The present invention relates to a plate thickness reduction pressing apparatus and method.

1. 1. Fig. 1 shows an example of a roughing mill used for hot rolling, and the roughing mill is provided with work rolls 2a, 2b arranged vertically opposite each other on opposite sides of a transfer line S that transfers a slab-like material 1 to be shaped, substantially horizontally, and backup rolls 3a, 3b contacting the work rolls 2a, 2b on the side opposite to the transfer line.
   
   In the above-mentioned roughing mill, the work roll 2a above the transfer line S is rotated counterclockwise, and the work roll 2b underneath the transfer line S is rotated clockwise, so that the material 1 to be shaped is caught between both work rolls 2a, 2b, and by pressing the upper backup roll 3a downwards, the material 1 to be shaped is moved from the upstream A side of the transfer line to the downstream B side of the line, and the material 1 to be shaped is pressed and formed in the direction of the thickness of the slab. However, unless the nip angle &thgr; of the material 1 to be shaped as it enters into the work rolls 2a, 2b is less than about 17°, slipping will occur between the upper and lower surfaces of the material 1 to be shaped and the outer surfaces of both work rolls 2a, 2b, and the work rolls 2a, 2b will no longer be able to grip and reduce the material 1 to be shaped.
   
   More explicitly, when the diameter D of the work rolls 2a, 2b is 1,200 mm, the reduction &Dgr;t of a single rolling pass is about 50 mm according to the above-mentioned nip angle &thgr; condition for the work rolls 2a, 2b, so when a material 1 to be shaped with a thickness T0 of 250 mm is rolled, the thickness T1 of the slab after being reduced and formed by a roughing mill becomes about 200 mm.
   
   According to the prior art, therefore, the material 1 to be shaped is rolled in a reversing mill, in which the material is moved backwards and forwards while gradually reducing the thickness of the plate, and when the thickness of the material 1 to be shaped is reduced to about 90 mm, the material 1 is sent to a finishing mill.
   
   Another system for reducing and forming the material 1 to be shaped according to the prior art is shown in Fig. 2; dies 14a, 14b with profiles like the plane shape of dies for a stentering press machine are positioned opposite each other above and below a transfer line S, and both dies 14a, 14b are made to approach each other and separate from each other in the direction orthogonal to the direction of movement of the material 1 using reciprocating means such as hydraulic cylinders, in synchronism with the transfer of the material 1, while reducing and forming the material 1 to be shaped in the direction of the thickness of the plate.
   
   The dies 14a, 14b are constructed with flat forming surfaces 19a, 19b gradually sloping from the upstream A side of the transfer line towards the downstream B side of the line, and flat forming surfaces 19c, 19d that continue from the aforementioned forming surfaces 19a, 19b in a direction parallel to and on opposite sides of the transfer line S.
   
   The width of the dies 14a, 14b is set according to the plate width (about 2,000 mm or more) of the material 1 to be shaped.
   
   However, when the material 1 to be shaped is rolled with the reversing method using the roughing mill shown in Fig. 1, space is required at each of the upstream A and downstream B ends of the transfer line S of the roughing mill, for pulling out the material 1 to be shaped as it comes out of the roughing mill, so the equipment must be long and large.
   
   When the material 1 to be shaped is reduced and formed in the direction of its plate thickness using the dies 14a, 14b shown in Fig. 2, the areas of the forming surfaces 19a, 19b, 19c and 19d in contact with the material 1 to be shaped are much longer than those of the dies of a stentering press machine, and the contact areas increase as the dies 14a, 14b approach the transfer line S, so that a large load must be applied to each of the dies 14a, 14b, during reduction.
   
   Furthermore, the power transmission members such as the eccentric shafts and rods for moving the dies 14a, 14b, the housing, etc. must be strong enough to withstand the above reducing loads, so each of these members and the housing must be made large in size.
   
   Moreover, when the material 1 to be shaped is reduced and formed in the direction of its plate thickness using the dies 14a, 14b, some of the material 1 is forced backwards towards the upstream A side on the transfer line depending on the shape and the stroke of the dies 14a, 14b, therefore, it becomes difficult to transfer the material 1 to be shaped to the downstream B side of the transfer line.
   
   When the material 1 to be shaped is reduced and formed in the direction of its plate thickness using the dies 14a, 14b shown in Fig. 2, the height of the lower surface of the material 1 after being reduced by the dies 14a, 14b is higher than the height of the lower surface of the material 1 immediately before being reduced by the dies, by an amount corresponding to the reduction in thickness.
   
   Consequently, the leading end of the material 1 to be shaped tends to droop downwards, therefore the table rollers (not illustrated) installed on the downstream B side of the transfer line, to support the material 1 being shaped, may catch the leading end of the material 1, possibly resulting in damage to both the table rollers and the material 1 being shaped.
   
   Recently, the flying-sizing press machine shown in Fig. 3 has been proposed.
   
   This flying-sizing press machine is provided with a housing 4 erected on a transfer line S so as to allow movement of a material 1 to be shaped, an upper shaft box 6a and a lower shaft box 6b housed in window portions 5 of the housing 4 opposite each other on opposite sides of the transfer line S, upper and lower rotating shafts 7a, 7b extending substantially horizontally in the direction orthogonal to the transfer line S and supported by the upper shaft box 6a or the lower shaft box 6b by bearings (not illustrated) on the non-eccentric portions, rods 9a, 9b located above and below the transfer line S, respectively, connected to eccentric portions of the rotating shafts 7a, 7b through bearings 8a, 8b at the end portions thereof, rod support boxes 11a, 11b connected to intermediate portions of the upper and lower rods 9a, 9b by bearings 10a, 10b with spherical surfaces and housed in the window portions 5 of the housing 4 and free to slide vertically, die holders 13a, 13b connected to the top portions of the rods 9a, 9b through bearings 12a, 12b with spherical surfaces, dies 14a, 14b mounted on the die holders 13a, 13b, and hydraulic cylinders 15a, 15b whose cylinder units are connected to intermediate locations along the length of the rods 9a, 9b by means of bearings and the tips of the piston rods are connected to the die holders 13a, 13b through bearings.
   
   The rotating shafts 7a, 7b are connected to the output shaft (not illustrated) of a motor through a universal coupling and a speed reduction gear, and when the motor is operated, the upper and lower dies 14a, 14b approach towards and move away from the transfer line S in synchronism with the transfer operation.
   
   The dies 14a, 14b are provided with flat forming surfaces 16a, 16b gradually sloping from the upstream A side of the transfer line towards the downstream B side of the transfer line so as to approach the transfer line S, and other flat forming surfaces 17a, 17b continuing from the aforementioned forming surfaces 16a, 16b in a direction parallel to the transfer line S.
   
   The width of the dies 14a, 14b is determined by the plate width (about 2,000 mm or more) of the material 1 to be shaped.
   
   A position adjusting screw 18 is provided at the top of the housing 4, to enable the upper shaft box 6a to be moved towards or away from the transfer line S, and by rotating the position adjusting screw 18 about its axis, the die 14a can be raised and lowered through the rotating shaft 7a, rod 9a, and the die holder 13a.
   
   When the material 1 to be shaped is reduced and formed in the direction of the plate thickness using the flying-sizing press machine shown in Fig. 3, the position adjusting screw 18 is rotated appropriately to adjust the position of the upper shaft box 6a, so that the spacing between the upper and lower dies 14a, 16b is determined according to the plate thickness of the material 1 to be shaped by reducing and forming in the direction of plate thickness.
   
   Next, the motor is operated to rotate the upper and lower rotating shafts 7a, 7b, and the material 1 to be shaped is inserted between the upper and lower dies 14a, 14b, and the material 1 is reduced and formed by means of the upper and lower dies 14a, 14b that move towards and away from each other and with respect to the transfer line S while moving in the direction of the transfer line S as determined by the displacement of the eccentric portions of the rotating shafts 7a, 7b.
   
   At this time, appropriate hydraulic pressure is applied to the hydraulic chambers of the hydraulic cylinders 15a, 15b, and the angles of the die holders 13a, 13b are changed so that the forming surfaces 17a, 17b of the upper and lower dies 14a, 14b, on the downstream B side of the transfer line, are always parallel to the transfer line S.
   
   However, the flying-sizing press machine shown in Fig. 3 has much larger contact areas between the forming surfaces 16a, 16b, 17a and 17b of the dies 14a, 14b and the material 1 to be formed, compared to the dies of a plate reduction press machine, and because the above-mentioned contact areas increase as the dies 14a, 14b approach the transfer line S, a large load must be applied to the dies 14a, 14b during reduction.
   
   In addition, the die holders 13a, 13b, rods 9a, 9b, rotating shafts 7a, 7b, shaft boxes 6a, 6b, housing 4, etc. must be strong enough to withstand the reducing load applied to the dies 14a, 14b, so that these members are made larger in size.
   
   Also, the flying-sizing press machine shown in Fig. 3 may suffer from the problem that the leading and trailing ends of the material 1 being reduced and formed are locally bent to the left or right, or with a camber so that when a long material 1 is being formed it generally warps, unless the centers of the reducing forces from the dies 14a, 14b on the material 1 to be shaped are in close alignment when the material 1 is reduced and formed by the upper and lower dies 14a, 14b.
2. 2. With a conventional rolling mill known in the prior art, in which a material is rolled between two work rolls, there is a reduction ratio limit of normally about 25% due to the nip angle limitation. Therefore, it is not possible to reduce the thickness of a material by a large ratio (for example, reducing a material from about 250 mm thickness to 30 to 60 mm) in a single pass, therefore three or four rolling mills are arranged in tandem in a tandem rolling system, or the material to be rolled is rolled backwards and forwards in a reverse rolling system. However, these systems are accompanied with practical problems such as the need for a long rolling line.
   
   On the other hand the planetary mill, Sendzimir mill, cluster mill, etc. have been proposed as means of pressing that allow a large reduction in one pass. However, with these rolling mills, small rolls press the material to be rolled at a high rotational speed, resulting in a great impact, therefore the life of the bearings etc. is so short that these mills are not suitable for mass production facilities.
   
   On the other hand, various kinds of press apparatus modified from the conventional stentering press machines have been proposed (for example, Japanese patent No. 014139, 1990 , unexamined Japanese patent publication Nos. 222651, 1986 , 175011, 1990 , etc.).
   
   An example of the "Flying-sizing press apparatus" according to the unexamined Japanese patent publication No. 175011, 1990 is shown in Fig. 4; rotating shafts 22 are arranged in the upper and lower sides or the left and right sides of the transfer line Z of a material to be shaped, and the bosses of rods 23 with a required shape are connected to eccentric portions of the rotating shafts 22, and in addition, dies 24 arranged on opposite sides of the transfer line of the material to be shaped are connected to the tips of the rods 23; when the rotating shafts 22 are rotated, the rods 23 coupled to the eccentric portions of the rotating shafts cause the dies 24 to press both the upper and lower surfaces of the material 1 to be shaped, thereby the thickness of the material to be shaped is reduced.
   
   However, the above-mentioned high-reduction means are associated with problems such as (1) a material to be reduced cannot be easily pressed by the flying-sizing apparatus in which the material is reduced as it is being transferred, (2) the means are complicated with many component parts, (3) many parts must slide under heavy loads, (4) the means are not suitable for heavily loaded frequent cycles of operation, etc.
   
   With conventional high-reduction pressing means known in the prior art, the position of the dies is controlled to adjust the thickness of the material to be pressed by means of a screw, wedge, hydraulic cylinder, etc., and as a result, there are the practical problems that the equipment is large, costly, complicated, and vibrates considerably.
3. 3. Conventionally, a roughing-down mill is used to roll a slab. The slab to be rolled is as short as 5m to 12m, and the slab is rolled by a plurality of roughing-down mills or by reversing mills in which the slab is fed forwards and backwards as it is rolled. In addition, a reduction press machine is also used. Recently, because a long slab manufactured by a continuous casting system has been introduced, there is a demand for the continuous transfer of the slab to a subsequent pressing system. When a material is rough rolled using a roughing-down mill, the minimum nip angle (about 17°) must be satisfied, so the reduction limit &Dgr;t per pass is about 50 mm. Because the slab is continuous, reverse rolling is not applicable, so that to obtain the desired thickness, a plurality of roughing-down mills must be installed in series, or if a single rolling mill is to be employed, the diameter of the work rolls should be very large.
   
   Consequently, a reduction press machine is used. Fig. 5 shows an example of such a machine in which the dies are pressed by sliders, to provide a flying-press machine that can press a moving slab. Dies 32 provided above and below the slab 1 are mounted on sliders 33, and the sliders 33 are moved up and down by the crank mechanisms 34. The dies 32, sliders 33 and crank mechanisms 34 are reciprocated in the direction of transferring the slab, by the feeding crank mechanisms 35. The slab 1 is conveyed by pinch rolls 36 and transfer tables 37. When the slab is being reduced, the dies 32, sliders 33 and crank mechanisms 34 are moved in the direction of transferring the slab by means of the feeding crank mechanisms 35, and the pinch rolls 36 transfer the slab 1 in synchronism with this transfer speed. A start-stop system can also be used; the slab 1 is stopped when the system is working as a reduction press machine and the slab is reduced, and after completing reduction, the slab is transferred by a length equal to a pressing length, and then pressing is repeated.
   
   There are problems in the design and manufacturing cost of the aforementioned roughing-down mill with large diameter rolls, and the use of rolls with a large diameter results in a shorter life for the rolls because of the low rolling speed and difficulty in cooling the rolls. With the reduction press machine using sliders and feeding crank mechanisms shown in Fig. 5, the cost of the equipment is high because the mechanisms for reciprocating the sliders etc. in the direction of movement of a slab are complicated and large in scale. In addition, the sliders vibrate significantly in the vertical direction. With a reduction press machine using a start-stop system, the slab must be accelerated and decelerated repeatedly from standstill to transfer speed, and vice versa. The slab is transferred using pinch rolls and transfer tables, and these apparatus become large due to the high acceleration and deceleration.
4. 4. When a material is reduced by a large amount, according to the prior art, long dies were used to reduce the material while it was fed through the dies by the length thereof during one or several pressings. Defining the longitudinal and lateral directions as the direction in which the pressed material is moved and the direction perpendicular to the longitudinal direction, respectively, the material to be pressed by a large amount in the longitudinal direction is pressed by dies that are long in the longitudinal direction using single pressing or by means of a plurality of pressing operations while feeding the material to be pressed in the longitudinal direction. Fig. 6 shows an example of the above-mentioned reduction press machine, and Fig. 7 illustrates its operation. The reduction press is equipped with dies 42 above and below a material 1 to be pressed, hydraulic cylinders 43 for pressing down the dies 42, and a frame 44 that supports the hydraulic cylinders 43. A pressing operation is described using the symbols L for the length of the dies 42, T for the original thickness of the material 1 to be pressed, and t for the thickness of the material after pressing. Fig. 7 (A) shows the state of the dies 42 set to a location with thickness T on a portion of material to be pressed next, adjacent to a portion with thickness t which has been pressed. (B) shows the state in which the dies have pressed down from the state (A). (C) is the state in which the dies 42 have been separated from the material 1 being pressed, that has then been moved longitudinally by the pressing length L, and completely prepared for the next pressing, which is the same state as (A). Operations (A) to (C) are repeated until all the material is reduced to the required thickness.
   
   The longer the dies, the greater the force that is required for reduction, so the reduction press machine must be large. With a press machine, pressing is usually repeated at high speed. When an apparatus with a large mass is reciprocated at a high speed, a large power is required to accelerate and decelerate the apparatus, therefore the ratio of the power required for acceleration and deceleration to the power needed for reducing the material to be pressed is so large that much power is spent on driving the apparatus. When the material is reduced, the volume corresponding to the thinned portion must be displaced longitudinally or laterally because the volumes of the material before and after reduction are substantially the same. If the dies are long, the material is constrained so that it is displaced longitudinally (this phenomenon is called material flow), so that pressing becomes difficult especially when the reduction is large.
   
   When a material to be rolled is reduced conventionally in a horizontal mill, the gap between the rolls of the horizontal mill is set so that the rolls are capable of gripping the material to be rolled considering the thickness of the material after forming, therefore the reduction in thickness allowed for a single pass is limited so that when a large reduction in the thickness is required, a plurality of horizontal mills have to be installed in series, or the material must be moved backwards and forwards through a horizontal mill while the thickness is gradually reduced, according to the prior art. Another system was also proposed in the unexamined Japanese patent publication No. 175011, 1990 ; eccentric portions are provided in rotating shafts, the motion of the eccentric portions is changed to an up/down movement using rods, and a material to be pressed is reduced continuously by these up/down movements.
   
   The system with a plurality of horizontal mills arranged in tandem (series) has the problems that the equipment is large and the cost is high. The system of passing a material to be pressed backwards and forwards through a horizontal mill has the problems that the operations are complicated and a long rolling time is required. The system disclosed in the unexamined Japanese patent application No. 175011, 1990 has the difficulty that large equipment must be used, because a fairly large rotating torque must be applied to the rotating shafts to produce the required reducing force as the movement of the eccentric portions of the rotating shafts has to be changed to an up/down motion to produce the necessary reducing force.
5. 5. Conventionally, a roughing-down mill is used to press a slab. The slab to be pressed is as short as 5 to 12 m, and to obtain the specified thickness, a plurality of roughing-down mills are provided, or the slab is moved backwards and forwards as it is pressed in the reversing rolling method. Other systems also used practically include a flying press machine that transfers a slab while it is being pressed, and a start-stop reduction press machine which stops conveying the material as it is being pressed and transfers the material during a time when it is not being pressed.
   
   Since long slabs are produced by continuous casting equipment, there is a practical demand for a slab to be conveyed continuously to a subsequent press apparatus. When a slab is rough rolled in a roughing-down mill, there is a nip angle limitation (about 17'), so the reduction per rolling cannot be made so large. Because the slab is continuous, it cannot be rolled by reverse rolling, therefore to obtain the preferred thickness, a plurality of roughing-down mills must be installed in series, or if a single mill is involved, the diameter of the work rolls must be made very large. There are difficulties, in terms of design and cost, in manufacturing such a roughing-down mill with large-diameter rolls, and large diameter rolls must be operated at a low speed when rolling a slab, so the rolls cannot be easily cooled, and the life of the rolls becomes shorter. Because a flying press can provide a large reduction in thickness and is capable of reducing a material while it is being conveyed, the press can continuously transfer the material being pressed to a downstream rolling mill. However, it has been difficult to adjust the speed of the material to be pressed so that the flying press and the downstream rolling mill can operate simultaneously to reduce and roll the material. In addition, it has not been possible to arrange a start-stop reduction press machine and a rolling mill in tandem to reduce a slab continuously; with the start-stop reduction press, the material being pressed is stopped during pressing, and is transferred when it is not being pressed.
   
   Another system in practical use is the flying system in which the sliders that press down on a slab are moved up and down in synchronism with the transfer speed of the slab.
   
   In the start-stop system, the heavy slab is accelerated and decelerated every cycle from standstill to the maximum speed Vmax, and accordingly the capacity of the transfer facilities such as the pinch rolls and transfer tables must be large. Because of the discontinuous operation, it is difficult to carry out further operations on a downstream press machine. The flying system requires a large capacity apparatus to produce the swinging motion, and to accelerate and decelerate the heavy sliders according to the speed of the slab. Another problem with this system is that this large capacity apparatus for producing the swinging motion causes considerable vibrations in the press machine.
   
   Still another problem with this system is that if the speed of the slab deviates from that of the sliders, flaws may be produced in the slab or the equipment may be damaged.
   
   Recently, a high-reduction press machine that can reduce a thick slab (material to be pressed) to nearly 1/3 of its original thickness in a single reduction operation, has been developed. Fig. 8 shows an example of a reduction press machine used for hot pressing. With this reduction press machine, dies 52a, 52b are disposed opposite each other vertically on opposite sides of the transfer line S, and are simultaneously moved towards and away from a material 1 to be pressed that travels on the transfer line S by the reciprocating apparatus 53a, 53b incorporating eccentric axes, rods, and hydraulic cylinders, so that material of a thickness of, for example, 250 mm can be reduced to 90 mm by a single reducing operation.
   
   However, the reduction of the aforementioned high-reduction press machine can be as large as 160 mm, that is, the reduction on one side is as large as 80 mm. According to the prior art, there is a small difference of thickness before and after pressing, so the transfer levels of the transfer devices of a press machine on the inlet and outlet sides are substantially the same. With the above-mentioned high-reduction press machine, however, there is the problem that the material 1 to be pressed is bent if the transfer levels are identical. Another problem of the machine is that the transfer device is overloaded.
   
   Further, prior art US 3,460,370 discloses an apparatus for swaging a continuous stock. This known apparatus comprises a pair of diametrically opposite dies, which are rigidely secured to the ends of connecting rods which slide in rotatable guides.
   
   Still further, from US 3,333,452 a method and apparatus for reducing the thickness of a slab is known. This known apparatus comprises forging toels, which are driven such that they will contact the slab symmetrically.

The present invention has been accomplished under the circumstances mentioned above, and the object of the present invention is to provide a plate thickness reduction press apparatus and a method that can efficiently reduce a material to be shaped in the direction of the thickness of the plate, can securely transfer the material to be shaped, and can decrease the load imposed on the dies during reduction.

To achieve the aforementioned object of the present invention a the plate thickness reduction pressing method specified in Claim 1 is provided.

Further a plate thickness reduction press apparatus as defined in Claim 2 is provided. Preferred embodiments thereof are defined in the sub-claims.

The other objects and advantages of the present invention will be revealed as follows by referring to the attached drawings.

• Fig. 1 is a schematic view of an example of a rolling mill used for hot rolling.
• Fig. 2 is a schematic view showing an example of reduction forming in the direction of plate thickness of a material to be shaped using dies.
• Fig. 3 is a conceptual view showing an example of a flying sizing press apparatus.
• Fig. 4 is a structural view of a conventional high-reduction press machine.
• Fig. 5 is a view showing a conventional flying reduction press machine.
• Fig. 6 is a view showing an example of the configuration of a reduction press machine using conventional long dies.
• Fig. 7 is a view showing the operation of the apparatus shown in Fig. 6.
• Fig. 8 shows the method of reducing thickness used during hot pressing.
• Fig. 9 is a conceptual view seen from the side of the transfer line of the seventh embodiment of the plate reduction press apparatus according to the present invention, when the upstream dies are in the most separated position from the transfer line and the downstream dies are in the closest position to the transfer line.
• Fig. 10 is a conceptual view seen from the side of the transfer line of the seventh embodiment of the plate reduction press apparatus according to the present invention, when the upstream dies are moving towards the transfer line and the downstream dies are moving away from the transfer line.
• Fig. 11 is a conceptual view seen from the side of the transfer line of the seventh embodiment of the plate reduction press apparatus according to the present invention, when the upstream dies are in the closest position to the transfer line and the downstream dies are in the most separated position from the transfer line.
• Fig. 12 is a conceptual view seen from the side of the transfer line of the seventh embodiment of the plate reduction press apparatus according to the present invention, when the upstream dies are moving away from the transfer line and the downstream dies are moving towards the transfer line
• Fig. 13 is a conceptual view showing the mechanisms for moving the sliders shown in Figs. 9 through 12, in a sectional view in the longitudinal direction of the transfer line.

The embodiments of the present invention are described as follows referring to the drawings.

Figs. 9 through 13 show an example of a plate reduction press apparatus according to the present invention; this plate reduction press apparatus is provided with a housing 319 erected at a predetermined location on the transfer line S so that the material 1 to be shaped can pass through the center portion of the housing, a pair of upstream sliders 324a, 324b arranged above and below the transfer line S opposite each other, a pair of downstream sliders 325a, 325b located on the downstream B side of the upstream sliders 324a, 324b in the transfer line, opposite each other above and below the transfer line S, upstream dies 330a, 330b supported by the upstream sliders 324a, 324b, downstream dies 333a, 333b supported by the downstream sliders 325a, 325b, mechanisms 336a, 336b for moving the upstream sliders that move the upstream sliders 324a, 324b towards the transfer line S and move the sliders away from the line S, the mechanisms 344a, 344b for moving the downstream sliders that move the downstream sliders 325a, 325b towards and away from the transfer line S, upstream hydraulic cylinders 352a, 352b as the mechanisms for moving the upstream dies that move the upstream dies 330a, 330b backwards and forwards along the transfer line S, hydraulic cylinders 354a, 354b as the mechanisms for moving the downstream dies that move the downstream dies 333a, 333b backwards and forwards along the transfer line S, and synchronous driving mechanisms 356a, 356b corresponding to both the above-mentioned mechanisms 336a, 336b, 344a and 344b for moving the sliders.

Inside a housing 319, upstream slider holders 320a, 320b are installed opposite each other above and below a transfer line S near the upstream A side of the transfer line, and constructed to be concave in the direction away from the transfer line, and downstream slider holders 321a, 321b are installed opposite each other on opposite sides of the transfer line S near the downstream B side of the transfer line, and constructed to be concave in the direction away from the transfer line; the downstream slider holders 321a, 321b are located closer to the transfer line S than the upstream slider holders 320a, 320b.

On the outer surface of the housing 319, there are rod insertion holes 322a, 322b communicating with the upstream slider holders 320a, 320b from the top and bottom of the housing, near the upstream A side of the transfer line, and rod insertion holes 323a, 323b communicating with the downstream slider holders 321a, 321b from the top and bottom of the housing, near the downstream B side of the transfer line, for each of the slider holders 320a, 320b, 321a, and 321b, at 2 locations each in a row in the lateral direction of the material 1 to be shaped.

The upstream sliders 324a, 324b are housed in the upstream slider holders 320a, 320b so that the sliders can slide in the direction towards and away from the transfer line S, and the downstream sliders 325a, 325b are housed in the downstream slider holders 321a, 321b so that the sliders can slide in the direction towards and away from the transfer line S.

On the surfaces facing the transfer line S of the upstream sliders 324a, 324b and the downstream sliders 325a, 325b, die holders 326a, 326b, 327a, and 327b are provided that can move backwards and forwards substantially horizontally in the direction of the transfer line S.

On the surfaces farthest from the transfer line, of the upstream sliders 324a, 324b and the downstream sliders 325a, 325b, brackets 328a, 328b, 329b, and 329b are constructed with 2 brackets at each location, immediately opposite the rod insertion holes 322a, 322b, 323a, and 323b.

The upstream dies 330a, 330b are provided with flat forming surfaces 331a, 331b that gradually approach the transfer line S from the upstream A side to the downstream B side of the transfer line, and flat forming surfaces 332a, 332b continuing from the downstream B side of the above-mentioned forming surfaces 331a, 331b in the direction of the transfer line, facing the transfer line S substantially horizontally, and the dies 330a, 330b are mounted on the aforementioned die holders 326a, 326b.

The downstream dies 333a, 333b are provided with flat forming surfaces 334a, 334b that gradually approach the transfer line S from the upstream A side to the downstream B side of the transfer line, and flat forming surfaces 335a, 335b continuing from the downstream B side of the above-mentioned forming surfaces 334a, 334b substantially parallel to and facing the transfer line S, and the dies 333a, 333b are mounted on the aforementioned die holders 327a, 327b.

The mechanisms 336a, 336b for moving the upstream sliders are composed of shaft boxes 337a, 337b above and below the housing 319 and positioned on the sides away from above-mentioned upstream slider holders 320a, 320b, crank shafts 339a, 339b extending substantially horizontally in the direction orthogonal to the transfer line S, whose non-eccentric portions 338a, 338b are supported by the shaft boxes 337a, 337b through bearings, and rods 342a, 342b inserted through the above-mentioned rod insertion holes 322a, 322b, and the big ends of which are connected to the eccentric portions 340a, 340b of the crank shafts 339a, 339b, and the tips of which are connected to the brackets 328a, 328b of the upstream sliders 324a, 324b by the pins 341a, 341b parallel to the crank shafts 339a, 339b, through bearings.

The shaft box 337a located above the transfer line S is supported by a support member 343a provided above the housing 319, and the shaft box 337b located below the transfer line S is supported by a support member 343b provided on the lower part of the housing in a manner such that it can be moved up and down.

In addition, the location of the shaft box 337b with respect to the transfer line S can be determined by moving it up or down with a position adjusting screw (not illustrated).

In these mechanisms 336a, 336b, for moving the upstream sliders, when the crank shafts 339a, 339b rotate, the displacements of the eccentric portions 340a, 340b are transmitted to the upstream sliders 324a, 324b through the rods 342a, 342b, and the die holders 326a, 326b and the upstream dies 330a, 330b move towards and away from the transfer line S together with the above-mentioned upstream sliders 324a, 324b.

The mechanisms 344a, 344b for moving the downstream sliders are composed of shaft boxes 345a, 345b arranged on the top and bottom of the housing 319 on the sides farther from the transfer line than the aforementioned downstream slider holders 321a, 321b, crank shafts 347a, 347b extending substantially horizontally in the direction orthogonal to the transfer line S, whose non-eccentric portions 346a, 346b are supported by the shaft boxes 345a, 345b through bearings, and rods 350a, 350b inserted through the above-mentioned rod insertion holes 323a, 323b, the big ends of which are connected to the eccentric portions 348a, 348b of the crank shafts 347a, 347b through bearings, and the tips of which are connected to the brackets 329a, 329b of the downstream sliders 325a, 325b through the bearings of pins 349a, 349b parallel to the crank shafts 347a, 347b.

The shaft box 345a located above the transfer line S is supported by and fixed to a support member 351a provided on top of the housing 319, and the shaft box 345b located below the transfer line S is supported by a support member 351b provided on bottom of the housing 319 in a manner such that it can be moved up and down.

Further, the location of the shaft box 345b with respect to the transfer line S can be set by moving it up or down with a position adjusting screw (not illustrated).

In the aforementioned mechanisms 344a, 344b for moving the downstream sliders, the displacements of the eccentric portions 348a, 348b associated with the rotation of the crank shafts 347a, 347b are transmitted to the downstream sliders 325a, 325b through the rods 350a, 350b, and the die holders 327a, 327b and the downstream dies 333a, 333b move towards and away from the transfer line S together with the above-mentioned downstream sliders 325a, 325b.

Upstream hydraulic cylinders 352a, 352b are installed on the upstream A side of the upstream sliders 324a, 324b on the transfer line so that the piston rods 353a, 353b point towards the downstream B side of the transfer line and are located parallel to the transfer line S, and the aforementioned piston rods 353a, 353b are connected to the upstream dies 330a, 330b.

With these upstream hydraulic cylinders 352a, 352b, when hydraulic pressure is applied to the hydraulic chambers on the head side, the piston rods 353a, 353b are pushed out, and the die holders 326a, 326b and the upstream dies 330a, 330b move towards the downstream B side of the upstream sliders 324a, 324b on the transfer line, and when hydraulic pressure is applied to the hydraulic chambers on the rod side, the piston rods 353a, 353b are retracted, and the die holders 326a, 326b and the upstream dies 330a, 330b move towards the upstream A side of the upstream sliders 324a, 324b on the transfer line.

The downstream hydraulic cylinders 354a, 354b are mounted near the downstream B side of the downstream sliders 325a, 325b on the transfer line so that the piston rods 355a, 355b point towards the upstream A side of the transfer line and are located parallel to the transfer line S, and the above-mentioned piston rods 355a, 355b are connected to the downstream dies 333a, 333b.

With these downstream hydraulic cylinders 354a, 354b, when hydraulic pressure is applied to the hydraulic chambers on the rod side, the piston rods 355a, 355b are retracted, and the die holders 327a, 327b and the upstream dies 333a, 333b move towards the downstream B side of the downstream sliders 325a, 325b on the transfer line, and when hydraulic pressure is applied to the hydraulic chambers on the head side, the piston rods 355a, 355b are pushed out, and the die holders 327a, 327b and the downstream dies 333a, 333b move towards the upstream A side of the downstream sliders 325a, 325b on the transfer line.

Synchronous drive mechanisms 356a, 356b are provided with input shafts 357a, 357b, upstream output shafts 358a, 358b, downstream output shafts 359a, 359b, and a plurality of gears (not illustrated) that transmit the rotation of the input shafts 357a, 357b to the output shafts 358a, 358b, 359a, and 359b, and when the input shafts 357a, 357b rotate, the output shafts 358a, 358b, 359a, and 359b rotate in the same direction at the same rotational speed.

The upstream output shaft 358a of the synchronous drive mechanism 356a is connected on one side through a universal coupling (not illustrated) to, a non-eccentric portion 338a of the crank shaft 339a that is a component of the mechanism 336a for moving the upstream slider and the downstream output shaft 359a is connected through a universal coupling (not illustrated), to a non-eccentric portion 338b of the crank shaft 347a that is a component of the mechanism 344a for moving the downstream slider.

The crank shafts 339a, 347a are connected to the aforementioned output shafts 358a, 359a in such a state that there is a phase angle difference of 180° between the eccentric portion 340a of the crank shaft 339a and the eccentric portion 348a of the crank shaft 347a.

The upstream output shaft 358b of the other synchronous drive mechanism 356b, is connected via a universal coupling (not illustrated) to a non-eccentric portion 338b of the crank shaft 339b, that is a component of the mechanism 336b for moving the upstream slider, and the downstream output shaft 359b, is connected through a universal coupling (not illustrated) to a non-eccentric portion 338b of the crank shaft 347b that is a component of the mechanism 344b for moving the downstream slider.

The crank shafts 339b, 347b are connected to the aforementioned output shafts 358b, 359b in such a state that there is a phase angle difference of 180° between the eccentric portion 340b of the crank shaft 339b and the eccentric portion 348b of the crank shaft 347b.

The input shafts 357a, 357b of the synchronous drive mechanisms 356a, 356b, are connected to the output shafts of motors through universal couplings (not illustrated), and one motor operates so that the crank shafts 339a, 347a rotate counterclockwise in Figs. 9 through 12, and the other motor operates so that the crank shafts 339b, 347b rotate clockwise in Figs. 9 through 12.

The rotational speeds of the upper and lower motors are controlled by a control device (not illustrated) synchronously in such a manner that the speed of rotation corresponds to the speed of the material 1 to be shaped, moving on the transfer line S, and the phase angles of the upper crank shafts 339a, 347a and the lower crank shafts 339b, 347b are symmetrical with respect to the transfer line S.

When the material 1 to be shaped is reduced and formed by the plate reduction press apparatus as shown in Figs. 9 through 13, position adjusting screws (not illustrated) for the lower shaft boxes 337b, 345b of the transfer line S are rotated appropriately, thereby the space between the upper dies 330a, 330b and the space between the downstream dies 333a, 333b are determined according to the plate thickness of the material 1 to be reduced and formed.

Also, both of the motors (not illustrated) connected to the synchronous drive mechanisms 356a, 356b are operated to rotate the crank shafts 339a, 347a above the transfer line S counterclockwise and the crank shafts 339b, 347b below the transfer line S clockwise.

Thus, as the crank shafts 339a, 339b rotate the displacements of the eccentric portions 340a, 340b, are transmitted to the upstream sliders 324a, 324b through the rods 342a, 342b, and the upstream dies 330a, 330b move towards and away from the transfer lines S together with the above-mentioned upstream sliders 324a, 324b, and as the crank shafts 347a, 347b rotate the displacements of the eccentric portions 348a, 348b are transmitted to the downstream sliders 325a, 325b through the rods 350a, 350b, and the downstream dies 333a, 333b move towards and away from the transfer line S in the reverse phase to the aforementioned upstream dies 330a, 330b, together with the above-mentioned sliders 325a, 325b.

Moreover, when the upstream dies 330a, 330b move towards the transfer line S, hydraulic pressure is applied to the fluid chambers on the head side of the upstream hydraulic cylinders 352a, 352b, and the upstream dies 330 a, 330b are moved to the downstream B side of the transfer line (see Figs. 10 and 11), and when the upstream dies 330a, 330b move away from the transfer line S, hydraulic pressure is applied to the fluid chambers on the rod side of the upstream hydraulic cylinders 352a, 352b, so that the upstream dies 330a, 330b are moved towards the upstream A side of the transfer line (see Figs. 12 and 9).

In the same way as above, when the downstream dies 333a, 333b move towards the transfer line S, hydraulic pressure is applied to the hydraulic chambers on the rod side of the downstream hydraulic cylinders 354a, 354b, and the downstream dies 333a, 333b are moved towards the downstream B side of the transfer line (see Figs. 12 and 9), and when the downstream dies 333a, 333b move away from the transfer line S, hydraulic pressure is applied to the hydraulic chambers on the head side of the downstream hydraulic cylinders 354a, 354b, so that the downstream dies 333a, 333b are moved towards the upstream A side of the transfer line (see Figs. 10 and 11).

Next, the end on the downstream B side of the transfer line of the material 1, to be reduced and shaped in the direction of the plate thickness, is inserted between the upstream dies 330a, 330b from the upstream A side of the transfer line, and the aforementioned material 1 to be shaped is moved towards the downstream B side of the transfer line, then the first plate reduction sub-method is carried out, in which the material 1 to be shaped is reduced and formed in the direction of the plate thickness, by means of the upper and lower upstream dies 330a, 330b that move towards the transfer line S and move in the downstream B direction of the transfer line.

At this time, the downstream dies 333a, 333b are moving away from the transfer line S and moving in the upstream A direction of the transfer line.

As the material 1 to be shaped moves towards the downstream B side of the transfer line, the first plate reduction sub-method as described above presses the portion of the end near the downstream B side of the transfer line of the material 1 to be shaped, then the end near the downstream B side of the transfer line of the material 1 after being shaped by the first plate thickness reduction sub-method, is inserted between the downstream dies 333a, 333b, and the material 1 to be shaped is further reduced and formed in the direction of the plate thickness by the upper and lower downstream dies 333a, 333b that move towards the transfer line S and also move in the downstream B direction of the transfer line, and this is defined as a second plate reduction sub-method.

At this time, because the upstream dies 330a, 330b are moving away from the transfer line S and moving in the upstream A direction of the transfer line, the rotational force transmitted from the upper and lower motors to the synchronous drive mechanisms 356a, 356b can be utilized efficiently to reduce and form the material 1 to be shaped by the downstream dies 333a, 333b.

In addition, the inertia forces of the crank shafts 339a, 339b and the rods 342a, 342b of the mechanisms 336a, 336b for moving the upstream sliders, the upstream dies 330a, 330b, etc. are transmitted to the downstream dies 333a, 333b through the synchronous drive mechanisms 356a, 356b, the crank shafts 347a, 347b and the rods 350a, 350b of the mechanisms 344a, 344b, for moving the downstream sliders etc., and assist the aforementioned downstream dies 333a, 333b to reduce and form the material 1 to be shaped.

When the second plate reduction sub-method is completed for the portion of the end near the downstream B side of the transfer line of the material 1 to be shaped, the upstream dies 330a, 330b are in the farthest position from the transfer line S (see Fig. 9), and as the material 1 to be shaped moves in the downstream B direction of the transfer line, an unreduced portion of the material 1 to be shaped, which is following after the portion already reduced by the first plate reduction sub-method, is inserted between the upstream dies 330a, 330b, so that the material 1 to be shaped is reduced by the first plate reduction sub-method as the upper and lower upstream dies 330a, 330b move towards the transfer line S.

In addition, because the downstream dies 333a, 333b are moving away from the transfer line S (see Fig. 10), the rotational forces transmitted from the upper and lower motors to the synchronous drive mechanisms 356a, 356b can be utilized efficiently to reduce and form the material 1 to be shaped by the upstream dies 330a, 330b.

Furthermore, the inertia forces of the crank shafts 347a, 347b and the rods 350a, 350b of the mechanisms 344a, 344b for moving the downstream sliders, the downstream dies 333a, 333b, etc. are transmitted to the upstream dies 330 a, 330b through the synchronous drive mechanisms 356a, 356b, the crank shafts 339a, 339b and the rods 342a, 342b of the mechanisms 330a, 330b for moving the upstream sliders, etc., and assist the above-mentioned upstream dies 330a, 330b to press and form the material 1 to be shaped.

When the first plate reduction sub-method is completed for the portion of the material 1 to be shaped, as described above, the downstream dies 333a, 333b are in the farthest position from the transfer line S (see Fig. 11), and as the material 1 to be shaped moves in the downstream B direction of the transfer line, the portion of the material 1 to be shaped, that has been reduced by the first plate reduction sub-method, and is in continuation with a portion which has already been reduced by the second plate reduction sub-method, is inserted between the downstream dies 333a, 333b, and as the upper and lower downstream dies 333a, 333b move towards the transfer line S, the material 1 to be shaped is processed by the second plate reduction sub-method, and as soon as it is finished, the upstream dies 330a, -330b move away from the transfer line S (see Fig. 12).

With the plate reduction press apparatus illustrated in Figs. 9 through 13, as described above, an unreduced portion of the material to be shaped is subjected to the first plate reduction sub-method in which the portion is reduced and formed in the direction of the plate thickness by means of the upstream dies 330a, 330b, and then the portion that has been reduced and formed of the material 1 to be shaped is further reduced and formed by the downstream dies 333a, 333b in the direction of the plate thickness, according to the second plate reduction sub-method, and so the material 1 to be shaped can be efficiently reduced and formed in the direction of the plate thickness.

Because the first and second plate reduction sub-methods are operated alternately on an unreduced portion of the material 1 to be shaped and a portion which has already been reduced by the first sub-method, respectively, the loads applied to the upstream dies 330a, 330b and the downstream dies 333a, 333b during pressing can be reduced, and therefore the rotational forces of the upper and lower motors transmitted to the synchronous drive mechanisms 356a, 356b can be used efficiently.

Consequently, the strengths required for the mechanisms 336a, 336b, 344a, and 344b for moving the sliders composed of various components and members such as the housing 319, sliders 324a, 324b, 325a, and 325b, die holders 326a, 326b, 327a, and 327b, shaft boxes 337a, 337b; 345a, and 345b, crank shafts 339a, 339b, 347a, and 347b, and rods 342a, 342b, 350a, and 350b can be reduced, so that these mechanisms, components and members can be made more compact.

Moreover, when the upstream dies 330a, 330b and the downstream dies 333a, 333b reduce and form the material 1 to be shaped, the dies move towards the downstream B side of the transfer line, so the movement of the material in a backward direction towards the upstream A side of the transfer line, when the material 1 to be shaped is reduced and formed, can be avoided.

The plate reduction press apparatus and sub-methods according to the present invention are not limited only to the embodiments described above, but for example, the hydraulic cylinders can be replaced by expanding actuators such as screw jacks, for the die moving mechanisms; all the crank shafts can be rotated by a single motor; each crank shaft can be rotated by an individual motor; the number of rods that transmit the displacements of the eccentric portions of the crank shafts to the sliders can be changed; or any other modifications can be incorporated unless they deviate from the claims of the present invention.

As described above, the plate reduction press apparatus and sub-methods of the present invention provide the following various advantages.

1. (1) According to the plate reduction pressing sub-method specified in Claim 1, an unreduced portion of the material to be shaped is reduced and formed by the first plate reduction sub-method in which the upper and lower upstream dies reduce the material in the direction of the plate thickness, and then the portion of the material to be shaped, after being reduced and formed by the first sub-method, is further reduced and formed by the upper and lower downstream dies in the direction of the plate thickness,by the second plate reduction sub-method, therefore the material to be shaped can be reduced and formed efficiently in the direction of the plate thickness.
2. (2) According to the plate reduction pressing methods specified in Claim 1, the first and second plate reduction sub-methods are carried out alternately on an unreduced portion of the material to be shaped and a portion of the material to be shaped, that has been reduced by the first sub-method, consequently the loads to be applied to the upstream and downstream dies during pressing can be reduced.
3. (3) With any of the late reduction press apparatus specified in Claim 2 through 5, the mechanisms for moving the upstream sliders move the upstream dies together with the upstream sliders towards the transfer line, and an unreduced portion of the material to be shaped is reduced by the upper and lower upstream dies in the direction of the plate thickness, and then the mechanism for.moving the downstream sliders move the downstream dies together with the downstream sliders towards the transfer line, and the portion of the material to be shaped, already reduced by the upstream dies, is further reduced by the upper and lower downstream dies in the direction of the plate thickness, so that the material to be shaped can be reduced and formed efficiently in the direction of the plate thickness.
4. (4) In any of the plate reduction press apparatus specified in Claims 2 through 5, the upstream dies are moved towards and away from the transfer line by the mechanisms for moving the upstream sliders in the reverse phase to the phase that the downstream dies are moved towards and away from the transfer line by the mechanisms for moving the downstream sliders, therefore the loads applied to the upstream and downstream dies during pressing are reduced, so the strengths required for the various components and members constituting the sliders on which the dies are mounted and the mechanisms for moving the sliders, can be reduced and they can be made more compact.

Although the present invention has been explained by referring to a number of preferred embodiments, it should be understood that the scope of claims included in the specification of the present invention should not be limited only to the embodiments described above. To the contrary, the scope of rights according to the present invention shall include all modifications, corrections or the like as long as they are included in the scope of the claims attached.