserted into this open winding form 48, which is limited and defined only by the two walls 7, 8.
  • this winding form 48 is now not subjected to tension, i. H. the coil conductors 2.6 to be bent are not rolled or stretched along the walls of this winding form 48 with stretching and bending, but rather the winding form 48 serves only as a spatial support or as a bearing block for the individual coils to be bent spatially.
  • the winding form 48 therefore only serves to ensure that the coils 2-6, which are already spatially finished and finished by the bending machine, are only placed on them and are butted together so that, after the winding process has ended, the exact outer profile of a stellarator coil 1 is produced by the individual coils 2 wound on one another -6 is reached.
  • the basic principle of the present bending machine is based on the fact that the winding form initially rests on a base rotary table which can be moved in a three-dimensional plane and can carry out any spatial movement in space, including a rotary movement.
  • this three-dimensional movement of the winding form has the purpose of tracking the winding form to the waveguide or coil to be bent.
  • the bending head is always exactly above the line to be bent, ie the winding shape, which according to the above description only serves as a bearing block, is always spatially below the bending head under that the bending head lies exactly in the bending line.
  • the bending head can therefore only be moved in the X direction according to the invention, but not in the Y direction and also not necessarily in the Z direction, although the displacement in the Z direction is preferred for other reasons and will be described later.
  • the displacement in the X direction should only be given in a preferred embodiment, because it is not necessary for a solution. However, it is preferred because, depending on the required bending contour, it is preferred to move the slide forward or backward in the X direction in order to achieve an even more precise tracking to the bending line.
  • winding form rests on a three-dimensionally movable table, which can also be rotated, and that the winding form is always set so spatially under the bending head that the currently required bending line is always tracked under the bending head.
  • the bending head itself is rigid and can only be moved in the X direction and possibly also in the Z direction for practical reasons.
  • the rigid arrangement of the bending head has the sense that the coils to be bent must always be exactly aligned with a coil, more precisely, removed from the coil straightening system without bending or other damage.
  • the coil straightening system always holds the coil exactly (displaceable in the Y and Z directions) so that the coil material to be unwound from the coil is always exactly aligned, that is, always coming in the same plane, into the bending head. This means that the coil straightening station can be moved and the bending head itself is stationary.
  • the bending head consists of a row of rollers arranged in the bending direction or in the longitudinal direction of the tube, the tube being completely encircled by a roller on its profile.
  • the bending head now consists of a series of such four-roller arrangements which form the bending head lying one behind the other in the longitudinal direction of the tube.
  • such a bending head now consists of, for example, four four-roller systems arranged one behind the other and spaced from one another, then z. B. the first three roller systems rigid both in the X direction and in the Y and Z direction, while the last, lying in the longitudinal direction of the tube four-roller arrangement is displaceable in the X, Y and Z directions.
  • this four-roller arrangement can be rotated with respect to the other three four-roller arrangements, so that torsion of the coil to be bent is achieved.
  • the system according to FIGS. 6-8 essentially consists of four components, the so-called RWR bending machine 10 being the most important component.
  • the bending machine 10 is preceded by a profile straightening system 11, which in turn is preceded by a straightening station 12 and this in turn by a coil station 13.
  • the coil conductors 17 to be bent are seated on a coil 16, the coil 16 being part of the coil station 13.
  • the coil 16 can be moved in the arrow direction 63 shown in the Z direction and also in the Y direction, in order to ensure that the end of the coil conductor 17 that is currently being developed is exactly opposite to a roll 18, which in turn aligned with the roller 19 of the device station 12.
  • the purpose of this measure is to ensure that the coil conductors 17 to be bent are always withdrawn in line 64 from the coil 16 without damage, friction and kinks.
  • the setting station 12 roughly sets up the coil conductor 17 to be bent.
  • the profile straightening insert 11 consists of a plurality of double rollers 20 which are driven in pairs and which are arranged one behind the other at a distance, the drawing in FIG. 2 also showing that also in Further double rollers 20 are provided in the Y direction, so that the coil conductor to be bent is positively embraced by the double rollers 20 from all sides.
  • the coil conductor 17 to be bent is aligned exactly axially so that it can be inserted into the bending head 52 in the aligned line 64. Because the coil conductor 17 is deformed by the winding process on the coil 16, the jig station 12 and the profile straightening system 11 provide for a reshaping, so that the coil conductor 17 to be bent is inserted into the bending head 52 as an undeformed straight line.
  • the task of this RWR bending machine is to move the winding form 48 arranged on a tool table 47 spatially in such a way that the coil conductor 17, which has been bent three-dimensionally by the bending head 52, is placed on the winding form 48 without further reshaping or bending.
  • the winding form 48 is therefore only used to hold and secure the position of the coil conductors 17 which have been bent by the bending head 52, whereby by special measures (namely by a difference in the rotary movement, that is to say a forward movement of the rotary movement for the tool table 47 with respect to the transport movement of the bending head 52) relative tension between the coil conductor 17, which has been bent by the bending head 52, and the winding form 48 is reached.
  • This differential movement is preferably used in the positive forming area of the winding form 48, while in the negative forming areas, as shown with the areas 65 in FIGS. 1 and 2, this lead is interrupted.
  • this area 65 the coil conductor profile 17, which is still under tension, is secured by a slide, this slide can be retracted both perpendicular to the surface 7 of the winding form 48 and also perpendicular to the bottom surface 8 of the winding form. This will relax the profile. Then it will Profile inserted into the winding form without pretensioning, again secured by second sliders which are perpendicular and perpendicular to it.
  • the bending machine 10 has a rail system 14 on the bottom, which serves to replace the coils 16, 50.
  • a rail system 14 which serves to replace the coils 16, 50.
  • the spherical winding of the coil conductor 17 by the bending head 52 is carried out starting from the center of the entire coil conductor 17 and starting from there to the left or right.
  • one half of the entire coil conductor 17 to be bent is present on one coil 16, while the other, not subject to the deformation, second half of the coil conductor 17 is present on the coil 50.
  • a coil change station is provided so that after the coil conductor 17 has been removed from the coil 16 to the coil 50, access is provided.
  • the coil 50 is in this case firmly mounted on a bearing block 51 on the base turntable 54 of the bending machine 10 and is held on the end face by shafts (not shown in more detail).
  • the coil 50 is moved onto the rail system 14 via a transport carriage (not shown in any more detail) and is brought to the coil station 13 in the direction of the arrow 15, the coil 50 then being clamped onto the coil station 13 and by the coil conductor to be unwound from the coil 50 is then introduced into the bending machine 10 via the device station 12 and profile straightening system 11.
  • the coil 50 After the coil 50 is connected with its second coil half 49 to the already wound winding form 48, it is a prerequisite that when changing the coil 50 from its position shown in FIG. 2 to the position of the coil station 13, the second coil half 49 is only manual is directed so that the second half of the bobbin can be threaded into the pre-aligning station in alignment.
  • the second spool half 49 is set up via a mobile straightening insert, which is not shown in the drawings for the sake of simplicity.
  • a machine frame 22 rests on the floor and carries on its upper side rails 23 which are oriented in the X direction and which are at a mutual, mutually parallel distance.
  • the rails carry a carriage 24 which can be moved in the X direction.
  • the movement of this slide 24 takes place here via spindles 25, which engage in spindle nuts (not shown in more detail) on the slide 24 and are each driven in rotation by a motor 26, the motors 26 being arranged on the machine frame 22.
  • a portal slide 27 is mounted so as to be movable in the direction of arrow Y.
  • the portal slide 27 in turn carries on its underside spindle nuts, each of which is penetrated by a spindle 29 and each spindle 29 is driven by a motor 28.
  • the portal slide 27 is thus moved in the Y direction according to FIG. 8.
  • a bearing plate 31 is attached to the side portals of the portal slide 27 and can be moved in the Z direction.
  • the portal slide 27 and the other associated parts are formed in an exactly mirror-symmetrical manner, only one side of the portal slide 27 is described in more detail below, after the other side is of exactly identical design.
  • the bearing plate 31 On the side of the portal slide 27, the bearing plate 31 is mounted so that it can be moved in the direction of the arrow Z, a drive motor 33 rotatingly driving a spindle 32 which passes through the spindle nuts of the bearing plate 31.
  • Each bearing plate 31 carries a shaft 34, the two mutually opposite shafts 34 being aligned in an axis 66 and - which is important for the invention - the axis 66 is exactly aligned with the conductor 17 to be bent in the zero position of the bending device.
  • this neutral bending position which is defined by the displaceable axis 66, the winding form 48 arranged on the tool table 47 is then moved accordingly, so that there is a change in the opposite position with respect to the bending head 52, which is always in the same position.
  • a rocker 35 is rotatably mounted on the shaft 34 about the axis 66, the rocker 35, like the portal slide 27 in the side view of FIG. 8, having an approximately U-shaped profile, the side legs of this U-shaped profile on the underside are connected to a portal 36, which portal swings in the drawing plane of FIG. 8 and can also be moved in the Z direction via the drive, consisting of the motor 37 and the spindle 38.
  • the individual winding layers 4, 5 of the coil 2, 6 to be wound can thus be tracked exactly during the winding process.
  • the spherical contours of the winding shape which has the shape of the stellarator coil 1 according to FIGS. 1, 2 and 3, are tracked.
  • a fixed substructure 39 e.g. formed from a plate which carries a ring-shaped ball bearing 40 at the top.
  • a shaft 41 is rotatably mounted on the substructure 39 and is rotatably driven by a motor 42 shown in FIG. 6.
  • the shaft 41 is rotatably connected to a base turntable 44.
  • This base rotary table 44 is thus rotatable in the direction of the arrow 45 shown.
  • a box frame 46 is fixedly attached to the base rotary table 44 and carries a tool table 47 on its upper side.
  • the winding form 48 is arranged on the tool table 47 and is shown in plan view in FIG. 5 and in side view in FIG. 6.
  • the pivot drive for the rocker 35 is formed by a motor 43.
  • this motor 43 is shown on the one side in FIG. 8, while it would also have to be arranged symmetrically on the other side of FIG. 3.
  • the winding form 48 essentially consists of the inner surface 7 and the bottom surface 8 of the stellarator coil according to FIGS. 1 and 2.
  • the structure of the bending head 52 is described below.
  • the bending head 52 consists of a complete roll bending machine which is able to carry out three-dimensional spatial bending under CNC control. It essentially consists of a machine housing 53 with a plurality of roller stations 54, 55 with the rollers 56, 57 which are arranged one behind the other and at a uniform distance from one another. 7, three rigid roller stations, each with rollers 55, are arranged one behind the other, all of which are driven in rotation and form the inlet for the coil conductor 17 to be bent.
  • Each roller station 54, 55 consists of four rollers 56, 57, two rollers being arranged opposite each other in pairs. Such an embodiment is shown schematically in FIG. 8, where a roller station is shown only as an example. It can be seen that the rollers 56 are arranged in pairs opposite one another to rollers 57 lying perpendicular thereto.
  • the rigid roller stations 55 serve to align the coil conductor 17 in alignment and to propel it in the direction of it Longitudinal axis is inserted into the movable roller station 54.
  • the movable roller station 54 in turn has pairs of opposing rollers 56 and rollers 57 perpendicular thereto, but with the difference that each individual roller of the roller pairs 56, 57 is arranged to be displaceable and adjustable.
  • Each roller 56, 57 of the respective pair of rollers is in this case slidably mounted on a circular arc and can be delivered and removed in the direction of the coil conductor 17 and can also be displaced in the direction of the longitudinal axis of the coil conductor.
  • the respective double rollers 56, 57 can be adjusted in both directions of rotation on a circular path in the Z direction, on a further circular path in the Y direction and additionally rotatable about the longitudinal axis of the coil conductor.
  • the bending head 52 pre-bends the coil conductor 17 completely finished in the required shape. It has a shape as shown in FIGS. 6 to 8. After leaving the movable rolling station 54, the coil conductor 17 accordingly has its required spherical shape and is then only threaded and inserted onto the winding form 48 which is adjusted in the three-dimensional direction.
  • the tracking of the winding form 48 exactly the corresponding previously given shape of the coil conductor therefore has the sense that a precise insertion of the coil conductor 17 leaving the reel station 54 onto the winding form 48 is ensured. This ensures that in the synchronous movement of the bending head 52 position on position are placed on each other with a perfect fit.
  • the bending process of the bending head 52 and the synchronous tracking of the winding form 48 is crucial for the precisely fitting manufacture of the winding layers 4, 5 of the coil conductors 17; i.e. by placing it on the winding form 48, there is no longer any essential deformation work itself.
  • the rotary drive for the tool table 47 is operated with a lead, so that the completely bent coil conductor 17 leaving the last roller station 54, with a slight pretension, lies layer by layer the winding form 48 are placed.
  • the preload can be set variably from zero to a maximum preload by adjusting the rotary drive in the direction of arrow 45.
  • this lead (in the direction of arrow 45) is removed in the negative shaping areas (areas 65 of the stellarator coil according to FIG. 1, 2) and corresponding slides are used instead to secure the shape of the coil conductors in these areas 65.
  • the entire bending head 52 is fixedly mounted on a bracket arm 59, i.e. it is fixed stationary in the room and the bracket arm 59 is mounted on a carriage 60 which can be moved on a tower 58 in the arrow directions 62 in the Z direction.
  • bracket arm 59 can be displaced in the direction of arrow 61 (X direction).
  • hollow profiles instead of the hollow profiles described, it is also possible to bend hollow profiles of open or closed profile shape.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacture Of Motors, Generators (AREA)
  • Bending Of Plates, Rods, And Pipes (AREA)
  • Reduction Rolling/Reduction Stand/Operation Of Reduction Machine (AREA)
  • Wire Processing (AREA)

Abstract

A method and apparatus for the cold deformation of ferrous and non-ferrous metal sections performs spherical bending of the section (17) by means of a bending tool (52) which can be moved and rotated in all three spatial axes. For high-precision and low-stress bending of hollow sections, during which the cross-section of the hollow section must not be changed, it is provided that the section to be bent spherically is bent freely in space without a bending form and abutment, by the bending tool designed as a bending head (52), and that, to safeguard the position of the final bent section (17) leaving the bending head, a winding accessory (48) adjustable in all three spatial axes and, in addition, rotatable, is made to follow in exact alignment under the neutral axis of the bending head at a short distance (three-dimensional coil roll bending process). <IMAGE>

Description

Die vorliegende Erfindung bezieht sich auf ein Verfahren und eine Vorrichtung zum Kaltumformen von Profilen aus Eisen- und Nichteisenmetallen, bei dem das ein Biegewerkzeug kontinuierlich durchlaufende Profil in allen drei Raumachsen (X, Y, Z) gebogen wird nach dem Oberbegriff der Patentansprüche 1 und 4.The present invention relates to a method and a device for the cold forming of profiles made of ferrous and non-ferrous metals, in which the profile continuously passing through a bending tool is bent in all three spatial axes (X, Y, Z) according to the preamble of patent claims 1 and 4 .

Räumliche Biegeverfahren sind bekannt. Beispielsweise ist mit der auf den gleichen Anmelder zurückgehenden DE-A1-36 18 701 bekannt, Profile aus Eisen- und Nichteisenmetallen durch ein räumliches Biegen praktisch jede gewünschte Formgebung zu verleihen. Bei dieser bekannten Vorrichtung wird jedoch das zu verformende Profil über ein Biegewerkzeug geführt, dort angepreßt und unter Formänderungsarbeit gebogen. Die Formänderungsarbeit findet also durch Abwälzung und durch Kraftübertragung am Biegewerkzeug statt.Spatial bending processes are known. For example, it is known from DE-A1-36 18 701, which goes back to the same applicant, to give profiles of ferrous and non-ferrous metals practically any desired shape by means of spatial bending. In this known device, however, the profile to be deformed is guided over a bending tool, pressed there and bent under deformation work. The deformation work takes place by passing on and by force transmission on the bending tool.

Mit diesem bekannten Verfahren und der dazugehörenden Vorrichtung ist jedoch nicht ein hochpräzises Biegen von empfindlichen Profilen möglich.With this known method and the associated device, however, high-precision bending of sensitive profiles is not possible.

Für die Verwendung in Fusionsreaktoren werden jedoch sogenannte Stellaratorspulen benötigt. Es handelt sich hierbei um räumlich gekrümmte, in sich geschlossene Spulenkörper, die mit hochempfindlichen, gegen Beschädigung zu schützende Spulenleiter zu bewickeln sind. Derartige Spulenleiter sind Hohlprofilstäbe, z. B. quadratischem oder rechteckigem Querschnitts. Sie tragen an der Außenseite eine gegen Beschädigung empfindliche Lackschicht und im Innenraum eine supraleitende Flüssigkeit, wobei während des Biegevorgangs weder eine Beschädigung der Außenhaut dieser empfindlichen Profile noch eine Veränderung im Querschnitt stattfinden darf.However, so-called stellarator coils are required for use in fusion reactors. These are spatially curved, self-contained bobbins to be wound with highly sensitive coil conductors to be protected against damage. Such coil conductors are hollow profile rods, for. B. square or rectangular cross-section. They have a paint layer that is sensitive to damage on the outside and a superconducting liquid in the interior, whereby neither damage to the outer skin of these sensitive profiles nor a change in cross-section may occur during the bending process.

Eine Vorrichtung, mit der ein Biegen ohne Beschädigung der Außenhaut erreicht werden kann, ist beispielsweise aus der US-A-4,624,121 bekannt. Diese Vorrichtung ermöglicht ein mehrdimensionales Biegen von Profilen mit horizontalen und vertikalen Biegemechanismen, sowie einen axialen Drehmechanismus. Dabei ist auf eine Grundplatte schwenkbar eine Bodenplatte derart angelenkt, daß diese um eine vertikale Achse verschwenkbar ist, an diese Bodenplatte ist im rechten Winkel und in Längsrichtung der Materiallängsachse eine vertikale Platte fest angebaut, an welche wiederum horizontale Biegeeinrichtungen angebracht sind, und durch welche das zu biegende Material durchgeführt wird und hinter welchen vertikale Biegeeinrichtungen angeordnet sind. Hierbei sind die vertikalen Biegeeinrichtungen gegenüber der Horizontalachse schwenkbar. Mit dieser herkömmlichen Biegevorrichtung ist es möglich, das zu biegende Profil räumlich zu biegen, jedoch eignet sich diese Vorrichtung besonders zum Biegen von Kurzteilen und weist daher keinerlei Wickelformen oder Aufnahmeeinheiten für gebogenes Material auf und eignet sich deshalb nicht zum Biegen von langen und geschlossenen Spulenkörpern.A device with which bending can be achieved without damaging the outer skin is known, for example, from US-A-4,624,121. This device enables multi-dimensional bending of profiles with horizontal and vertical bending mechanisms, as well as an axial rotating mechanism. Here, a base plate is pivoted on a base plate in such a way that it can be pivoted about a vertical axis, a vertical plate is firmly attached to this base plate at right angles and in the longitudinal direction of the longitudinal axis of the material, to which in turn horizontal bending devices are attached, and through which the material to be bent is carried out and behind which vertical bending devices are arranged. Here, the vertical bending devices can be pivoted with respect to the horizontal axis. With this conventional bending device it is possible to spatially bend the profile to be bent, but this device is particularly suitable for bending short parts and therefore has no winding forms or receiving units for bent material and is therefore not suitable for bending long and closed coil formers.

Der vorliegenden Erfindung liegt deshalb die Aufgabe zugrunde, ein eingangs genanntes Verfahren und die dazugehörende Vorrichtung so weiterzubilden, daß die beschriebenen empfindlichen geschlossenen Profile, z. B. Spulkörper mit hoher Präzision ohne Beschädigung gebogen werden können.The present invention is therefore based on the object of developing an aforementioned method and the associated device so that the described sensitive closed profiles, for. B. bobbin can be bent with high precision without damage.

Zur Lösung der Aufgabe sieht das Verfahren die Merkmale des Patentanspruchs 1 vor. Vorrichtungsmäßig wird die Aufgabe durch die technische Lehre des Patentanspruches 4 gelöst.To achieve the object, the method provides the features of claim 1. In terms of the device, the problem is solved by the technical teaching of claim 4.

Wesentliches Merkmal der vorliegenden Erfindung ist es, daß das Biegewerkzeug als Biegekopf ausgebildet ist, und daß dem den Biegekopf verlassenden fertig gebogenen Profil eine Wickelform in geringem Abstand genau fluchtend unter der Biegelinie des Biegekopfes in allen drei Raumachsen (X,Y,Z) verstellbar und zusätzlich drehbar derart nachgeführt wird, daß das fertig gebogene Profil ohne weitere Formänderungsarbeit auf die Wickelform aufgenommen wird.An essential feature of the present invention is that the bending tool is designed as a bending head, and that the winding profile leaving the bending head has a winding shape at a small distance exactly aligned below the bending line of the bending head in all three spatial axes (X, Y, Z) and can also be rotated so that the finished bent profile is added to the winding form without further deformation work.

Wesentlich ist also, daß das zu biegende Profil (Spulenleiter) von einem frei im Raum arbeitenden Biegekopf gebogen wird, ohne daß ein Biegewerkzeug (Biegeschablone) verwendet wird, an welcher erst durch kraftschlüssiges Anlegen die zur Biegung notwendige Formänderungsarbeit geleistet wird.It is therefore essential that the profile to be bent (coil conductor) is bent by a bending head that works freely in space, without using a bending tool (bending template), on which the deformation work necessary for the bending is performed only by force-fitting.

Wesentliches Merkmal der Vorrichtung ist es, daß zunächst von einem in X-Richtung frei in den Raum weisenden Konsolarm ausgegangen wird, der im weiteren auch in Z-Richtung verschiebbar ist. Das zu verformende Profil wird in dieser bevorzugten Richtung, das heißt in X-Richtung in den Biegeraum eingeführt und am Biegekopf räumlich gebogen.An essential feature of the device is that it is initially assumed that the console arm points freely into the space in the X direction and can also be moved in the Z direction. The profile to be deformed is introduced into the bending space in this preferred direction, that is to say in the X direction, and spatially bent at the bending head.

Um nun eine unzulässige Verbiegung dieses fertig gebogenen, empfindlichen Profils zu vermeiden ist vorgesehen, daß zur Lagensicherung des fertig gebogenen Profils eine Wickelform genau fluchtend unter der Biegelinie des Biegekopfes in geringem Abstand in allen drei Raumachsen verstellbar und zusätzlich drehbar nachgeführt wird.In order to avoid an inadmissible bending of this finished, sensitive profile, it is provided that, to secure the position of the finished bent profile, a winding shape exactly aligned under the bending line of the bending head can be adjusted at a small distance in all three spatial axes and additionally rotated.

Es handelt sich also um ein räumliches Wickelrollbiege-Verfahren (abgekürzt RWRB-Verfahren) mit dem bevorzugt ein Bewickeln in sich geschlossener Spulen möglich ist. Dieses Bewickeln erfolgt dadurch, daß die Wickelform drehbar angetrieben unterhalb des Biegekopfes angeordnet ist und das die Biegeform verlassende, räumlich gebogene Profil im Sinne einer Aufwickelvorrichtung aufnimmt.It is therefore a spatial winding roll bending process (abbreviated RWRB process) with which it is preferably possible to wind self-contained coils. This winding takes place in that the winding form is arranged in a rotatably driven manner below the bending head and the spatially curved one leaving the bending form Profile in the sense of a winding device.

Statt des drehenden Antriebes der Wickelform ist auch ein linearer Antrieb der Wickelform denkbar, d.h. das räumlich gekrümmte Profil verläßt dann in Richtung seiner Längsachse den Biegekopf und wird aus einem gleichfalls in Richtung der Längsachse bewegbaren Wickelform aufgenommen.Instead of the rotating drive of the winding form, a linear drive of the winding form is also conceivable, i.e. the spatially curved profile then leaves the bending head in the direction of its longitudinal axis and is taken up from a winding form which is likewise movable in the direction of the longitudinal axis.

Die Wickelform ist hierbei (in beiden oben beschriebenen Ausführungsformen) direkt unterhalb und in geringem Abstand vom Auslaufende des Biegekopfes angeordnet, so daß eine weitere, nicht erwünschte Formänderungsarbeit beim Übergang vom Biegekopf auf die Wickelform vermieden wird.The winding form is in this case (in both of the above-described embodiments) arranged directly below and at a short distance from the outlet end of the bending head, so that a further, undesirable deformation work during the transition from the bending head to the winding form is avoided.

Wird das Verfahren zur Bewicklung einer Stellaratorspule verwendet, ist das zu biegende Profil ein Spulenleiter und die Wickelform dient also lediglich der Aufnahme und Lagensicherung der fertig gebogenen Spulenleiter und in der Wickelform selbst wird keine Formänderungsarbeit mehr geleistet.If the method for winding a stellarator coil is used, the profile to be bent is a coil conductor and the winding form is therefore only used to hold and secure the finished bent coil conductor and no further deformation work is carried out in the winding form itself.

Zur Erzielung eines gedrängten, eng zusammenliegenden Wickelaufbaues ist es jedoch erforderlich, daß die fertig gebogenen Spulenleiter unter geringer Spannung in Längsrichtung dicht aneinander liegend auf der Wickelform gewickelt werden.In order to achieve a compact, closely-lying winding structure, however, it is necessary that the fully bent coil conductors are wound tightly against one another in the longitudinal direction on the winding form under low tension.

Hierzu ist nach dem Gegenstand des Anspruches 2 vorgesehen, daß in positiven Formungsbereichen der Stellaratorspule der Drehantrieb des Werkzeugtisches geringfügig schneller dreht als es der Abzugsgeschwindigkeit der Rollstation des Biegekopfes entspricht, so daß eine geringfügige Spannung in Längsrichtung auf das fertig gebogene Profil aufgebracht wird, die damit "relativ stramm", unter einer leichten Vorspannung Lage auf Lage, auf die Wickelform aufgewickelt werden. Die Vorspannung kann variabel von Null beginnend bis auf eine maximale Vorspannung über den Drehantrieb eingestellt werden.For this purpose it is provided according to the subject matter of claim 2 that in positive forming areas of the stellarator coil the rotary drive of the tool table rotates slightly faster than it corresponds to the withdrawal speed of the rolling station of the bending head, so that a slight tension in the longitudinal direction is applied to the finished bent profile, so that "relatively tight", with a slight pre-tension layer by layer, wound on the winding form will. The preload can be set variably from zero to a maximum preload via the rotary drive.

Soweit jedoch die Stellaratorspule auch "negative Formungsbereiche" aufweist, ist erfindungsgemäß vorgesehen, daß die Differenzgeschwindigkeit und der sich damit ergebende Vorlauf zwischen dem Drehantrieb des Werkzeugtisches und der Abzugsgeschwindigkeit der Rollstationen des Biegekopfes zu Null gemacht wird und dadurch ein "strammes Aufwickeln" in diesen Bereichen entfällt. In diesen Bereichen wird vielmehr das fertig geformte Profil durch Schieber und andere Lagensicherungsmittel festgehalten, die erst dann entfernt werden, wenn dieser kritische negative Formungsbereich durch die darüberliegende Lage gesichert ist.However, if the stellarator coil also has "negative shaping areas", the invention provides that the differential speed and the resultant advance between the rotary drive of the tool table and the take-off speed of the roll station of the bending head are made zero and thereby a "tight winding" in these areas not applicable. Rather, the finished molded profile is held in these areas by slides and other position securing means, which are only removed when this critical negative shaping area is secured by the overlying layer.

Die darüberliegende Lage wird dann wiederum durch die vorher beschriebenen Lagensicherungsmittel gehalten.The layer above is then held in turn by the position securing means described above.

Eine Vorrichtung zur Ausübung des Verfahrens verwendet also ein die Formänderungsarbeit ausführendes Biegewerkzeug, das als starr am freien Ende eines Konsolarmes angeordneter Biegekopf ausgebildet ist, und wobei in geringem Abstand zum Biegekopf eine Wickelform zur Aufnhame des fertig gebogenen Profils derart dreidimensional verstellbar und drehend antreibbar auf einem Werkzeugtisch angeordnet ist, daß das fertig gebogene Profil ohne weitere Formänderungsarbeit auf der Wickelform aufgenommen werden kann.A device for carrying out the method thus uses a bending tool that carries out the deformation work, which is designed as a bending head arranged rigidly on the free end of a bracket arm, and with a winding shape at a short distance from the bending head for receiving the finished bent profile in such a way that it can be adjusted three-dimensionally and driven in a rotating manner Tool table is arranged that the finished bent profile can be recorded on the winding form without further deformation work.

Eine Biegemaschine zur dreidimensionalen Nachführung der Wickelform weist im wesentlichen folgende Maschinenteile auf:

  • ein Maschinenrahmen,
  • ein darüberliegender Schlitten, der auf dem Maschinenrahmen in X-Richtung verfahrbar ist, wobei der Schlitten Träger des Y-Schienensystems ist,
  • ein darüber sich befindender Portalschlitten, der in Y-Richtung verfahrbar ist,
  • der Portalschlitten hat jeweils beidseitige Säulenrahmen, die schwere Lagerschilder tragen zur Aufnahme einer Schwinge, die Lagerschilder sind über seitliche Schlitten vertikal verfahrbar,
  • die Schwinge nimmt ein kleineres Portal auf, welches seitlich über Schlitten vertikal verfahrbar ist,
  • auf diesem Portal ruht ein Basisdrehtisch,
  • der Basisdrehtisch hält über einem Kastenrahmen in einer zweiten Ebene einen Werkzeugtisch, auf welchem die Wickelform gelagert ist, über welche das Profil formgewickelt wird,
  • der Biegekopf (mit räumlicher Biegefähigkeit) ist zusammen mit einem KOnsolarm verschiebbar angeordnet,
  • die Biegestation ist über zehn Achsen gesteuert und kann jeden beliebigen Biegepunkt einer Wickelform anfahren.
A bending machine for three-dimensional tracking of the winding form essentially has the following machine parts:
  • a machine frame,
  • an overlying sled on the machine frame can be moved in the X direction, the slide being the carrier of the Y rail system,
  • a portal slide located above it, which can be moved in the Y direction,
  • the portal slide has column frames on both sides, the heavy bearing plates support a rocker arm, the bearing plates can be moved vertically using the side slide,
  • the swing arm accommodates a smaller portal, which can be moved vertically laterally via a slide,
  • a basic rotary table rests on this portal,
  • the base turntable holds a tool table on a box frame on a second level, on which the winding form is mounted, over which the profile is wound,
  • the bending head (with spatial flexibility) is slidably arranged together with a KOnsolarm,
  • the bending station is controlled via ten axes and can approach any bending point of a winding form.

Zum Einführen des vom Coil abzuwickelnden Spulenleiters gehört eine Profilrichtanlage, welche CNC-gesteuert ist. Sie besteht aus verschiedenen Rollensätzen in Tandemausführung, welche alle motorisch angetrieben sind und in X-, Y- und Z-Richtung sowie drehend so ausgerichtet sind, um ein sauberes Richten zu ermöglichen.
Diese Profilrichtanlage richtet das Leiterprofil des Hohlleiters, wenn es von einem Coil abgewickelt wird.A profile straightening system, which is CNC-controlled, belongs to the introduction of the coil conductor to be unwound from the coil. It consists of various roller sets in tandem design, all of which are motor-driven and are oriented in the X, Y and Z directions and rotating so as to enable clean straightening.
This profile straightener straightens the conductor profile of the waveguide when it is unwound from a coil.

Die Coilstation, auf welcher der Hohlleiter abgewickelt ist, besteht aus einem Grund-Fundamentschienenrahmen in Y-Richtung zur Aufnahme eines Fahrchassis. Auf dem Fahrchassis ist der Lagerrahmen angeordnet zur Aufnahme des Coils. Der Lagerrahmen ist über zwei Schienentürme über in Z-Richtung verfahrbar, sowie in Y-Richtung. Damit kann das abzuwickelnde Profil immer exakt auf der gleichen Abrollposition gehalten werden zur Einführung in die Profilrichtanlage.The coil station, on which the waveguide is unwound, consists of a base foundation rail frame in the Y direction to accommodate a chassis. The bearing frame for receiving the coil is arranged on the chassis. The storage frame can be moved via two rail towers in the Z direction and in the Y direction. In order to the profile to be unwound can always be held in exactly the same rolling position for introduction into the profile straightening system.

Die Coilstation hat also die Aufgabe stets dafür zu sorgen, daß das von diesem Coil abzuwickelnde Hohlprofil genau immer in der gleichen Lage in die RWR-Biegestation eingeführt wird. Die soll verhindern, daß unzulässige Biegungen und Verformungen auf den Hohlleiter bereits schon vor Einlaufen in die Biegemaschine erzeugt werden. Ferner ist diese relativ aufwendig gebaute Coilstation Voraussetzung dafür, daß die Leiter immer auf ein Zehntel Millimeter genau in die Biegestation eingeführt werden, nur dadurch kann die geforderte Genauigkeit beim Biegevorgang selbst erzeugt werden.The coil station therefore always has the task of ensuring that the hollow profile to be unwound from this coil is always inserted into the RWR bending station in exactly the same position. This is to prevent impermissible bends and deformations from being generated on the waveguide before they enter the bending machine. Furthermore, this relatively complex coil station is a prerequisite for the conductors always being inserted into the bending station with a precision of a tenth of a millimeter; only in this way can the required accuracy be generated during the bending process itself.

Teil der Gesamtanlage zum Biegen derartiger Hohlleiter ist noch eine Coil-Transportanlage, die aus einer Schienenanlage besteht, die von der RWR-Biegestation zur Coilstation führt. Nachdem das erste Coil abgewickelt wurde wird das Coilgestell aus dem Lager ausgeklinkt und auf der Schienenanlage nach hinten herausgefahren zum Abtransport. Das aufgewickelte zweite Coil, das bisher im Lagerraum der RWR-Biegestation untergebracht war, wird abgerollt über die Schienenanlage in die Coilstation eingefahren, eingeklinkt und auf die Position gebracht. Mit einem mobilen Richtgerät wird die nun frei abgerollte Profilstrecke fluchtend ausgerichtet, in den Biegekopf und in die Richtmaschine eingefädelt und für den zweiten Wickelvorgang mit umgekehrtem Drehsinn vorbereitet. der Technik neu sind.Part of the overall system for bending such waveguides is a coil transport system, which consists of a rail system that leads from the RWR bending station to the coil station. After the first coil has been unwound, the coil frame is released from the warehouse and moved out to the rear on the rail system for removal. The coiled second coil, which was previously housed in the storage room of the RWR bending station, is unrolled, driven into the coil station via the rail system, latched and brought into position. With a mobile straightening device, the now freely rolled profile section is aligned, threaded into the bending head and into the straightening machine and prepared for the second winding process with the opposite direction of rotation. of technology are new.

Im folgenden wird die Erfindung anhand von lediglich einen Ausführungsweg darstellende Zeichnungen näher erläutert. Hierbei gehen aus den Zeichnungen und ihrer Beschreibung weitere erfindungswesentliche Merkmale und Vorteile der Erfindung hervor.The invention is explained in more detail below with the aid of drawings which illustrate only one embodiment. Here, from the drawings and their description, further features and advantages of the invention that are essential to the invention emerge.

Es zeigen:

Figur 1:
die Stellaratorspule in Draufsicht, nämlich in Richtung des Pfeiles A in Figur 3;
Figur 2:
die gleiche Stellaratorspule in Ansicht des Pfeiles B in Figur 1
Figur 3:
die Seitenansicht der Stellaratorspule;
Figur 4:
einen Schnitt gemäß der Linie C/D in Figur 1 durch die Stellaratorspule;
Figur 5:
das Innenprofil der Stellaratorspule gemäß Figur 4, wobei schematisiert der Wicklungssinn und die Anordnung der einzelnen Wicklungen der Innenspule 2 sowie der Außenspule 6 angegeben ist;
Figur 6:
eine RWB-Biegemaschine nach der Erfindung in Seitenansicht;
Figur 7:
die Draufsicht auf Figur 6
Figur 8:
die Stirnansicht der Maschine.
Show it:
Figure 1:
the stellarator coil in plan view, namely in the direction of arrow A in Figure 3;
Figure 2:
the same stellarator coil in the view of arrow B in Figure 1
Figure 3:
the side view of the stellarator coil;
Figure 4:
a section along the line C / D in Figure 1 through the stellarator coil;
Figure 5:
the inner profile of the stellarator coil according to Figure 4, wherein the winding sense and the arrangement of the individual windings of the inner coil 2 and the outer coil 6 is indicated schematically;
Figure 6:
a RWB bending machine according to the invention in side view;
Figure 7:
the top view of Figure 6
Figure 8:
the front view of the machine.

Wichtig ist der Hinweis, daß zwar eine Wickelform verwendet wird, welche hinsichtlich der Flächen 7,8 die Formgebung einer Stellaratorspule 1 aufweist, wobei jedoch diese Wickelform 48 lediglich die Innenwand 7 sowie die Bodenwand 8 aufweist, so daß die zu biegenden Spulenleiter 2-6 in diese offene, nur durch die beiden Wände 7,8 begrenzte und definierte Wickelform 48 eingelegt werden.It is important to note that although a winding shape is used which has the shape of a stellarator coil 1 with respect to the surfaces 7, 8, this winding shape 48 only has the inner wall 7 and the bottom wall 8, so that the coil conductors 2-6 to be bent are inserted into this open winding form 48, which is limited and defined only by the two walls 7, 8.

Wichtig ist der Hinweis, daß diese Wickelform 48 nun nicht auf Zug beansprucht wird, d. h. die zu biegenden Spulenleiter 2,6 werden nicht unter Streckung und Biegung an den Wänden dieser Wickelform 48 abgewälzt oder entlanggeführt, sondern die Wickelform 48 dient nur als räumliches Auflager oder als Lagerbock für die räumlich zu biegenden Einzelspulen.It is important to note that this winding form 48 is now not subjected to tension, i. H. the coil conductors 2.6 to be bent are not rolled or stretched along the walls of this winding form 48 with stretching and bending, but rather the winding form 48 serves only as a spatial support or as a bearing block for the individual coils to be bent spatially.

Das bedeutet, daß die Einzelspulen frei sphärisch im Raum gebogen werden, und zwar von einer Biegemaschine wie sie nachfolgend beschrieben wird und die so gebogenen Einzelspulen werden dann ohne Zug, Druck oder Streckbeanspruchung auf die Wickelform 48 aufgelegt oder eingelegt.This means that the individual coils are freely spherically bent in space , specifically by a bending machine as described below, and the individual coils bent in this way are then placed or inserted onto the winding form 48 without tension, pressure or stretching stress.

Die Wickelform 48 dient also nur dazu, daß die räumlich bereits fertig von der Biegemaschine gebogenen Spulen 2-6 nur aufgelegt werden und Stoß an Stoß aneinander gefügt werden, so daß nach Beendigung des Wickelvorganges das genaue Außenprofil einer Stellaratorspule 1 durch die aufeinander gewickelten Einzelspulen 2-6 erreicht wird.The winding form 48 therefore only serves to ensure that the coils 2-6, which are already spatially finished and finished by the bending machine, are only placed on them and are butted together so that, after the winding process has ended, the exact outer profile of a stellarator coil 1 is produced by the individual coils 2 wound on one another -6 is reached.

Das Grundprinzip der vorliegenden Biegemaschine beruht darauf, daß zunächst die Wickelform auf einem in dreidimensionaler Ebene bewegbaren Basisdrehtisch aufliegt, der jede räumliche Bewegung im Raum ausführen kann, einschließlich einer Drehbewegung. Diese dreidimensionale Bewegung der Wickelform hat nach der vorliegenden Erfindung den Zweck, die Wickelform dem zu biegenden Hohlleiter bzw. Spule nachzuführen.The basic principle of the present bending machine is based on the fact that the winding form initially rests on a base rotary table which can be moved in a three-dimensional plane and can carry out any spatial movement in space, including a rotary movement. According to the present invention, this three-dimensional movement of the winding form has the purpose of tracking the winding form to the waveguide or coil to be bent.

Das heißt also, der Biegekopf selbst ist stationär angeordnet und er steht frei im Raum und ist lediglich in X-Richtung verschiebbar.This means that the bending head itself is stationary and it is free in space and can only be moved in the X direction.

Der Biegekopf steht damit immer exakt über der zu biegenden Linie, d.h. also die Wickelform, die ja gemäß der vorstehenden Beschreibung nur als Lagerbock dient, wird immer unter den Biegekopf räumlich so untergefahren, daß der Biegekopf genau in der Biegelinie liegt.The bending head is always exactly above the line to be bent, ie the winding shape, which according to the above description only serves as a bearing block, is always spatially below the bending head under that the bending head lies exactly in the bending line.

Der Biegekopf kann also lediglich in X-Richtung nach der Erfindung verschoben werden, nicht aber in Y-Richtung und auch nicht notwendigerweise in Z-Richtung, obwohl die Verschiebung in Z-Richtung aus anderen Gründen bevorzugt wird und später beschrieben wird. Die Verschiebung in X-Richtung soll nur in einer bevorzugten Ausführungsform angegeben werden, denn sie ist nicht lösungsnotwendig. Sie wird aber bevorzugt, weil es je nach der geforderten Biegekontur bevorzugt ist, mit dem Schlitten in X-Richtung nach vorne oder hinten zu verfahren, um eine noch genauere Nachführung an die Biegelinie zu erreichen.The bending head can therefore only be moved in the X direction according to the invention, but not in the Y direction and also not necessarily in the Z direction, although the displacement in the Z direction is preferred for other reasons and will be described later. The displacement in the X direction should only be given in a preferred embodiment, because it is not necessary for a solution. However, it is preferred because, depending on the required bending contour, it is preferred to move the slide forward or backward in the X direction in order to achieve an even more precise tracking to the bending line.

Wichtig ist also, daß die Wickelform auf einem dreidimensional bewegbaren Tisch ruht, der auch drehbar ist und daß die Wickelform dadurch immer so räumlich unter dem Biegekopf eingestellt wird, daß genau immer die aktuell geforderte Biegelinie unter dem Biegekopf nachgeführt wird.It is therefore important that the winding form rests on a three-dimensionally movable table, which can also be rotated, and that the winding form is always set so spatially under the bending head that the currently required bending line is always tracked under the bending head.

Der Biegekopf selbst ist starr und lediglich aus praktischen Gründen in X-Richtung und eventuell auch in Z-Richtung verfahrbar.The bending head itself is rigid and can only be moved in the X direction and possibly also in the Z direction for practical reasons.

Die starre Anordnung des Biegekopfes hat den Sinn, daß ja die zu biegenden Spulen ohne Verbiegung oder sonstige Beschädigung immer genau fluchtend von einem Coil, und zwar genauer gesagt, von der Coil-Richtanlage abgezogen werden müssen. Die Coil-Richtanlage hält das Coil immer genau so (verschiebbar in Y- und Z-Richtung) daß das von dem Coil abzuwickelnde Spulenmaterial immer genau fluchtend, das heißt, immer in der gleichen Ebene kommend, in den Biegekopf eingeführt wird. Das heißt also, die Coil-Richtstation ist bewegbar und der Biegekopf selbst ist stationär.The rigid arrangement of the bending head has the sense that the coils to be bent must always be exactly aligned with a coil, more precisely, removed from the coil straightening system without bending or other damage. The coil straightening system always holds the coil exactly (displaceable in the Y and Z directions) so that the coil material to be unwound from the coil is always exactly aligned, that is, always coming in the same plane, into the bending head. This means that the coil straightening station can be moved and the bending head itself is stationary.

Der Biegekopf besteht aus einer Reihe in Biegerichtung oder in Längsrichtung des Rohres angeordneten Rollen, wobei das Rohr vollumfänglich an seinem Profil von jeweils einer Rolle eingefaßt wird.The bending head consists of a row of rollers arranged in the bending direction or in the longitudinal direction of the tube, the tube being completely encircled by a roller on its profile.

Das heißt also, an den Seitenflächen in horizontaler Richtung sind innen und außen des Rohres zwei Rollen angeordnet und das Rohr wird von oben und unten ebenfalls von jeweils einer Rolle umfaßt. Dadurch wird das Rohr an einer Stelle von jeweils vier Rollen umfaßt. Der Biegekopf besteht nun aus einer Reihe derartiger Vier-Rollenanordnungen, die in Längsrichtung des Rohres hintereinander liegend den Biegekopf bilden. Durch gegeneinander Verschieben der einzelnen Rollen in X- Y- oder Z-Richtung kann damit jedes beliebige sphärische Profil der Spule oder des Hohlleiters gebogen werden.This means that two rollers are arranged on the inside and outside of the tube on the side surfaces in the horizontal direction, and the tube is also encompassed by one roller each from above and below. As a result, the tube is encompassed by four rollers at a point. The bending head now consists of a series of such four-roller arrangements which form the bending head lying one behind the other in the longitudinal direction of the tube. By shifting the individual rollers against each other in the X, Y or Z direction, any spherical profile of the coil or the waveguide can be bent.

Besteht nun ein solcher Biegekopf aus beispielsweise vier hintereinander liegend angeordneten und im gegenseitigen Abstand voneinander angeordneten Vier-Rollensystemen dann wären z. B. die ersten drei Rollensysteme starr sowohl in X-Richtung als auch in Y- und Z-Richtung, während die letzte, in Längsrichtung des Rohres liegende Vier-Rollenanordnung in X-, Y- und Z-Richtung verschiebbar ist.
Zusätzlich kann diese Vier-Rollenanordnung bezüglich der anderen drei Vier-Rollenanordnungen verdreht werden, so daß damit eine Torsion der zu biegenden Spule erreicht wird.If such a bending head now consists of, for example, four four-roller systems arranged one behind the other and spaced from one another, then z. B. the first three roller systems rigid both in the X direction and in the Y and Z direction, while the last, lying in the longitudinal direction of the tube four-roller arrangement is displaceable in the X, Y and Z directions.
In addition, this four-roller arrangement can be rotated with respect to the other three four-roller arrangements, so that torsion of the coil to be bent is achieved.

Mit dem beschriebenen Biegekopf kann also eine freie, räumliche Biegung der Spule erreicht werden.With the described bending head, a free, spatial bending of the coil can be achieved.

Zur Funktion der letzten Biegestation, die aus den beschriebenen vier Rollen besteht, die in X-, Y- und Z-Richtung verschiebbar sind, wird noch angefügt, daß einander gegenüberliegende Rollen z. B. in X- oder in Z-Richtung auf einem Radius verschiebbar sind, so daß immer diese Rollen formschlüssig an den einander gegenüberliegenden und zueinander parallelen Innen- und Außenseiten bzw. Ober- und Unterseite des zu biegenden Rohres anliegen.To function of the last bending station, which consists of the four rollers described, which can be moved in the X, Y and Z directions, it is added that opposing rollers z. B. in the X or Z direction are displaceable on a radius, so that these roles always fit positively on the opposite and mutually parallel inner and outer sides or top and bottom of the pipe to be bent.

Würden einander gegenüberliegende Rollen der Vier-Rollen-Anordnung nicht auf einem Kurvenradius verschiebbar sein, dann käme es zu Friktionen an der Spulenaußenseite und die Spule würde dadurch beschädigt werden.If opposing rollers of the four-roller arrangement could not be displaced on a curve radius, friction would occur on the outside of the spool and the spool would be damaged as a result.

Im folgenden wird nun die Maschine der vorliegenden Erfindung anhand eines Ausführungsbeispieles näher beschrieben.The machine of the present invention will now be described in more detail with reference to an embodiment.

Die erfindungsgemäße Anlage gemäß den Figuren 6 - 8 besteht im wesentlichen aus vier Komponenten, wobei die sogenannte RWR-Biegemaschine 10 die wichtigste Komponente darstellt.The system according to FIGS. 6-8 essentially consists of four components, the so-called RWR bending machine 10 being the most important component.

Der Biegemaschine 10 ist eine Profilrichtanlage 11 vorgeschaltet, der wiederum eine Vorrichtstation 12 und dieser wiederum eine Coil-Station 13 vorgeschaltet ist.The bending machine 10 is preceded by a profile straightening system 11, which in turn is preceded by a straightening station 12 and this in turn by a coil station 13.

Die zu biegenden Spulenleiter 17 sitzen hierbei auf einem Coil 16, wobei das Coil 16 Teil der Coilstation 13 ist.The coil conductors 17 to be bent are seated on a coil 16, the coil 16 being part of the coil station 13.

Wichtig ist, daß das Coil 16 in der eingezeichneten Pfeilrichtung 63 in Z-Richtung und ebenfalls in Y-Richtung verfahrbar ist, um dafür zu sorgen, daß das gerade aktuell abzuwickelnde Ende des Spulenleiters 17 genau fluchtend gegenüberliegend zu einer Rolle 18 liegt, die wiederum fluchtend der Rolle 19 der Vorrichtstation 12 gegenüberliegt.It is important that the coil 16 can be moved in the arrow direction 63 shown in the Z direction and also in the Y direction, in order to ensure that the end of the coil conductor 17 that is currently being developed is exactly opposite to a roll 18, which in turn aligned with the roller 19 of the device station 12.

Sinn dieser Maßnahme ist, dafür zu sorgen, daß die zu biegenden Spulenleiter 17 ohne Beschädigungen, Reibungen und Knickungen stets fluchtend in einer Linie 64 von dem Coil 16 abgezogen werden.The purpose of this measure is to ensure that the coil conductors 17 to be bent are always withdrawn in line 64 from the coil 16 without damage, friction and kinks.

Die Vorrichtstation 12 führt ein grobes Vorrichten des zu biegenden Spulenleiters 17 aus.The setting station 12 roughly sets up the coil conductor 17 to be bent.

Damit soll ein fluchtendes Einführen in die Profilrichteinlage 11 ermöglicht werden.This is intended to enable flush insertion into the profile straightening insert 11.

Die Profilrichteinlage 11 besteht aus mehreren paarweise angetriebenen Doppel-Rollen 20 die im Abstand hintereinander liegend angeordnet sind, wobei in der Zeichnung Fig. 2 noch dargestellt ist, daß auch in Y-Richtung weitere Doppel-Rollen 20 vorgesehen sind, so daß der zu biegende Spulenleiter formschlüssig von allen Seiten her von den Doppel-Rollen 20 umfaßt wird.The profile straightening insert 11 consists of a plurality of double rollers 20 which are driven in pairs and which are arranged one behind the other at a distance, the drawing in FIG. 2 also showing that also in Further double rollers 20 are provided in the Y direction, so that the coil conductor to be bent is positively embraced by the double rollers 20 from all sides.

In der Profilrichtanlage 11 wird der zu biegende Spulenleiter 17 genau axial fluchtend ausgerichtet, so daß er in der fluchtenden Linie 64 in den Biegekopf 52 eingeführt werden kann. Weil der Spulenleiter 17 durch den Aufwickelvorgang auf das Coil 16 verformt wird sorgen die Vorrichtstation 12 und die Profilrichtanlage 11 für eine Rückverformung, so daß der zu biegende Spulenleiter 17 als unverformte Gerade in den Biegekopf 52 eingeführt wird.In the profile straightening unit 11, the coil conductor 17 to be bent is aligned exactly axially so that it can be inserted into the bending head 52 in the aligned line 64. Because the coil conductor 17 is deformed by the winding process on the coil 16, the jig station 12 and the profile straightening system 11 provide for a reshaping, so that the coil conductor 17 to be bent is inserted into the bending head 52 as an undeformed straight line.

Aufgabe dieser RWR-Biegemaschine ist, die auf einem Werkzeugtisch 47 angeordnete Wickelform 48 räumlich sphärisch so zu bewegen, daß der von dem Biegekopf 52 fertig dreidimensional gebogene Spulenleiter 17 ohne weitere Rückverformung oder Verbiegung auf die Wickelform 48 aufgelegt wird.The task of this RWR bending machine is to move the winding form 48 arranged on a tool table 47 spatially in such a way that the coil conductor 17, which has been bent three-dimensionally by the bending head 52, is placed on the winding form 48 without further reshaping or bending.

Die Wickelform 48 dient also lediglich zur Halterung und Lagensicherung der fertig von dem Biegekopf 52 gebogenen Spulenleitern 17, wobei durch besondere Maßnahmen (nämlich durch eine Differenz in der Drehbewegung, d. h. also ein Vorlauf der Drehbewegung für den Werkzeugtisch 47 bezüglich der Transportbewegung des Biegekopfes 52 eine relative Spannung zwischen dem vom Biegekopf 52 fertig gebogenen Spulenleiter 17 und der Wickelform 48 erreicht wird.The winding form 48 is therefore only used to hold and secure the position of the coil conductors 17 which have been bent by the bending head 52, whereby by special measures (namely by a difference in the rotary movement, that is to say a forward movement of the rotary movement for the tool table 47 with respect to the transport movement of the bending head 52) relative tension between the coil conductor 17, which has been bent by the bending head 52, and the winding form 48 is reached.

Diese Differenzbewegung (Vorlauf) wird bevorzugt im positiven Formungsbereich der Wickelform 48 angewandt, während in den negativen Formungsbereichen, wie sie mit den Bereichen 65 in Figur 1 und 2 dargestellt sind, dieser Vorlauf unterbrochen wird. In diesem Bereich 65 wird das noch unter Spannung stehende Spulenleiterprofil 17 über einen Schieber gesichert, dieser Schieber kann sowohl senkrecht zur Fläche 7 der Wickelform 48 als auch senkrecht zur Bodenfläche 8 der Wickelform eingefahren werden. Damit wird das Profil entspannt. Dann wird das Profil in die Wickelform ohne Vorspannung eingelegt, wiederum durch quer und senkrecht hierzu stehende zweite Schieber gesichert. Sobald man jetzt aus dem negativen Bereich 65 herausfährt, wird der Vorlauf wieder erzeugt und eine weitere Einlegung der dadurch vorgespannten und fertig gebogenen Spulenleiter erfolgt in die Wickelform, wobei die Schieber in diesem negativen Formungsbereich fest angelegt bleiben. Es wird also dafür gesorgt, daß der Spulenleiter auch in den negativen Formungsbereichen 65 der Wickelform 48 auf Maß gebogen bleibt und die Schieber werden dann von Lage zu Lage verstellt, so daß stets in den negativen Formungsbereichen die Schieber zur Sicherung der gebogenen Spulenleiter verwendet werden.This differential movement (lead) is preferably used in the positive forming area of the winding form 48, while in the negative forming areas, as shown with the areas 65 in FIGS. 1 and 2, this lead is interrupted. In this area 65, the coil conductor profile 17, which is still under tension, is secured by a slide, this slide can be retracted both perpendicular to the surface 7 of the winding form 48 and also perpendicular to the bottom surface 8 of the winding form. This will relax the profile. Then it will Profile inserted into the winding form without pretensioning, again secured by second sliders which are perpendicular and perpendicular to it. As soon as you now move out of the negative area 65, the lead is generated again and the coil conductors, which are thereby preloaded and bent, are inserted further into the winding form, the slides remaining firmly attached in this negative forming area. It is therefore ensured that the coil conductor remains bent to size even in the negative shaping regions 65 of the winding form 48 and the slides are then adjusted from position to position, so that the sliders are always used in the negative shaping regions to secure the bent coil conductor.

Im folgenden wird nun die genauere Funktion der Coil-Wechselanlage beschrieben.The more precise function of the coil changing system will now be described.

Die Biegemaschine 10 weist eine bodenseitige Schienenanlage 14 auf, die zur Auswechslung der Coils 16,50 dient. Wie bereits schon in der Einleitung angeführt, sind zwei Coils vorhanden, nämlich ein Coil 16, welches Teil der Coil-Station 13 ist und ein weiteres Coil 50, welches die noch nicht verformten und noch nicht von diesem Coil abgezogenen Spulenleiter 17 enthält.The bending machine 10 has a rail system 14 on the bottom, which serves to replace the coils 16, 50. As already mentioned in the introduction, there are two coils, namely a coil 16 which is part of the coil station 13 and a further coil 50 which contains the coil conductors 17 which have not yet been deformed and have not yet been removed from this coil.

Die sphärische Wicklung der Spulenleiter 17 durch den Biegekopf 52 wird ausgehend von der Mitte des gesamten Spulenleiters 17 vorgenommen und von dort aus nach links oder rechts laufend begonnen.The spherical winding of the coil conductor 17 by the bending head 52 is carried out starting from the center of the entire coil conductor 17 and starting from there to the left or right.

Das heißt, die eine Hälfte des gesamten zu biegenden Spulenleiters 17 liegt auf dem einen Coil 16 vor, während die anderen, nicht der Verformung unterliegende, zweite Hälfte des Spulenleiters 17 auf dem Coil 50 vorliegt.That is, one half of the entire coil conductor 17 to be bent is present on one coil 16, while the other, not subject to the deformation, second half of the coil conductor 17 is present on the coil 50.

Damit man dann nach vollendetem Abziehen des Spulenleiters 17 von dem Coil 16 zu dem Coil 50 Zugriff hat ist eine Coil-Wechselstation vorgesehen.A coil change station is provided so that after the coil conductor 17 has been removed from the coil 16 to the coil 50, access is provided.

Das Coil 50 ist hierbei auf einem Lagerbock 51 auf dem Basisdrehtisch 54 der Biegemaschine 10 fest gelagert und wird von nicht näher dargestellten Wellen stirnseitig gehalten.The coil 50 is in this case firmly mounted on a bearing block 51 on the base turntable 54 of the bending machine 10 and is held on the end face by shafts (not shown in more detail).

Sobald das Coil 16 abgewickelt ist, wird das Coil 50 über einen nicht näher dargestellten Transportwagen auf die Schienenanlage 14 verfahren und in Pfeilrichtung 15 auf die Coil-Station 13 gebracht, wobei dann das Coil 50 auf der Coil-Station 13 eingespannt wird und der von dem Coil 50 abzuwickelnde Spulenleiter dann über die Vorrichtstation 12 und Profilrichtanlage 11 in die Biegemaschine 10 eingeführt wird.As soon as the coil 16 has been unwound, the coil 50 is moved onto the rail system 14 via a transport carriage (not shown in any more detail) and is brought to the coil station 13 in the direction of the arrow 15, the coil 50 then being clamped onto the coil station 13 and by the coil conductor to be unwound from the coil 50 is then introduced into the bending machine 10 via the device station 12 and profile straightening system 11.

Nachdem das Coil 50 mit seiner zweiten Spulenhälfte 49 mit der bereits fertig bewickelten Wickelform 48 verbunden ist, ist Voraussetzung, daß beim Wechsel des Coils 50 von seiner in Fig. 2 eingezeichneten Lage in die Lage der Coil-Station 13 die zweite Spulenhälfte 49 erst manuell gerichtet wird, damit eine fluchtende Einfädelung der zweiten Spulenhälfte in die Vorrichtstation erfolgen kann.After the coil 50 is connected with its second coil half 49 to the already wound winding form 48, it is a prerequisite that when changing the coil 50 from its position shown in FIG. 2 to the position of the coil station 13, the second coil half 49 is only manual is directed so that the second half of the bobbin can be threaded into the pre-aligning station in alignment.

Das Vorrichten der zweiten Spulenhälfte 49 erfolgt hierbei über eine mobile Richteinlage, die aus Vereinfachungsgründen in den Zeichnungen nicht eingetragen ist.The second spool half 49 is set up via a mobile straightening insert, which is not shown in the drawings for the sake of simplicity.

Der Aufbau der Biegemaschine 10 ist nun folgendermaßen:
Auf dem Boden ruht ein Maschinenrahmen 22, der an seiner Oberseite in X-Richtung ausgerichtete Schienen 23 trägt, die einen gegenseitigen, voneinander parallelen Abstand aufweisen.The structure of the bending machine 10 is now as follows:
A machine frame 22 rests on the floor and carries on its upper side rails 23 which are oriented in the X direction and which are at a mutual, mutually parallel distance.

Die Schienen tragen einen Schlitten 24, der in X-Richtung verfahrbar ist. Das Verfahren dieses Schlittens 24 erfolgt hierbei über Spindeln 25, die in nicht näher dargestellte Spindelmuttern am Schlitten 24 eingreifen und drehend jeweils von einem Motor 26 angetrieben werden, wobei die Motoren 26 an dem Maschinenrahmen 22 angeordnet sind.The rails carry a carriage 24 which can be moved in the X direction. The movement of this slide 24 takes place here via spindles 25, which engage in spindle nuts (not shown in more detail) on the slide 24 and are each driven in rotation by a motor 26, the motors 26 being arranged on the machine frame 22.

Auf diesem Schlitten 24 ist ein Portalschlitten 27 in Pfeilrichtung Y verfahrbar gelagert. Hierbei trägt der Portalschlitten 27 an seiner Unterseite wiederum Spindelmuttern, die jeweils von einer Spindel 29 durchgriffen sind und jede Spindel 29 durch jeweils einen Motor 28 angetrieben ist.On this slide 24, a portal slide 27 is mounted so as to be movable in the direction of arrow Y. Here, the portal slide 27 in turn carries on its underside spindle nuts, each of which is penetrated by a spindle 29 and each spindle 29 is driven by a motor 28.

Damit wird der Portalschlitten 27 also in Y-Richtung gemäß Fig. 8 verfahren.The portal slide 27 is thus moved in the Y direction according to FIG. 8.

Etwa im oberen Drittel des Portalschlittens 27 ist ein Lagerschild 31 in Z-Richtung verfahrbar an den Seitenportalen des Portalschlittens 27 befestigt.Approximately in the upper third of the portal slide 27, a bearing plate 31 is attached to the side portals of the portal slide 27 and can be moved in the Z direction.

Nachdem der Schlitten 24, der Portalschlitten 27 und die sonstigen dazugehörenden Teile genau spiegelsymmetrisch ausgebildet sind wird im folgenden nur die eine Seite des Portalschlittens 27 näher beschrieben, nachdem die andere Seite genau identisch ausgebildet ist.After the slide 24, the portal slide 27 and the other associated parts are formed in an exactly mirror-symmetrical manner, only one side of the portal slide 27 is described in more detail below, after the other side is of exactly identical design.

An der Seite des Portalschlittens 27 ist also das Lagerschild 31 in Pfeilrichtung Z verfahrbar gelagert, wobei hierzu ein Antriebsmotor 33 eine Spindel 32 drehend antreibt, welche die Spindelmuttern des Lagerschildes 31 durchgreift.On the side of the portal slide 27, the bearing plate 31 is mounted so that it can be moved in the direction of the arrow Z, a drive motor 33 rotatingly driving a spindle 32 which passes through the spindle nuts of the bearing plate 31.

Jedes Lagerschild 31 trägt eine Welle 34, wobei die beiden einander gegenüberliegenden Wellen 34 fluchtend in einer Achse 66 liegen und - was wichtig für die Erfindung ist - die Achse 66 in Nullposition der Biegeeinrichtung genau mit dem zu biegenden Leiter 17 fluchtet.Each bearing plate 31 carries a shaft 34, the two mutually opposite shafts 34 being aligned in an axis 66 and - which is important for the invention - the axis 66 is exactly aligned with the conductor 17 to be bent in the zero position of the bending device.

Dies definiert eine neutrale Biegeposition. Ausgehend von dieser neutralen Biegeposition, welche durch die verschiebbare Achse 66 definiert wird, wird dann die auf dem Werkzeugtisch 47 angeordnete Wickelform 48 entsprechend verfahren, so daß sich eine geänderte Gegenüberlage bezüglich dem stets in der gleichen Lage verharrenden Biegekopf 52 ergibt.This defines a neutral bending position. Starting from this neutral bending position, which is defined by the displaceable axis 66, the winding form 48 arranged on the tool table 47 is then moved accordingly, so that there is a change in the opposite position with respect to the bending head 52, which is always in the same position.

An der Welle 34 ist drehbar um die Achse 66 eine Schwinge 35 gelagert, wobei die Schwinge 35 genauso wie der Portalschlitten 27 in der Seitenansicht der Fig. 8 ein etwa U-förmiges Profil aufweist, wobei die Seitenschenkel dieses U-förmigen Profils an der Unterseite mit einem Portal 36 verbunden sind, welches Portal in der Zeichenebene der Fig. 8 schwingend ist und über den Antrieb, bestehend aus dem Motor 37 und der Spindel 38, in Z-Richtung noch zusätzlich verfahrbar ist.A rocker 35 is rotatably mounted on the shaft 34 about the axis 66, the rocker 35, like the portal slide 27 in the side view of FIG. 8, having an approximately U-shaped profile, the side legs of this U-shaped profile on the underside are connected to a portal 36, which portal swings in the drawing plane of FIG. 8 and can also be moved in the Z direction via the drive, consisting of the motor 37 and the spindle 38.

Damit können während des Wicklungsvorganges die einzelnen Wicklungslagen 4,5 der zu wickelnden Spule 2,6 genau nachgeführt werden.The individual winding layers 4, 5 of the coil 2, 6 to be wound can thus be tracked exactly during the winding process.

Zusätzlich zu dieser Schwingungsbewegung werden die sphärischen Konturen der Wickelform, welche die Form der Stellaratorspule 1 gemäß den Figuren 1,2 und 3 hat, nachgeführt.In addition to this oscillatory movement, the spherical contours of the winding shape, which has the shape of the stellarator coil 1 according to FIGS. 1, 2 and 3, are tracked.

Auf dem schwingenden Portal 36 ist ein fester Unterbau 39, z.B. aus einer Platte gebildet, der an der Oberseite ein kranzförmiges Kugellager 40 trägt.A fixed substructure 39, e.g. formed from a plate which carries a ring-shaped ball bearing 40 at the top.

Auf dem Unterbau 39 ist eine Welle 41 drehbar gelagert, die von einem in Fig. 6 dargestellten Motor 42 drehend angetrieben ist. Die Welle 41 ist drehfest mit einem Basisdrehtisch 44 verbunden. Damit ist dieser Basisdrehtisch 44 in der eingezeichneten Pfeilrichtung 45 drehbar.A shaft 41 is rotatably mounted on the substructure 39 and is rotatably driven by a motor 42 shown in FIG. 6. The shaft 41 is rotatably connected to a base turntable 44. This base rotary table 44 is thus rotatable in the direction of the arrow 45 shown.

Statt des hier beschriebenen Drehantriebs für den Basisdrehtisch 44 ist selbstverständlich auch ein Antrieb über einen Zahnkranz mit einem darin kämmenden Ritzel, welches von einem Motor angetrieben ist, möglich.Instead of the rotary drive described here for the base rotary table 44, it is of course also possible to drive it via a ring gear with a pinion meshing therein, which is driven by a motor.

Auf dem Basisdrehtisch 44 ist ein Kastenrahmen 46 fest befestigt, der an seiner Oberseite einen Werkzeugtisch 47 trägt.A box frame 46 is fixedly attached to the base rotary table 44 and carries a tool table 47 on its upper side.

Auf dem Werkzeugtisch 47 ist die Wickelform 48 angeordnet, die in Fig. 5 in Draufsicht und Fig. 6 in Seitenansicht dargestellt ist.The winding form 48 is arranged on the tool table 47 and is shown in plan view in FIG. 5 and in side view in FIG. 6.

Es sei noch angefügt, daß der Schwenkantrieb für die Schwinge 35 durch einen Motor 43 gebildet wird. Aus Vereinfachungsgründen ist auf der einen Seite in Fig. 8 nur dieser Motor 43 dargestellt, während er auf der anderen Seite der Fig. 3 ebenfalls symmetrisch angeordnet sein müßte.It should also be added that the pivot drive for the rocker 35 is formed by a motor 43. For the sake of simplicity, only this motor 43 is shown on the one side in FIG. 8, while it would also have to be arranged symmetrically on the other side of FIG. 3.

Wie in der Erläuterung zu Fig.1 und Fig. 2 gegeben, besteht die Wickelform 48 im wesentlichen aus der Innenfläche 7 und der Bodenfläche 8 der Stellaratorspule gemäß Fig. 1 und 2.
Im folgenden wird der Aufbau des Biegekopfes 52 beschrieben. Der Biegekopf 52 besteht aus einem kompletten Rollenbiegewerzeug, welches in der Lage ist, dreidimensionale räumliche Biegungen CNC-gesteuert vorzunehmen.
Er besteht im wesentlichen aus einem Maschinengehäuse 53 mit mehreren hintereinander liegend und im gleichmäßigen Abstand voneinander angeordneten Rollenstationen 54,55 mit den Rollen 56,57.
In einer bevorzugten Ausführungsform sind hierbei gemäß Fig. 7 drei starre Rollenstationen mit jeweils Rollen 55 hintereinander liegend angeordnet, welche alle drehend angetrieben sind und den Einlauf für den zu biegenden Spulenleiter 17 bilden.As given in the explanation of FIGS. 1 and 2, the winding form 48 essentially consists of the inner surface 7 and the bottom surface 8 of the stellarator coil according to FIGS. 1 and 2.
The structure of the bending head 52 is described below. The bending head 52 consists of a complete roll bending machine which is able to carry out three-dimensional spatial bending under CNC control.
It essentially consists of a machine housing 53 with a plurality of roller stations 54, 55 with the rollers 56, 57 which are arranged one behind the other and at a uniform distance from one another.
7, three rigid roller stations, each with rollers 55, are arranged one behind the other, all of which are driven in rotation and form the inlet for the coil conductor 17 to be bent.

Jede Rollenstation 54,55 besteht hierbei aus vier Rollen 56,57, wobei jeweils zwei Rollen paarweise einander gegenüberliegend angeordnet sind. Schematisiert ist eine derartige Ausführungsform in Fig. 8 dargestellt, wo nur als Beispiel eine Rollenstation dargestellt ist. Man sieht, daß die Rollen 56 paarweise einander gegenüberliegend zu senkrecht hierzu liegenden Rollen 57 angeordnet sind.Each roller station 54, 55 consists of four rollers 56, 57, two rollers being arranged opposite each other in pairs. Such an embodiment is shown schematically in FIG. 8, where a roller station is shown only as an example. It can be seen that the rollers 56 are arranged in pairs opposite one another to rollers 57 lying perpendicular thereto.

Die starren Rollenstationen 55 dienen zur fluchtenden Positionierung des Spulenleiters 17 und zu dessen Vortrieb der damit in Richtung seiner Längsachse in die bewegliche Rollenstation 54 eingeführt wird.The rigid roller stations 55 serve to align the coil conductor 17 in alignment and to propel it in the direction of it Longitudinal axis is inserted into the movable roller station 54.

Die bewegliche Rollenstation 54 weist wiederum paarweise einander gegenüberliegende Rollen 56 und senkrecht hierzu stehende Rollen 57 auf, jedoch mit dem Unterschied, daß hierbei jede einzelne Rolle der Rollenpaare 56,57 verschiebbar und verstellbar angeordnet ist. Jede Rolle 56,57 des jeweiligen Rollenpaares ist hierbei auf einem Kreisbogen verschiebbar gelagert und in Richtung zu den Spulenleiter 17 zustellbar und entfernbar und zusätzlich noch in Richtung der Längsachse des Spulenleiters verschiebbar.The movable roller station 54 in turn has pairs of opposing rollers 56 and rollers 57 perpendicular thereto, but with the difference that each individual roller of the roller pairs 56, 57 is arranged to be displaceable and adjustable. Each roller 56, 57 of the respective pair of rollers is in this case slidably mounted on a circular arc and can be delivered and removed in the direction of the coil conductor 17 and can also be displaced in the direction of the longitudinal axis of the coil conductor.

Das heißt also, die jeweiligen Doppel-Rollen 56,57 sind auf einer Kreisbahn in Z-Richtung, auf einer weiteren Kreisbahn in Y-Richtung und zusätzlich drehbar um die Längsachse des Spulenleiters herum in beiden Drehrichtungen verstellbar.This means that the respective double rollers 56, 57 can be adjusted in both directions of rotation on a circular path in the Z direction, on a further circular path in the Y direction and additionally rotatable about the longitudinal axis of the coil conductor.

Damit ist es möglich, dem zu biegenden Spulenleiter ein beliebiges sphärisch gekrümmtes Profil im Raum zu geben, wobei eine zusätzliche Torsionsbiegung überlagert werden kann.This makes it possible to give the coil conductor to be bent any spherical profile in space, whereby an additional torsional bend can be superimposed.

Das heißt, der erfindungsgemäße Biegekopf 52 biegt in der geforderten Formgebung den Spulenleiter 17 vollständig fertig vor. Er hat eine Formgebung wie es in den Fig. 6 bis 8 dargestellt ist. Nach dem Verlassen der beweglichen Rollstation 54 hat demgemäß der Spulenleiter 17 seine geforderte sphärische Formgebung und wird dann auf die in dreidimensionaler Richtung nachgeführte Wickelform 48 lediglich eingefädelt und eingelegt.That is, the bending head 52 according to the invention pre-bends the coil conductor 17 completely finished in the required shape. It has a shape as shown in FIGS. 6 to 8. After leaving the movable rolling station 54, the coil conductor 17 accordingly has its required spherical shape and is then only threaded and inserted onto the winding form 48 which is adjusted in the three-dimensional direction.

Die Nachführung der Wickelform 48 genau der entsprechenden vorher gegebenen Formgebung des Spulenleiters hat also den Sinn, daß ein formgenaues Einlegen des die Rollenstation 54 verlassenden Spulenleiters 17 auf die Wickelform 48 gewährleistet ist. Damit wird gesorgt, daß im synchronen Bewegungsablauf des Biegekopfes 52 Lage auf Lage paßgenau aufeinander gelegt werden.The tracking of the winding form 48 exactly the corresponding previously given shape of the coil conductor therefore has the sense that a precise insertion of the coil conductor 17 leaving the reel station 54 onto the winding form 48 is ensured. This ensures that in the synchronous movement of the bending head 52 position on position are placed on each other with a perfect fit.

Der Biegevorgang des Biegekopfes 52 und die synchrone Nachführung der Wickelform 48 ist entscheidend für die paßgenaue Anfertigung der Wickellagen 4,5 der Spulenleiter 17; d.h. durch das Auflegen auf die Wickelform 48 wird also selbst keine wesentliche Formänderungsarbeit mehr geleistet.The bending process of the bending head 52 and the synchronous tracking of the winding form 48 is crucial for the precisely fitting manufacture of the winding layers 4, 5 of the coil conductors 17; i.e. by placing it on the winding form 48, there is no longer any essential deformation work itself.

Im Sinne der vorher stehenden Beschreibung wird bei der positiven Formgebung außerhalb der Bereiche 65 der Stellaratorspule 1 der Drehantrieb für den Werkzeugtisch 47 mit einem Vorlauf betrieben, so daß die die letzte Rollenstation 54 verlassenden, fertig gebogenen Spulenleiter 17 unter einer leichten Vorspannung Lage auf Lage auf die Wickelform 48 aufgelegt werden. Die Vorspannung kann variabel von Null beginnend bis auf eine maximale Vorspannung durch Einstellung des Drehantriebes in Pfeilrichtung 45 eingestellt werden.In the sense of the description above, in the case of the positive shaping outside of the regions 65 of the stellarator coil 1, the rotary drive for the tool table 47 is operated with a lead, so that the completely bent coil conductor 17 leaving the last roller station 54, with a slight pretension, lies layer by layer the winding form 48 are placed. The preload can be set variably from zero to a maximum preload by adjusting the rotary drive in the direction of arrow 45.

Wie vorher beschrieben, wird in den negativen Formungsbereichen (Bereiche 65 der Stellaratorspule gemäß Fig. 1,2) dieser Vorlauf (in Pfeilrichtung 45) entfernt und es werden stattdessen entsprechende Schieber zur Sicherung der Formgebung der Spulenleiter in diesen Bereichen 65 verwendet.As previously described, this lead (in the direction of arrow 45) is removed in the negative shaping areas (areas 65 of the stellarator coil according to FIG. 1, 2) and corresponding slides are used instead to secure the shape of the coil conductors in these areas 65.

Es wird noch angefügt, daß der gesamte Biegekopf 52 an einem Konsolarm 59 fest gelagert ist, d.h. er ist stationär im Raum befestigt und der Konsolarm 59 ist an einem Schlitten 60 gelagert, der auf einem Turm 58 in den Pfeilrichtungen 62 in Z-Richtung verfahrbar ist.It is added that the entire bending head 52 is fixedly mounted on a bracket arm 59, i.e. it is fixed stationary in the room and the bracket arm 59 is mounted on a carriage 60 which can be moved on a tower 58 in the arrow directions 62 in the Z direction.

Zusätzlich ist noch vorgesehen, daß der gesamte Konsolarm 59 in Pfeilrichtung 61 (X-Richtung) verschiebbar ist.In addition, it is also provided that the entire bracket arm 59 can be displaced in the direction of arrow 61 (X direction).

Diese beiden Verschiebungen in den Pfeilrichtungen 61,62 werden bevorzugt, weil bei komplizierten Wickelvorgängen zusätzliche überlagerte Bewegungsabläufe gebraucht werden, die damit durch eine zusätzliche Verschiebung des Biegekopfes 52 erreicht werden.These two displacements in the arrow directions 61, 62 are preferred because, in the case of complicated winding processes, additional superimposed motion sequences are required, which are thus achieved by an additional displacement of the bending head 52.

Statt der beschriebenen Hohlprofile ist damit auch ein Biegen von Hohlprofilen offener oder geschlossener Profilform möglich.Instead of the hollow profiles described, it is also possible to bend hollow profiles of open or closed profile shape.

Wichtig bei dem vorliegenden Biegevorgang ist, daß die Biegung der Spulenleiter absolut schonend ist, sie tragen sogar eine Lackbeschichtung, die während des Biegevorganges nicht beschädigt werden darf und sie tragen eine supraleitende Füllung, die auch während des Biegevorganges nicht gequetscht oder in ihrem Querschnitt verändert werden darf. Die beschriebene Biegemaschine erfüllt alle diese Forderungen.It is important in the present bending process that the bending of the coil conductors is absolutely gentle, they even have a lacquer coating that must not be damaged during the bending process and they have a superconducting filling that is not squeezed or changed in cross-section during the bending process may. The bending machine described fulfills all of these requirements.

ZEICHNUNGS-LEGENDEDRAWING LEGEND

11
StellaratorspuleStellarator coil
22nd
InnenspuleInner coil
33rd
WicklungsaufbauWinding construction
44th
WicklungslageWinding position
55
WicklungslageWinding position
66
AußenspuleOuter coil
77
InnenwandInterior wall
88th
BodenwandBottom wall
99
PfeilrichtungArrow direction
1010th
RWR-BiegemaschineRWR bending machine
1111
ProfilrichtanlageProfile straightening system
1212th
VorrichtstationDressing station
1313
Coil-StationCoil station
1414
Schienenanlage (nur für Coil)Rail system (only for coil)
1515
PfeilrichtungArrow direction
1616
Coil 1Coil 1
1717th
SpulenleiterCoil conductor
1818th
Rollerole
1919th
Rolle (Vorrichtstation 12)Roll (preparation station 12)
2020th
Doppel-Rollen (Profilrichtanlage 11)Double rollers (profile straightener 11)
2121
PfeilrichtungArrow direction
2222
MaschinenrahmenMachine frame
2323
Schienerail
2424th
Schlittencarriage
2525th
Spindelspindle
2626
Motorengine
2727
PortalschlittenPortal sledge
2828
Motorengine
2929
Spindelspindle
3030th
Rollenführung (Portalschlitten 27)Roller guide (portal slide 27)
3131
LagerschildEnd shield
3232
Spindelspindle
3333
Motorengine
3434
Wellewave
3535
SchwingeSwingarm
3636
PortalchassisPortal chassis
3737
Motorengine
3838
Spindelspindle
3939
UnterbauSubstructure
4040
Kugellagerball-bearing
4141
Wellewave
4242
Motor (für Tisch)Motor (for table)
4343
Motor (für Schwinge 35)Motor (for swing arm 35)
4444
BasisdrehtischBasic turntable
4545
PfeilrichtungArrow direction
4646
KastenrahmenBox frame
4747
WerkzeugtischTool table
4848
Wickelform (Biegeschablone)Winding form (bending template)
4949
zweite Spulenhälfte (Spulenleiter 17)second coil half (coil conductor 17)
5050
Coil 2Coil 2
5151
LagerbockBearing block
5252
BiegekopfBending head
5353
MaschinengehäuseMachine housing
5454
Rollstation (beweglich)Rolling station (mobile)
5555
Rollstation (staar)Rollstation (staar)
5656
Rollenroll
5757
Rollenroll
5858
Turmtower
5959
KonsolarmLow console
6060
Schlittencarriage
6161
Pfeilrichtung (X-Richtung)Arrow direction (X direction)
6262
PfeilrichtungArrow direction
6363
PfeilrichtungArrow direction
6464
Linieline
6565
BereichArea
6666
Achseaxis
6767
Säulenrahmen (Portalsch.27)Column frame (Portalsch.27)

Claims (7)

  1. Method for cold forming profiles of ferrous and non-ferrous metals, in which the profile (17) which continuously passes through a bending tool is bent in all three spatial axes (X, Y, Z), the bending being carried without a bending die as the profile (17) passes through free space at the outlet end of the bending tool by a roller arrangement (54) which travels and rotates along all three spatial axes (X, Y, Z), characterised in that the bending tool (53, 54, 55) is designed as a bending head (52), and that the completed, bent profile (17) leaving the bending head (52) is tracked by a coil former (48) at a slight distance precisely aligned beneath the bending line of the bending head (52) for adjustment in all three spatial axes (X, Y, Z) and also for rotation in such a way that the completed, bent profile is received on the coil former (48) without any further shape-altering work.
  2. Method according to claim 1, for winding a stellarator coil, in which the profile to be bent is a coil conductor, and each individual coil winding has positive and negative deformation areas, characterised in that in positive deformation areas of the coil former (48) through an advance in the rotational movement of the coil former (48) in relation to the conveying movement of the roller station (54) of the bending head (52) a slight tension in the longitudinal direction is applied to the completely formed coil conductor (17), whilst in negative deformation areas (65) of the coil former (48) the advance is nil, and in these areas the completely formed coil conductor (17) is tensioned on the coil former (48) by means of the layer securing means.
  3. Method according to one of the claims 1 or 2, characterised in that the profile (17) to be bent is unwound from a coil (16) and aligned in a straight line by means of initial aligning station (12) and profile aligning station (1) arranged one behind the other and enters the bending head (52) as a profile aligned in a straight line.
  4. Device for carrying out the method according to one of the claims 1 to 3, with a bending tool for conveying the profile (17) with a plurality of roller stations (54, 55) arranged one behind the other and including the profile (17), wherein the roller station (54) arranged at the outlet end of the bending tool has a 4-roller arrangement and this roller station (54) as a whole is rotatable about the X-axis opposite the other roller stations (55) and wherein for the spatial bending of the profile (17) the oppositely arranged rollers (56, 57) of this roller station (55) are adjustable in a circular arc about the Y axis or the Z axis, characterised in that the bending tool is designed as a bending head (52) rigidly arranged on the free end of a console arm (59) and that at a slight distance from the bending head (52) a coil former (48), for receiving the completed, bent profile, is arranged on a worktable (47) for three-dimensional adjustment and to be rotatably driven in such a way that the completed, bent profile can be received on the coil former (48) without any further shape altering work.
  5. Device according to claim 4, characterised in that the console arm (59) is mounted on a fixed pillar (58) for displacement in the Z-direction.
  6. Device according to one of the claims 4 and 5, characterised in that for the three-dimensional tracking of the coil former (48) the device has the following machine parts:
    - a machine frame (22)
    - a carriage (24), situated above the machine frame (22), which can travel in the X-direction, the carriage (24) being the support for the Y-rail system,
    - a moveable portal carriage (27) situated above this, (roller guide 30),
    - the portal carriage (27) in each case has column frames (67) on both sides, which carry heavy bearing plates (31) for receiving a rocker arm (35), the bearing plates (31) are vertically displaceable via lateral carriages,
    - the rocker arm receives a smaller portal (36) which laterally can be vertically displaceable via the carriage,
    - on this portal (36) rests a base rotating table (44),
    - the base rotating table (44) through a box frame (46) supports in a second plane a worktable (47) on which is mounted the coil former (48) on which is formed the profile (17),
    - the bending head (52) - with spatial bending ability - is arranged for displacement together with a console arm (59),
    - the bending station is controlled through ten axes and can reach any desired bending point of a coil former (48).
  7. Device according to one of the claims 4 to 6, characterised in that a coil changing mechanism is provided by means of which a coil (16), on which is provided half of the entire coil conductor (17) to be bent, can be exchanged, after the completed removal of the coil conductor from the coil (16), for a further coil (50), which contains the second half of the coil conductor (17).
EP90101359A 1989-02-03 1990-01-24 Method and apparatus for the cold deformation of ferrous and non-ferrous metal sections by spatial coil roll bending Expired - Lifetime EP0381025B1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AT9090101359T ATE105519T1 (en) 1989-02-03 1990-01-24 METHOD AND DEVICE FOR COLD FORMING OF FERROUS AND NON-FERROUS METALS BY SPATIAL WRAPPING ROLLING.

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE3903298A DE3903298A1 (en) 1989-02-03 1989-02-03 METHOD AND DEVICE FOR COLD FORMING PROFILES FROM IRON AND NON-FERROUS METALS BY SPACIAL ROLLING ROLL BENDING
DE3903298 1989-02-03

Publications (2)

Publication Number Publication Date
EP0381025A1 EP0381025A1 (en) 1990-08-08
EP0381025B1 true EP0381025B1 (en) 1994-05-11

Family

ID=6373406

Family Applications (1)

Application Number Title Priority Date Filing Date
EP90101359A Expired - Lifetime EP0381025B1 (en) 1989-02-03 1990-01-24 Method and apparatus for the cold deformation of ferrous and non-ferrous metal sections by spatial coil roll bending

Country Status (4)

Country Link
EP (1) EP0381025B1 (en)
JP (1) JPH03124323A (en)
AT (1) ATE105519T1 (en)
DE (2) DE3903298A1 (en)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0630297A1 (en) * 1992-05-29 1994-12-28 Panaghiotis A. Anagnostopoulos Method and mechanism for the production of upwinding spiral wire products

Family Cites Families (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2713376A (en) * 1951-12-17 1955-07-19 Cyril Bath Co Metal-forming machine
SE337054B (en) * 1968-12-16 1971-07-26 Mekanomatik Ab
US3640112A (en) * 1969-05-12 1972-02-08 Republic Steel Corp Coiling method and apparatus
DE2518798C3 (en) * 1975-04-28 1979-02-01 Vladimir Nikolaevitsch Shubin Bending head for tube bending machines
AT368724B (en) * 1976-05-28 1982-11-10 Hufnagl & Co Rista Draht BENDING MACHINE FOR WIRE
US4365492A (en) * 1980-06-25 1982-12-28 Intercole Bolling Corp. Ring former and cutoff
DE3578663D1 (en) * 1984-01-30 1990-08-23 Hashimoto Forming Kogyo Co DEVICE FOR PRODUCING OBJECTS CURVED IN SEVERAL DIRECTIONS.
DE3618701A1 (en) * 1986-06-04 1987-12-10 Spaeth Gmbh & Co Kg Stahlbau B METHOD AND DEVICE FOR COLD FORMING PROFILES FROM IRON AND NON-FERROUS METALS

Also Published As

Publication number Publication date
DE3903298A1 (en) 1990-08-09
EP0381025A1 (en) 1990-08-08
DE59005656D1 (en) 1994-06-16
ATE105519T1 (en) 1994-05-15
JPH03124323A (en) 1991-05-27

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