Roll forming apparatus, method thereof, and bumper beam manufactured by the method

A roll forming apparatus, comprising:

• a first uncoiler provided at a front portion of a process line, the first uncoiler uncoiling a first coil to form a middle plate and supplying the middle plate;
• a roll core former provided at the rear of the first uncoiler in the process line, the roll core former bending the middle plate supplied from the first uncoiler to be a zigzag shape so as to form a core panel;
• a second uncoiler provided at the rear of the roll core former in the process line, the second uncoiler uncoiling upper and lower coils to form upper and lower plates, respectively, and supplying the upper and lower plates to upper and lower surfaces of the core panel, respectively;
• a guide roller provided at the rear of the second uncoiler in the process line, the guide roller guiding and aligning both sides of the core panel and the upper and lower plates supplied from the second uncoiler;
• a roller welder provided at the rear of the guide roller in the process line, the roller welder welding the core panel and the upper and lower plates by using upper and lower roller electrodes so as to make a sandwich-type composite panel;
• a brake press provided at the rear of the roller welder in the process line, the brake press boring a plurality of holes for assembling a bumper beam in the composite panel supplied from the roller welder;
• and
• a roll former unit provided at the rear of the brake press in the process line and comprising a plurality of roll formers disposed in series, the roll former unit bending the composite panel supplied from the brake press to form the bumper beam.