CA2643248A1 - Multi function metal forming apparatus and method - Google Patents
Multi function metal forming apparatus and method Download PDFInfo
- Publication number
- CA2643248A1 CA2643248A1 CA 2643248 CA2643248A CA2643248A1 CA 2643248 A1 CA2643248 A1 CA 2643248A1 CA 2643248 CA2643248 CA 2643248 CA 2643248 A CA2643248 A CA 2643248A CA 2643248 A1 CA2643248 A1 CA 2643248A1
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- Canada
- Prior art keywords
- strip
- sheet metal
- processing apparatus
- forming
- metal processing
- 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.)
- Abandoned
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Classifications
-
- 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
- B21D35/00—Combined processes according to or processes combined with methods covered by groups B21D1/00 - B21D31/00
-
- 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
- B21D43/00—Feeding, positioning or storing devices combined with, or arranged in, or specially adapted for use in connection with, apparatus for working or processing sheet metal, metal tubes or metal profiles; Associations therewith of cutting devices
- B21D43/02—Advancing work in relation to the stroke of the die or tool
- B21D43/021—Control or correction devices in association with moving strips
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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
- B21D43/00—Feeding, positioning or storing devices combined with, or arranged in, or specially adapted for use in connection with, apparatus for working or processing sheet metal, metal tubes or metal profiles; Associations therewith of cutting devices
- B21D43/28—Associations of cutting devices therewith
- B21D43/287—Devices for handling sheet or strip material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23D—PLANING; SLOTTING; SHEARING; BROACHING; SAWING; FILING; SCRAPING; LIKE OPERATIONS FOR WORKING METAL BY REMOVING MATERIAL, NOT OTHERWISE PROVIDED FOR
- B23D25/00—Machines or arrangements for shearing stock while the latter is travelling otherwise than in the direction of the cut
- B23D25/02—Flying shearing machines
- B23D25/08—Flying shearing machines having two coacting shearing blades mounted independently
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Bending Of Plates, Rods, And Pipes (AREA)
Abstract
A multi-function strip sheet metal processing apparatus having a strip feed system, and a rotary punch apparatus for receiving the strip and forming spaced apart formations along its length and punch control means for controlling the timing and location of such forming operations on the strip, and having a shear apparatus and controls for shearing the strip at spaced intervals in spaces between the spaced apart formations, and having roller die assemblies downstream of said shear apparatus, and having diagonal flange rolls for forming inner bends.
Also disclosed is a method of forming work pieces from strip sheet metal and in which the strip is processed by repeatedly punching formations at spaced intervals, repeatedly bending spaced apart flanges at spaced intervals, repeatedly shearing the strip into work pieces, and roll forming continuous flanges and formations along the work pieces.
Also disclosed is a method of forming work pieces from strip sheet metal and in which the strip is processed by repeatedly punching formations at spaced intervals, repeatedly bending spaced apart flanges at spaced intervals, repeatedly shearing the strip into work pieces, and roll forming continuous flanges and formations along the work pieces.
Description
FIELD OF THE INVENTION
The invention relates to apparatus and method for forming strip sheet metal, and in particular to such an apparatus and method having a plurality of different functions which can be performed, including punching openings, stamping and drawing flanges, cutting to length, and roll forming .
These operations can be performed on a strip in sequence one after the other, or can be performed selectively, at the wish of the operator.
The apparatus also adjusts for variations in thickness of the strip sheet material, and can be adjusted to accept material of different widths.
BACKGROUND OF THE INVENTION
Metal forming of continuous strip sheet metal is usually carried out by Roll Forming.
This well known process forms strip sheet metal into lengthwise bends and folds, along the length of the strip. In many cases such machines will accept one thickness and one width of strip, and must be manually changed over to accommodate a strip of different gauge or width characteristics.
Metal strip of a given gauge is known to exhibit minor variations in thickness. These minor variations can cause serious defects in the end product. Certain roll forming apparatus has been developed which can accommodate such variations of strip thickness, as the strip is passing through the roller stands. These machines can also be changed over from a strip having one gauge or one width to another strip with different specifications, with a minimum of down time.
Examples are shown in US Patents 6,647,754 - Variable width roll forming apparatus, 6,644,086 - Retro-fit roll forming mill with jack screw, and 6,282,932 - Axial and transverse roller die adjustment apparatus and method.
Roll forming machines do not have the ability of punching holes or forming flanges spaced apart along the strip. Rotary punching and stamping machines have been developed for this purpose. These machines will punch holes, and will form flanges around such holes, along a continuously moving strip. Cutting or shearing strip material into lengths has been carried out with flying dies. However rotary shearing is more flexible. It is also faster, and can be cut at closer intervals.
Examples of such machines are shown in US Letters Patent 6,725,751 Rotary Punch Apparatus and 6,205,898 Rotary cutoff device and method.
These machines enable a manufacturer to make a continuos strip with holes punched at intervals, and with flanges stamped around such holes, or other formations formed at spaced intervals, and such strip can be roll formed to provide longitudinal bends, in a roll former, downstream of the rotary punches.
However where such products are to be used for a specific market, for example for use as studs or joists in construction, the strip must be cut to length, into separate work pieces , for a particular job site, or market. In this case it becomes necessary to preselect the locations of the holes and flanges to be formed, at spaced intervals which match the requirements of the job site. The two ends of each cut workpiece must be free of holes and flanges, in most cases.
Machines are required having the ability to punch or not punch, stamp or not stamp, and cutters which can cut at precise lengths, in order to perform these operations satisfactorily.
Putting all these complex machines, with their own specific abilities, into a single production line, requires a very large investment.
Where production of the work pieces warrants such an investment, then this is acceptable. However in many cases a manufacturer will not have sufficient volume of orders to keep the entire line busy making one product.
The manufacturer will want a line which is capable of making a wide variety of different work pieces or products, in order to justify the large investment .
A line having numerous different functions, which can be changed over from making one work piece, to making another with a minimum of down time required for change over, will also achieve savings in floor space, and in training of skilled help.
BRIEF SUMMARY OF THE INVENTION
With a view to satisfying the need for such a machine the invention provides a multi-function strip sheet metal processing apparatus having the usual strip feed systems, and further having at least one rotary punch apparatus for receiving the strip and forming spaced apart formations along its length, and having punch control means for controlling the timing and location of such forming operations on said strip, and further having a shear apparatus and controls for shearing the strip at spaced intervals, in spaces between said spaced apart formations and having a plurality of roller die assemblies downstream of said shear apparatus, for forming lengthwise bends.
The invention further comprises such an apparatus wherein the punch control means is operable to discontinue punching while permitting said strip to pass through said punch apparatus, untouched.
The invention further comprises such an apparatus wherein the rotary punch apparatus is mounted on transverse movement means, whereby said rotary punch apparatus can be moved transversely out of alignment with said strip.
The invention further comprises such an apparatus wherein said rotary punch apparatus incorporates upper and lower rotors each carrying respective dies, and being rotatable in a forward direction for forming said strip, and being rotatable in a reverse direction, for positioning said dies .
The invention further comprises such an apparatus wherein said rotors are guided by cam follower rollers, and guide cams, and incorporating moveable gates on said guide cams for controlling said cam follower rollers.
The invention further comprises such an apparatus wherein there are two said pairs of rotors and two said pairs of dies, a first pair of said dies punching openings and flange at spaced intervals in said strip and a second pair of said dies forming alternate openings and flanges;
The invention further comprises such an apparatus wherein said punch control means is operable to speed up rotation of said rotors just prior to closing of said dies on said strip, and thereafter slowing down said rotation, as said dies close on said strip, and thereafter speeding up said rotors as said dies begin to open from said strip.
The invention further comprises such an apparatus wherein said punch control means is operable to stop rotation of said rotors and permit said strip to pass there between without contacting said dies.
The invention relates to apparatus and method for forming strip sheet metal, and in particular to such an apparatus and method having a plurality of different functions which can be performed, including punching openings, stamping and drawing flanges, cutting to length, and roll forming .
These operations can be performed on a strip in sequence one after the other, or can be performed selectively, at the wish of the operator.
The apparatus also adjusts for variations in thickness of the strip sheet material, and can be adjusted to accept material of different widths.
BACKGROUND OF THE INVENTION
Metal forming of continuous strip sheet metal is usually carried out by Roll Forming.
This well known process forms strip sheet metal into lengthwise bends and folds, along the length of the strip. In many cases such machines will accept one thickness and one width of strip, and must be manually changed over to accommodate a strip of different gauge or width characteristics.
Metal strip of a given gauge is known to exhibit minor variations in thickness. These minor variations can cause serious defects in the end product. Certain roll forming apparatus has been developed which can accommodate such variations of strip thickness, as the strip is passing through the roller stands. These machines can also be changed over from a strip having one gauge or one width to another strip with different specifications, with a minimum of down time.
Examples are shown in US Patents 6,647,754 - Variable width roll forming apparatus, 6,644,086 - Retro-fit roll forming mill with jack screw, and 6,282,932 - Axial and transverse roller die adjustment apparatus and method.
Roll forming machines do not have the ability of punching holes or forming flanges spaced apart along the strip. Rotary punching and stamping machines have been developed for this purpose. These machines will punch holes, and will form flanges around such holes, along a continuously moving strip. Cutting or shearing strip material into lengths has been carried out with flying dies. However rotary shearing is more flexible. It is also faster, and can be cut at closer intervals.
Examples of such machines are shown in US Letters Patent 6,725,751 Rotary Punch Apparatus and 6,205,898 Rotary cutoff device and method.
These machines enable a manufacturer to make a continuos strip with holes punched at intervals, and with flanges stamped around such holes, or other formations formed at spaced intervals, and such strip can be roll formed to provide longitudinal bends, in a roll former, downstream of the rotary punches.
However where such products are to be used for a specific market, for example for use as studs or joists in construction, the strip must be cut to length, into separate work pieces , for a particular job site, or market. In this case it becomes necessary to preselect the locations of the holes and flanges to be formed, at spaced intervals which match the requirements of the job site. The two ends of each cut workpiece must be free of holes and flanges, in most cases.
Machines are required having the ability to punch or not punch, stamp or not stamp, and cutters which can cut at precise lengths, in order to perform these operations satisfactorily.
Putting all these complex machines, with their own specific abilities, into a single production line, requires a very large investment.
Where production of the work pieces warrants such an investment, then this is acceptable. However in many cases a manufacturer will not have sufficient volume of orders to keep the entire line busy making one product.
The manufacturer will want a line which is capable of making a wide variety of different work pieces or products, in order to justify the large investment .
A line having numerous different functions, which can be changed over from making one work piece, to making another with a minimum of down time required for change over, will also achieve savings in floor space, and in training of skilled help.
BRIEF SUMMARY OF THE INVENTION
With a view to satisfying the need for such a machine the invention provides a multi-function strip sheet metal processing apparatus having the usual strip feed systems, and further having at least one rotary punch apparatus for receiving the strip and forming spaced apart formations along its length, and having punch control means for controlling the timing and location of such forming operations on said strip, and further having a shear apparatus and controls for shearing the strip at spaced intervals, in spaces between said spaced apart formations and having a plurality of roller die assemblies downstream of said shear apparatus, for forming lengthwise bends.
The invention further comprises such an apparatus wherein the punch control means is operable to discontinue punching while permitting said strip to pass through said punch apparatus, untouched.
The invention further comprises such an apparatus wherein the rotary punch apparatus is mounted on transverse movement means, whereby said rotary punch apparatus can be moved transversely out of alignment with said strip.
The invention further comprises such an apparatus wherein said rotary punch apparatus incorporates upper and lower rotors each carrying respective dies, and being rotatable in a forward direction for forming said strip, and being rotatable in a reverse direction, for positioning said dies .
The invention further comprises such an apparatus wherein said rotors are guided by cam follower rollers, and guide cams, and incorporating moveable gates on said guide cams for controlling said cam follower rollers.
The invention further comprises such an apparatus wherein there are two said pairs of rotors and two said pairs of dies, a first pair of said dies punching openings and flange at spaced intervals in said strip and a second pair of said dies forming alternate openings and flanges;
The invention further comprises such an apparatus wherein said punch control means is operable to speed up rotation of said rotors just prior to closing of said dies on said strip, and thereafter slowing down said rotation, as said dies close on said strip, and thereafter speeding up said rotors as said dies begin to open from said strip.
The invention further comprises such an apparatus wherein said punch control means is operable to stop rotation of said rotors and permit said strip to pass there between without contacting said dies.
The invention further comprises such an apparatus wherein said shear is operable to shear said strip at a predetermined length, and including length sensing meas sensing the length of said strip and operable to deliver a shear signal to said shear.
The invention further comprises such an apparatus and further including feed rolls positioned between said punch rotors and said shear for providing a positive feed of said strip .
The invention further comprises such an apparatus wherein forming rolls are incorporated with said feed rolls, said forming rolls engaging parts of said flanges and forming the same with longitudinal bends.
The invention further comprises such an apparatus wherein said feed rolls and forming rolls are mounted together on transverse rails , and adjustment mechanism for moving them transversely relative to said strip.
The invention further comprises such an apparatus wherein said roller die assemblies consist of lower rolls and upper rolls, and means for adjusting the spacing between said lower and upper rolls in response to variations in thickness of the work pieces.
The invention further comprises such an apparatus wherein there are right and left hand sets of lower and upper rolls, and wherein said right and left hand sets are moveable transversely away from and towards one another, to accommodate work pieces of varying width.
The invention further comprises such an apparatus wherein there are two sets of angle rolls and including swingable mounting blocks for supporting said angle rolls and adjustment means for adjusting the angular position of said mounting blocks.
The invention further comprises such an apparatus and further including feed rolls positioned between said punch rotors and said shear for providing a positive feed of said strip .
The invention further comprises such an apparatus wherein forming rolls are incorporated with said feed rolls, said forming rolls engaging parts of said flanges and forming the same with longitudinal bends.
The invention further comprises such an apparatus wherein said feed rolls and forming rolls are mounted together on transverse rails , and adjustment mechanism for moving them transversely relative to said strip.
The invention further comprises such an apparatus wherein said roller die assemblies consist of lower rolls and upper rolls, and means for adjusting the spacing between said lower and upper rolls in response to variations in thickness of the work pieces.
The invention further comprises such an apparatus wherein there are right and left hand sets of lower and upper rolls, and wherein said right and left hand sets are moveable transversely away from and towards one another, to accommodate work pieces of varying width.
The invention further comprises such an apparatus wherein there are two sets of angle rolls and including swingable mounting blocks for supporting said angle rolls and adjustment means for adjusting the angular position of said mounting blocks.
The invention provides a method of forming work pieces from a strip sheet metal supply and in which the strip is processed by repeatedly punching formations at spaced intervals, repeatedly bending spaced apart flanges at spaced intervals, repeatedly shearing the strip into work pieces, and roll forming continuous flanges along the work pieces.
The various features of novelty which characterize the invention are pointed out with more particularity in the claims annexed to and forming a part of this disclosure.
For a better understanding of the invention, its operating advantages and specific objects attained by its use, reference should be made to the accompanying drawings and descriptive matter in which there are illustrated and described preferred embodiments of the invention.
IN THE DRAWINGS
Figure 1 a is a side elevation of a first portion of a multi-function apparatus illustrating the invention;
Figure lb is a side elevation of a second portion of the multi-function apparatus illustrating the invention;
Figure 2, is a schematic illustration showing the various different stages of operations labelled a to g, that can be performed on a sheet metal work piece;
Figure 3 is a perspective illustration of three stations of the apparatus of Fig I
Figure 4 is a side elevation of the apparatus of Fig 3;
Figure 5 is a perspective illustration of one of the rotary punch portions of the apparatus;
Figure 6 is a perspective of the die carrier for the female die of the rotary punch portion of Fig 5;
Figure 7 is a is a perspective of the die carrier for the male die of the rotary punch portion of Fig 5;
Figure 8 is a perspective of one side of the guide cams for rotary punch portion of Fig 5;
Figure 9 is a side elevation of one side of the guide cams for the rotary punch portion of Fig 5, in a first position;
Figure 10 is a is a side elevation of one side of the guide cams for the rotary punch portion of Fig 5, in a second position;
Figure 11 is a perspective illustration of the feed and form portion of the apparatus;
Figure 12 is an exploded perspective illustration of one side of the feed and form portion of the apparatus;
Figure 13 is an exploded perspective illustration of the other side of the feed and form portion of the apparatus;
Figure 14 is a perspective illustration of the rotary shear portion of the apparatus;
Figure 15 is a perspective illustration of one of the shear rotors of the rotary shear portion of the apparatus;
Figure 16 is a perspective illustration of the other of the shear rotors of the rotary shear portion of the apparatus;
Figure 17 is a perspective illustration of the guide cams of the rotary shear portion;
Figure 18 is a side elevation of the guide cams of the rotary shear portion;
Figure 19 is a perspective of a lead portion of the roller die assemblies;
Figure 20 is a perspective of the trailing end portion of the roller die assemblies;
Figure 21 is a cut away perspective of the diagonal flange roll dies;
Figure 22 is an end view in elevation of the diagonal roll dies;
Figure 23 is a side elevation of the lancing rolls for forming slots in one embodiment of product; and, Figure 24 is a section along line 24- 24 of Fig 23.
DESCRIPTION OF A SPECIFIC EMBODIMENT
Referring first of all to figure 1a, it will be seen that this figure illustrates the first portion of the apparatus. This first portion begins with the uncoiler (10).
The uncoiler (10) is merely illustrative of such equipment which is typical in the roll forming art. The purpose is to receive a coil of sheet metal strip (12), and to the enable the sheet metal strip (12) to be unwound from the coil and fed into the remainder of the machinery downstream. As such, the uncoiler (10) is regarded as being well known in the art and is not specifically described in detail. Once unwound from the uncoiler (10), the sheet metal strip (12) is supported by the extendable support arms (14), which can be extended to receive the sheet metal strip (12), as it is unwound from the coil. The extendable support arms (14) are supported on the next portion of the line which comprises the flattener (16).
The flattener (16) is also a piece of equipment which is generally well known in the art and has been in use for many years. It consists of a plurality of upper and lower rolls, which engage the upper and lower sides of the sheet metal strip, and form it into a flat strip, removing any curling tendency which may have arisen as a result of the sheet metal strip being formed into a coil. The details of the flattener are not described, since it is regarded as well known in the art.
From the flattener (16), the strip passes to a first rotary punch (18), and from the first rotary punch (18) the strip passes to a second rotary punch (20). From the second rotary punch (20), the strip passed through a feed/form unit (22), and from the feed/form unit (22) the strip passes to the rotary shear (24).
Figure lb illustrates the second portion of the apparatus or roll forming line (26) ending in a stacking table (28).
It will be appreciated that this apparatus can perform a variety of different functions on a sheet metal strip (12), and is also capable of performing some of these functions, and omitting others, as may be required for a particular customer or order or product.
The various different functions can best be understood by reference to figures 2a to 2g.
Figure 2a illustrates merely a flat piece of sheet metal strip (12), as it would exit from the flattener (16).
Figure 2b represents the sheet metal strip after it passes through the first and second rotary punches (18) and (20). In this case, openings are blanked out and flanges are formed usually at right angles, around the opening formed by the rotary punches.
Figure 2c illustrates the sheet metal strip as it passes through the feed/form unit (22). In this case, the flanges on either side of the openings in the sheet metal strip are shown as being bent, usually at right angles.
Figure 2d illustrates the sheet metal strip after it passes through the rotary shear (24), and is cut into separate lengths or work pieces (32).
Figure 2e illustrates a work piece (32) as it passes through a first portion of the roll forming line (26), Fig 2 f illustrates the work pice at an intermediate stage of the roll forming line, and,.
Figure 2g illustrates the work piece as it passes through a final portion of the roll forming line (26).
It will be appreciated as explained above, that these illustrations from figures 2a to 2f show various steps or functions that can be carried out, in sequence, on the sheet metal strip (12), by use of the apparatus. It is also understood that one or more of the operations can simply be omitted if it is not required. Other operations can be performed by means of suitable controls any portion of the apparatus can be maintained inactive and out of contact with the sheet metal strip (12), so that the sheet metal strip (12) passes that portion of the apparatus without any work being performed on it at that station, or can be activated in other cases.
ROTARY PUNCH AND FORM
The first rotary punch (18) and second rotary punch (20) components of the apparatus will now be described in more detail.
The first rotary punch (18) and second rotary punch (20) are of essentially identical construction. The function of both the first rotary punch (18) and second rotary punch (20) is to punch openings or holes in the sheet metal strip (12) at spaced intervals as the sheet metal strip (12) is moving, and to form portions of the sheet metal strip (12), around the holes or the openings formed.
These operations can be performed by each of the punches, alternately.
Each of the first rotary punch (18) and second rotary punch (20) units are comprised of upper rotors (34) and lower rotors (36), mounted in upright end plates (38), and rotatable in opposite directions. Swingable die carriers (40) are carried, two on the upper rotors (34) and two on the lower rotors (36). The swingable die carriers (40) in turn support respectively male dies (42) (upper rotor) and female dies (44) (lower rotor).
The swingable die carriers (40) are swingably mounted on their respective upper rotors (34) and lower rotors (36). In order to control the swinging movement of the swingable die carriers (40), the swingable die carriers (40) are provided with cam followers (46).
The cam followers (46) engage respective inner guide cams (48) and outer guide cams (50). The inner guide cams (48) and outer guide cams (50) define predetermined guide paths, around which the cam followers (46) will run, as the upper rotors (34) and lower rotors (36) rotate. Swingable gates (52) are provided for controlling movement of the cam followers (46) as they traverse around the inner guide cams (48) and outer guide cams (50) . The swingable gates (52) are provided with abutments which permit the upper rotors (34) and lower rotors (36) to be rotated either in one direction, or in a reverse direction, so that the cam followers (46) traverse around their respective inner guide cams (48) and outer guide cams (50) either in one direction or in the opposite direction. This feature significantly assists in the operation of the entire line as will be described below. Respective drive motors (54) for each of the first rotary punch (18) and second rotary punch (20), driving through suitable drive trains, and are electronically coupled so that they may be driven in timed relation to the operation of the entire line. Each of the first rotary punch (18) and second rotary punch (20) are supported on mounting cross bars (56) extending transversely across the line.
The mounting cross bars (56) are in turn slidedly supported on slide rails (58).
In this way each of the first rotary punch (18) and second rotary punch (20) can be slid sideways out of the line, for servicing or for die changes and the like.
While there are described only two rotary punch stations, namely the first rotary punch (18) and the second rotary punch (20) it will be understood that there may be merely one station, or three or more stations, depending on the requirements of the customer.
The stations may perform various respective functions. One or more of the stations may be left inactive. In this way a wide variety of different work pieces can be produced, on the one multi-function line.
FEED AND FORM UNIT
It will be appreciated that in this embodiment the function of the first rotary punch (18) and second rotary punch (20) is to form openings through the strip, and to form flanges or edge formations around the edges of the openings, or otherwise form spaced apart formations in the strip. These edge flanges, in some construction products such as studs or joists, may require additional bends or formations, to provide specific extra features in the product. In order to provide for this, and in addition, in order to provide for a positive control over the feed of the sheet metal strip (12), the feed/form unit (22) is provided immediately downstream of the second rotary punch (20).
Referring now to figures 11, 12 and 13, it can be seen that feed/form unit (22) is made up of lower bearing blocks (60), providing lower bearings and upper bearing blocks (62), providing upper bearings. Between the two lower bearing blocks (60) there are in this case three lower die shafts (64), extending from side to side parallel to each other. Between the two upper bearing blocks (62) there are in this case three upper die shafts (66) extending from side to side. The lower die shafts (64) carry lower feed rolls (68) and the upper die shafts (66) carry respective upper feed rolls (70).
Between the three pairs of lower feed rolls (68) and upper feed rolls (70), there are two sets of angle die holders (72). The angle die holders (72) in turn hold moveable angle die rolls (74).
The angle die rolls (74) engage the flanges formed around the openings, by the first and second rotary punches and form these flanges over into additional angled formations for reasons to be described below, (Fig 2b and 2c). These angled flanges are thus formed repeatedly, spaced apart from one another, as the sheet metal strip (12) passes through the feed/form unit (22). The feed/form unit also includes a length measuring unit (76).
The lower and upper bearing blocks (60) and (62) are coupled by vertical jack screws (78) and screw drive (80). This enables the blocks to be adjusted vertically, for changes in thickness of the strip (12). Transverse jack screw (82) and drive enable the blocks to be adjusted apart or together for strips of different widths.
ROTARY SHEAR UNIT
The sheet metal strip (12), after it exits the feed/form unit (22), then passes to the rotary shear (24). The rotary shear (24) operates to shear the sheet metal strip (12) into work pieces (32) of specific lengths. As outlined above, the length of the work piece (32) will usually be a function of the construction site or particular building design for which it is intended, assuming the work piece (32) is a piece of construction material.
Work pieces of this kind such as studs and joists, for example, must have ends which are free from openings, so that they are strong. It will thus be appreciated that the rotary shear (24) must function to shear the strip in a space between two openings. It will then become apparent that the first rotary punch (18) and second rotary punch (20) must be controlled in such a way that they provide their openings and flanges at predetermined locations along the sheet metal strip (12). They must be controlled in such a way that they interrupt their operation to provide a predetermined spacing between two of the openings, in which the rotary shear (24) can then operate and shear the sheet metal strip (12).
The rotary shear (24), in order to provide its selective, intermittent shearing function, is provided with a lower shear rotor (84), and a upper shear rotor (86), mounted in registration adjacent one another, and rotatable in opposite directions. Each of the lower shear rotor (84) and upper shear rotor (86), in this embodiment, carry a respective swingable lower cutting die (88) and upper cutting die (90). The lower cutting die (88) and upper cutting die (90) are swingably mounted on their respective lower shear rotor (84) and upper shear rotor (86) in much the same fashion as the swingable die carriers (40) are mounted on there respective upper rotors (86) and lower rotors (84).
In order to swing the lower cutting die (88) and upper cutting die (90) into the correct position, and operate them for shearing the sheet metal strip (12), each of the lower cutting die (88) and upper cutting die (90) are provided with a respective rotor cam follower (92). The rotor cam follower (92) of the lower cutting die (88) and the upper cutting die (90) follow a respective rotor cam guide (94). The rotor cam guides (94) are mounted on respective side bearing plates (96). The side bearing plates (96) are mounted on a base mounting plate (98). The base mounting plate (98) in turn is adjustably moveable by means of a control screw (100), mounted in an fixed bar (102).
It should also be noted that lower cutting die (88) and upper cutting die (90) are provided with respective corner punches (104) which function to cut corners or notches in the ends of the sheet metal strip (12) work piece, when required.
It will be appreciated that the shearing function takes place after a predetermined length of the sheet metal strip (12) has passed through the rotary shear (24). The leading end of the sheet metal strip (12) will thus enter the roll forming line (26), before the sheet metal strip (12) is sheared by the rotary shear (24), in most cases. Once sheared, each separate piece of strip (12) becomes a work piece (32).
ROLL FORMING LINE
The work piece (32) will then pass along the roll forming line (26) through the various roller die stands. The various roller die stands will form edge flanges longitudinally as illustrated generally in figures 2e and 2f. It will be appreciated that the forming of the inturned flange illustrated in figure 2f will be performed as a last function.
This function is performed in a plurality of diagonal roll dies (106) which engage the inside of the work piece (32), and hold it so that it can be folded inwardly over itself as illustrated in figure 2f.
In order to provide for variations in the gauge or thickness of the sheet metal strip (12), the clearance between dies carried on the roller die stands (108) can be adjusted while the line is in operation. This is achieved by means of the lower support plate (110) supporting the lower dies in each roller die stands (108), and the upper support plate (112) supporting the upper dies in each roller die stands (108). The upper support plate (112) is adjustable upwardly and downwardly relative to the lower support plate (110).
Vertical jack screws (114) are provided at spaced intervals, operated by suitable drive means. The thickness of the sheet metal strip (12) can be sensed, for example, by measuring unit (76) in the feed/form unit (22), or by providing an independent gauge sensor (not shown).
In order to provide accommodation for variations in the width of the sheet metal strip, the lower support plate (110) and upper support plate (112) of each roller die stands (108) can be adjusted transversely by means of transverse adjustment screws (116) and suitable drive means.
The diagonal roll dies (106) are adjustable vertically, by means of vertical jack screw (118), and are also adjustable transversely by means of transverse adjustment screws (120).
Opposite to each of the diagonal roll dies there is a complementary vertical bearing roll (122) which bears against the side flange of the workpiece .
The diagonal roll dies (106) and their respective vertical bearing rolls (122) are thus offset right and left lengthwise along two of the work piece (32).
Certain products are required to have a series of closely spaced openings .
Such products typically include stud products for embedment in concrete panels. By providing such closely spaced openings, in the part of the stud that is embedded in concrete, concrete can flow through the openings and thus form a secure bond with each stud.
For this purpose, a pair of lancing rolls (124) are provided, located at a suitable station along the roll forming line (26).
The lancing rolls (124) consist of a upper lance roll (126) and a lower lance roll (128), driven by suitable gears (Fig 23-24).
The lower lance roll (128) has suitable lance formations, and the upper lance roll (126) has recesses complementing them. As an edge portion of a work pieces passes between them a series of openings will be lanced out, closely spaced apart there along.
For other products, where such openings are not required, then the upper lance roll (126) can be raised up by lance roll screw (130).
OPERATION
The production of a typical series of workpieces on the apparatus will proceed essentially as follows;
A coil of strip sheet metal (12) is mounted on the uncoiler (10). Such sheet metal will pass through the flattener (14), and from there to the first rotary punch (18) and to the second rotary punch (20). In the two punch stations the first and second punches in most cases will both punch openings through the metal, the openings being punched by the first and second punches alternately, so that the openings can be as close together as is required for the product. It will be appreciated that if openings are required which are further apart that it may be possible to perform all of this using only one of the two punch stations.
Each of the rotary punch units is capable of blanking out openings through the strip, and also forming edge flanges around the openings when required. In addition the rotary punch units are also capable of forming transverse and diagonal ridges and grooves across the work piece for additional strength, and forming other depressions in the strip depending upon the nature of the product that is being produced. A
typical cycle of one of the rotary punches will be to rotate both the upper rotors (34) and the lower rotors (36) simultaneously in the forward direction, bringing the male dies (42) and the female dies (44) around so that they engage and blank out and form the sheet metal and then open apart once more. These operations will require the upper rotors (34) and lower rotors (36) to start off at a predetermined first rotational speed, and then gradually slow down until they are fully engaged with the sheet metal and then speed up again as they open. This is achieved both by the cam followers with the inner guide cams (48) and outer guide cams (50) respectively and also by the central processing controller (30) controlling the speed of the drive motors. In some cases it is possible for the upper rotors (34) and the lower rotors (36) to be reversed so that they rotate in the opposite direction to the direction of travel of the sheet metal.
After passing through the first rotary punch (18) and second rotary punch (20), the sheet metal strip then passes into the feed and form unit (22). In the feed/form unit (22), the sheet metal is securely engaged by the feed rollers (68) and (70), mounted on lower die shafts and upper die shafts. Between the feed rollers, the angle die rolls (74), mounted on angle die holder (72), operate to engage the upstanding flanges around the openings on the strip sheet metal. As each flange is engaged, it is bent outwardly at 90 degrees, so as to lie in a plane substantially spaced from and parallel to the plane of the strip itself. These bends form the flanges into generally three sided channel shapes for added strength. These channels extend lengthwise anlong the shorter and longer linear sides of each main opening. At the same time the length of the strip passing through the feed/form unit (22) is sensed and detected by the length measuring unit (76). The length measuring unit (76) continuously feeds length signals to the central processing controller (30).
The central processing controller (30) will receive such length signals and at the appropriate moment deliver a cut signal to the rotary shear (24) unit. This will cause the lower shear rotor and the upper shear rotor to rotate in unison forwardly, bringing the lower cutting die and upper cutting die into contact with the strip, shearing it between two adjacent openings.
As explained above, where the end use of the work pieces is in construction, for example, then both ends of each workpiece must be free of openings. For this purpose, the central processing controller (30) will have delivered "punch," or "no punch" signals to the first rotary punch (18) and second rotary punch (20). The precise measurement of the workpiece therefore will control both the operation of the first rotary punch (18) and second rotary punch (20), and will withhold them from operation when a space is required between two openings to signify the beginning or the end of the workpiece (32). The same central processing controller (30) will signal rotary shear (24) to shear the workpiece in the extra space allowed between the two openings.
As the rotary shear cuts the strip, the leading end of the strip has already entered the roll forming line and has been gripped by the rolls in that line so that although it has been sheared upstream of the roll forming line its progress through the roll forming line is controlled.
In the case of the majority of the products, the roll forming line will progressively form edge flanges longitudinally along both edges of the workpiece simultaneously, which are substantially identical, as shown in the progressive views in Figure 2a to 2g.
However, if the product being produced is required to have an edge flange for embedment in a concrete panel, then one edge of the work piece is turned out at an angle, after that edge has passed through the rotary lance (124). The rotary lance (124) will form a series of closely spaced openings in the one edge of the work piece. That edge will then be rolled into the angular Z shape required for embedment.
In order to form the edge flanges to close tolerances, the diagonal rolls engage the workpiece and deliver accurate inside corners.
Various different work pieces can be formed on the apparatus. Usually, though not exclusively they will be some form of metal stud used in construction.
These may be simple C-section, or thermal studs, with openings formed in various patterns to reduce thermal conduction.
Another form of stud is used in making composite thin shell concrete panels.
This form of work piece is for use in forming composite reinforced concrete and steel panels.
Such concrete and steel reinforced panels are known in the art. A thin shell of concrete is reinforced by a framework of metal work pieces, having edge portions embedded in the concrete.
In these work pieces, it will be appreciated that in the vast majority of cases the work piece will have two ends so that it can be put in place in construction.
For this purpose, while openings will be formed along the length of each stud , the ends of the studs are formed solid - i.e. openings have not been formed at the ends. This function is achieved by signals sent from the CPU to the first and second punching rotors, to allow a greater length of strip metal to pass between them without being punched or formed at all. Such similar signals will be sent by the CPU to the rotary shear (24) , to shear the work piece in such a space between openings.
In cases where embedment studs are required to be formed into a framework, embedment flanges are formed along one, or both edges. However, at each end of the work piece the flanges will be notched out. This is achieved by the rotary shear (24) and the corner punches (104) incorporated in the rotary shear. In this way it is possible for the embedment studs to be formed with the embedment flange turned outwardly, and, by providing notches at each end of such embedment flanges the embedment flanges can be seated in conventional C-section studs, to form a generally rectangular reinforcing framework.
It will thus be appreciated that all of these forms of studs, and others not illustrated, can be made on the apparatus described above, giving the apparatus great flexibility in production. In addition, these various products can be made one after the other by simply changing various parts of the apparatus described above without requirement for major down time, stripping the machine and retooling it extensively.
Indeed much of the tooling can be left in place, and when for example lancing of slotted openings is not required the lance is simply disabled. When main openings are not required, one or both of the rotary punches can be disabled.
By operation of the CPU, the timing of the operation of the rotary punches, and the rotary shear, can be regulated to produce studs with openings at various centres, and work pieces of various lengths, having end portions without openings, for particular orders.
The foregoing is a description of a preferred embodiment of the invention which is given here by way of example only. The invention is not to be taken as limited to any of the specific features as described, but comprehends all such variations thereof as come within the scope of the appended claims.
For a better understanding of the invention, its operating advantages and specific objects attained by its use, reference should be made to the accompanying drawings and descriptive matter in which there are illustrated and described preferred embodiments of the invention.
IN THE DRAWINGS
Figure 1 a is a side elevation of a first portion of a multi-function apparatus illustrating the invention;
Figure lb is a side elevation of a second portion of the multi-function apparatus illustrating the invention;
Figure 2, is a schematic illustration showing the various different stages of operations labelled a to g, that can be performed on a sheet metal work piece;
Figure 3 is a perspective illustration of three stations of the apparatus of Fig I
Figure 4 is a side elevation of the apparatus of Fig 3;
Figure 5 is a perspective illustration of one of the rotary punch portions of the apparatus;
Figure 6 is a perspective of the die carrier for the female die of the rotary punch portion of Fig 5;
Figure 7 is a is a perspective of the die carrier for the male die of the rotary punch portion of Fig 5;
Figure 8 is a perspective of one side of the guide cams for rotary punch portion of Fig 5;
Figure 9 is a side elevation of one side of the guide cams for the rotary punch portion of Fig 5, in a first position;
Figure 10 is a is a side elevation of one side of the guide cams for the rotary punch portion of Fig 5, in a second position;
Figure 11 is a perspective illustration of the feed and form portion of the apparatus;
Figure 12 is an exploded perspective illustration of one side of the feed and form portion of the apparatus;
Figure 13 is an exploded perspective illustration of the other side of the feed and form portion of the apparatus;
Figure 14 is a perspective illustration of the rotary shear portion of the apparatus;
Figure 15 is a perspective illustration of one of the shear rotors of the rotary shear portion of the apparatus;
Figure 16 is a perspective illustration of the other of the shear rotors of the rotary shear portion of the apparatus;
Figure 17 is a perspective illustration of the guide cams of the rotary shear portion;
Figure 18 is a side elevation of the guide cams of the rotary shear portion;
Figure 19 is a perspective of a lead portion of the roller die assemblies;
Figure 20 is a perspective of the trailing end portion of the roller die assemblies;
Figure 21 is a cut away perspective of the diagonal flange roll dies;
Figure 22 is an end view in elevation of the diagonal roll dies;
Figure 23 is a side elevation of the lancing rolls for forming slots in one embodiment of product; and, Figure 24 is a section along line 24- 24 of Fig 23.
DESCRIPTION OF A SPECIFIC EMBODIMENT
Referring first of all to figure 1a, it will be seen that this figure illustrates the first portion of the apparatus. This first portion begins with the uncoiler (10).
The uncoiler (10) is merely illustrative of such equipment which is typical in the roll forming art. The purpose is to receive a coil of sheet metal strip (12), and to the enable the sheet metal strip (12) to be unwound from the coil and fed into the remainder of the machinery downstream. As such, the uncoiler (10) is regarded as being well known in the art and is not specifically described in detail. Once unwound from the uncoiler (10), the sheet metal strip (12) is supported by the extendable support arms (14), which can be extended to receive the sheet metal strip (12), as it is unwound from the coil. The extendable support arms (14) are supported on the next portion of the line which comprises the flattener (16).
The flattener (16) is also a piece of equipment which is generally well known in the art and has been in use for many years. It consists of a plurality of upper and lower rolls, which engage the upper and lower sides of the sheet metal strip, and form it into a flat strip, removing any curling tendency which may have arisen as a result of the sheet metal strip being formed into a coil. The details of the flattener are not described, since it is regarded as well known in the art.
From the flattener (16), the strip passes to a first rotary punch (18), and from the first rotary punch (18) the strip passes to a second rotary punch (20). From the second rotary punch (20), the strip passed through a feed/form unit (22), and from the feed/form unit (22) the strip passes to the rotary shear (24).
Figure lb illustrates the second portion of the apparatus or roll forming line (26) ending in a stacking table (28).
It will be appreciated that this apparatus can perform a variety of different functions on a sheet metal strip (12), and is also capable of performing some of these functions, and omitting others, as may be required for a particular customer or order or product.
The various different functions can best be understood by reference to figures 2a to 2g.
Figure 2a illustrates merely a flat piece of sheet metal strip (12), as it would exit from the flattener (16).
Figure 2b represents the sheet metal strip after it passes through the first and second rotary punches (18) and (20). In this case, openings are blanked out and flanges are formed usually at right angles, around the opening formed by the rotary punches.
Figure 2c illustrates the sheet metal strip as it passes through the feed/form unit (22). In this case, the flanges on either side of the openings in the sheet metal strip are shown as being bent, usually at right angles.
Figure 2d illustrates the sheet metal strip after it passes through the rotary shear (24), and is cut into separate lengths or work pieces (32).
Figure 2e illustrates a work piece (32) as it passes through a first portion of the roll forming line (26), Fig 2 f illustrates the work pice at an intermediate stage of the roll forming line, and,.
Figure 2g illustrates the work piece as it passes through a final portion of the roll forming line (26).
It will be appreciated as explained above, that these illustrations from figures 2a to 2f show various steps or functions that can be carried out, in sequence, on the sheet metal strip (12), by use of the apparatus. It is also understood that one or more of the operations can simply be omitted if it is not required. Other operations can be performed by means of suitable controls any portion of the apparatus can be maintained inactive and out of contact with the sheet metal strip (12), so that the sheet metal strip (12) passes that portion of the apparatus without any work being performed on it at that station, or can be activated in other cases.
ROTARY PUNCH AND FORM
The first rotary punch (18) and second rotary punch (20) components of the apparatus will now be described in more detail.
The first rotary punch (18) and second rotary punch (20) are of essentially identical construction. The function of both the first rotary punch (18) and second rotary punch (20) is to punch openings or holes in the sheet metal strip (12) at spaced intervals as the sheet metal strip (12) is moving, and to form portions of the sheet metal strip (12), around the holes or the openings formed.
These operations can be performed by each of the punches, alternately.
Each of the first rotary punch (18) and second rotary punch (20) units are comprised of upper rotors (34) and lower rotors (36), mounted in upright end plates (38), and rotatable in opposite directions. Swingable die carriers (40) are carried, two on the upper rotors (34) and two on the lower rotors (36). The swingable die carriers (40) in turn support respectively male dies (42) (upper rotor) and female dies (44) (lower rotor).
The swingable die carriers (40) are swingably mounted on their respective upper rotors (34) and lower rotors (36). In order to control the swinging movement of the swingable die carriers (40), the swingable die carriers (40) are provided with cam followers (46).
The cam followers (46) engage respective inner guide cams (48) and outer guide cams (50). The inner guide cams (48) and outer guide cams (50) define predetermined guide paths, around which the cam followers (46) will run, as the upper rotors (34) and lower rotors (36) rotate. Swingable gates (52) are provided for controlling movement of the cam followers (46) as they traverse around the inner guide cams (48) and outer guide cams (50) . The swingable gates (52) are provided with abutments which permit the upper rotors (34) and lower rotors (36) to be rotated either in one direction, or in a reverse direction, so that the cam followers (46) traverse around their respective inner guide cams (48) and outer guide cams (50) either in one direction or in the opposite direction. This feature significantly assists in the operation of the entire line as will be described below. Respective drive motors (54) for each of the first rotary punch (18) and second rotary punch (20), driving through suitable drive trains, and are electronically coupled so that they may be driven in timed relation to the operation of the entire line. Each of the first rotary punch (18) and second rotary punch (20) are supported on mounting cross bars (56) extending transversely across the line.
The mounting cross bars (56) are in turn slidedly supported on slide rails (58).
In this way each of the first rotary punch (18) and second rotary punch (20) can be slid sideways out of the line, for servicing or for die changes and the like.
While there are described only two rotary punch stations, namely the first rotary punch (18) and the second rotary punch (20) it will be understood that there may be merely one station, or three or more stations, depending on the requirements of the customer.
The stations may perform various respective functions. One or more of the stations may be left inactive. In this way a wide variety of different work pieces can be produced, on the one multi-function line.
FEED AND FORM UNIT
It will be appreciated that in this embodiment the function of the first rotary punch (18) and second rotary punch (20) is to form openings through the strip, and to form flanges or edge formations around the edges of the openings, or otherwise form spaced apart formations in the strip. These edge flanges, in some construction products such as studs or joists, may require additional bends or formations, to provide specific extra features in the product. In order to provide for this, and in addition, in order to provide for a positive control over the feed of the sheet metal strip (12), the feed/form unit (22) is provided immediately downstream of the second rotary punch (20).
Referring now to figures 11, 12 and 13, it can be seen that feed/form unit (22) is made up of lower bearing blocks (60), providing lower bearings and upper bearing blocks (62), providing upper bearings. Between the two lower bearing blocks (60) there are in this case three lower die shafts (64), extending from side to side parallel to each other. Between the two upper bearing blocks (62) there are in this case three upper die shafts (66) extending from side to side. The lower die shafts (64) carry lower feed rolls (68) and the upper die shafts (66) carry respective upper feed rolls (70).
Between the three pairs of lower feed rolls (68) and upper feed rolls (70), there are two sets of angle die holders (72). The angle die holders (72) in turn hold moveable angle die rolls (74).
The angle die rolls (74) engage the flanges formed around the openings, by the first and second rotary punches and form these flanges over into additional angled formations for reasons to be described below, (Fig 2b and 2c). These angled flanges are thus formed repeatedly, spaced apart from one another, as the sheet metal strip (12) passes through the feed/form unit (22). The feed/form unit also includes a length measuring unit (76).
The lower and upper bearing blocks (60) and (62) are coupled by vertical jack screws (78) and screw drive (80). This enables the blocks to be adjusted vertically, for changes in thickness of the strip (12). Transverse jack screw (82) and drive enable the blocks to be adjusted apart or together for strips of different widths.
ROTARY SHEAR UNIT
The sheet metal strip (12), after it exits the feed/form unit (22), then passes to the rotary shear (24). The rotary shear (24) operates to shear the sheet metal strip (12) into work pieces (32) of specific lengths. As outlined above, the length of the work piece (32) will usually be a function of the construction site or particular building design for which it is intended, assuming the work piece (32) is a piece of construction material.
Work pieces of this kind such as studs and joists, for example, must have ends which are free from openings, so that they are strong. It will thus be appreciated that the rotary shear (24) must function to shear the strip in a space between two openings. It will then become apparent that the first rotary punch (18) and second rotary punch (20) must be controlled in such a way that they provide their openings and flanges at predetermined locations along the sheet metal strip (12). They must be controlled in such a way that they interrupt their operation to provide a predetermined spacing between two of the openings, in which the rotary shear (24) can then operate and shear the sheet metal strip (12).
The rotary shear (24), in order to provide its selective, intermittent shearing function, is provided with a lower shear rotor (84), and a upper shear rotor (86), mounted in registration adjacent one another, and rotatable in opposite directions. Each of the lower shear rotor (84) and upper shear rotor (86), in this embodiment, carry a respective swingable lower cutting die (88) and upper cutting die (90). The lower cutting die (88) and upper cutting die (90) are swingably mounted on their respective lower shear rotor (84) and upper shear rotor (86) in much the same fashion as the swingable die carriers (40) are mounted on there respective upper rotors (86) and lower rotors (84).
In order to swing the lower cutting die (88) and upper cutting die (90) into the correct position, and operate them for shearing the sheet metal strip (12), each of the lower cutting die (88) and upper cutting die (90) are provided with a respective rotor cam follower (92). The rotor cam follower (92) of the lower cutting die (88) and the upper cutting die (90) follow a respective rotor cam guide (94). The rotor cam guides (94) are mounted on respective side bearing plates (96). The side bearing plates (96) are mounted on a base mounting plate (98). The base mounting plate (98) in turn is adjustably moveable by means of a control screw (100), mounted in an fixed bar (102).
It should also be noted that lower cutting die (88) and upper cutting die (90) are provided with respective corner punches (104) which function to cut corners or notches in the ends of the sheet metal strip (12) work piece, when required.
It will be appreciated that the shearing function takes place after a predetermined length of the sheet metal strip (12) has passed through the rotary shear (24). The leading end of the sheet metal strip (12) will thus enter the roll forming line (26), before the sheet metal strip (12) is sheared by the rotary shear (24), in most cases. Once sheared, each separate piece of strip (12) becomes a work piece (32).
ROLL FORMING LINE
The work piece (32) will then pass along the roll forming line (26) through the various roller die stands. The various roller die stands will form edge flanges longitudinally as illustrated generally in figures 2e and 2f. It will be appreciated that the forming of the inturned flange illustrated in figure 2f will be performed as a last function.
This function is performed in a plurality of diagonal roll dies (106) which engage the inside of the work piece (32), and hold it so that it can be folded inwardly over itself as illustrated in figure 2f.
In order to provide for variations in the gauge or thickness of the sheet metal strip (12), the clearance between dies carried on the roller die stands (108) can be adjusted while the line is in operation. This is achieved by means of the lower support plate (110) supporting the lower dies in each roller die stands (108), and the upper support plate (112) supporting the upper dies in each roller die stands (108). The upper support plate (112) is adjustable upwardly and downwardly relative to the lower support plate (110).
Vertical jack screws (114) are provided at spaced intervals, operated by suitable drive means. The thickness of the sheet metal strip (12) can be sensed, for example, by measuring unit (76) in the feed/form unit (22), or by providing an independent gauge sensor (not shown).
In order to provide accommodation for variations in the width of the sheet metal strip, the lower support plate (110) and upper support plate (112) of each roller die stands (108) can be adjusted transversely by means of transverse adjustment screws (116) and suitable drive means.
The diagonal roll dies (106) are adjustable vertically, by means of vertical jack screw (118), and are also adjustable transversely by means of transverse adjustment screws (120).
Opposite to each of the diagonal roll dies there is a complementary vertical bearing roll (122) which bears against the side flange of the workpiece .
The diagonal roll dies (106) and their respective vertical bearing rolls (122) are thus offset right and left lengthwise along two of the work piece (32).
Certain products are required to have a series of closely spaced openings .
Such products typically include stud products for embedment in concrete panels. By providing such closely spaced openings, in the part of the stud that is embedded in concrete, concrete can flow through the openings and thus form a secure bond with each stud.
For this purpose, a pair of lancing rolls (124) are provided, located at a suitable station along the roll forming line (26).
The lancing rolls (124) consist of a upper lance roll (126) and a lower lance roll (128), driven by suitable gears (Fig 23-24).
The lower lance roll (128) has suitable lance formations, and the upper lance roll (126) has recesses complementing them. As an edge portion of a work pieces passes between them a series of openings will be lanced out, closely spaced apart there along.
For other products, where such openings are not required, then the upper lance roll (126) can be raised up by lance roll screw (130).
OPERATION
The production of a typical series of workpieces on the apparatus will proceed essentially as follows;
A coil of strip sheet metal (12) is mounted on the uncoiler (10). Such sheet metal will pass through the flattener (14), and from there to the first rotary punch (18) and to the second rotary punch (20). In the two punch stations the first and second punches in most cases will both punch openings through the metal, the openings being punched by the first and second punches alternately, so that the openings can be as close together as is required for the product. It will be appreciated that if openings are required which are further apart that it may be possible to perform all of this using only one of the two punch stations.
Each of the rotary punch units is capable of blanking out openings through the strip, and also forming edge flanges around the openings when required. In addition the rotary punch units are also capable of forming transverse and diagonal ridges and grooves across the work piece for additional strength, and forming other depressions in the strip depending upon the nature of the product that is being produced. A
typical cycle of one of the rotary punches will be to rotate both the upper rotors (34) and the lower rotors (36) simultaneously in the forward direction, bringing the male dies (42) and the female dies (44) around so that they engage and blank out and form the sheet metal and then open apart once more. These operations will require the upper rotors (34) and lower rotors (36) to start off at a predetermined first rotational speed, and then gradually slow down until they are fully engaged with the sheet metal and then speed up again as they open. This is achieved both by the cam followers with the inner guide cams (48) and outer guide cams (50) respectively and also by the central processing controller (30) controlling the speed of the drive motors. In some cases it is possible for the upper rotors (34) and the lower rotors (36) to be reversed so that they rotate in the opposite direction to the direction of travel of the sheet metal.
After passing through the first rotary punch (18) and second rotary punch (20), the sheet metal strip then passes into the feed and form unit (22). In the feed/form unit (22), the sheet metal is securely engaged by the feed rollers (68) and (70), mounted on lower die shafts and upper die shafts. Between the feed rollers, the angle die rolls (74), mounted on angle die holder (72), operate to engage the upstanding flanges around the openings on the strip sheet metal. As each flange is engaged, it is bent outwardly at 90 degrees, so as to lie in a plane substantially spaced from and parallel to the plane of the strip itself. These bends form the flanges into generally three sided channel shapes for added strength. These channels extend lengthwise anlong the shorter and longer linear sides of each main opening. At the same time the length of the strip passing through the feed/form unit (22) is sensed and detected by the length measuring unit (76). The length measuring unit (76) continuously feeds length signals to the central processing controller (30).
The central processing controller (30) will receive such length signals and at the appropriate moment deliver a cut signal to the rotary shear (24) unit. This will cause the lower shear rotor and the upper shear rotor to rotate in unison forwardly, bringing the lower cutting die and upper cutting die into contact with the strip, shearing it between two adjacent openings.
As explained above, where the end use of the work pieces is in construction, for example, then both ends of each workpiece must be free of openings. For this purpose, the central processing controller (30) will have delivered "punch," or "no punch" signals to the first rotary punch (18) and second rotary punch (20). The precise measurement of the workpiece therefore will control both the operation of the first rotary punch (18) and second rotary punch (20), and will withhold them from operation when a space is required between two openings to signify the beginning or the end of the workpiece (32). The same central processing controller (30) will signal rotary shear (24) to shear the workpiece in the extra space allowed between the two openings.
As the rotary shear cuts the strip, the leading end of the strip has already entered the roll forming line and has been gripped by the rolls in that line so that although it has been sheared upstream of the roll forming line its progress through the roll forming line is controlled.
In the case of the majority of the products, the roll forming line will progressively form edge flanges longitudinally along both edges of the workpiece simultaneously, which are substantially identical, as shown in the progressive views in Figure 2a to 2g.
However, if the product being produced is required to have an edge flange for embedment in a concrete panel, then one edge of the work piece is turned out at an angle, after that edge has passed through the rotary lance (124). The rotary lance (124) will form a series of closely spaced openings in the one edge of the work piece. That edge will then be rolled into the angular Z shape required for embedment.
In order to form the edge flanges to close tolerances, the diagonal rolls engage the workpiece and deliver accurate inside corners.
Various different work pieces can be formed on the apparatus. Usually, though not exclusively they will be some form of metal stud used in construction.
These may be simple C-section, or thermal studs, with openings formed in various patterns to reduce thermal conduction.
Another form of stud is used in making composite thin shell concrete panels.
This form of work piece is for use in forming composite reinforced concrete and steel panels.
Such concrete and steel reinforced panels are known in the art. A thin shell of concrete is reinforced by a framework of metal work pieces, having edge portions embedded in the concrete.
In these work pieces, it will be appreciated that in the vast majority of cases the work piece will have two ends so that it can be put in place in construction.
For this purpose, while openings will be formed along the length of each stud , the ends of the studs are formed solid - i.e. openings have not been formed at the ends. This function is achieved by signals sent from the CPU to the first and second punching rotors, to allow a greater length of strip metal to pass between them without being punched or formed at all. Such similar signals will be sent by the CPU to the rotary shear (24) , to shear the work piece in such a space between openings.
In cases where embedment studs are required to be formed into a framework, embedment flanges are formed along one, or both edges. However, at each end of the work piece the flanges will be notched out. This is achieved by the rotary shear (24) and the corner punches (104) incorporated in the rotary shear. In this way it is possible for the embedment studs to be formed with the embedment flange turned outwardly, and, by providing notches at each end of such embedment flanges the embedment flanges can be seated in conventional C-section studs, to form a generally rectangular reinforcing framework.
It will thus be appreciated that all of these forms of studs, and others not illustrated, can be made on the apparatus described above, giving the apparatus great flexibility in production. In addition, these various products can be made one after the other by simply changing various parts of the apparatus described above without requirement for major down time, stripping the machine and retooling it extensively.
Indeed much of the tooling can be left in place, and when for example lancing of slotted openings is not required the lance is simply disabled. When main openings are not required, one or both of the rotary punches can be disabled.
By operation of the CPU, the timing of the operation of the rotary punches, and the rotary shear, can be regulated to produce studs with openings at various centres, and work pieces of various lengths, having end portions without openings, for particular orders.
The foregoing is a description of a preferred embodiment of the invention which is given here by way of example only. The invention is not to be taken as limited to any of the specific features as described, but comprehends all such variations thereof as come within the scope of the appended claims.
Claims (20)
1. A multi-function strip sheet metal processing apparatus having a strip feed systems, and comprising ;
one rotary punch apparatus for receiving the strip and forming spaced apart formations at least along its length;
punch control means for controlling the timing and location of such forming operations on said strip;
a shear apparatus and controls for shearing the strip at spaced intervals, in spaces between said spaced apart formations and;
a plurality of roller die assemblies downstream of said shear apparatus operable to roll length wise bends in said strip.
one rotary punch apparatus for receiving the strip and forming spaced apart formations at least along its length;
punch control means for controlling the timing and location of such forming operations on said strip;
a shear apparatus and controls for shearing the strip at spaced intervals, in spaces between said spaced apart formations and;
a plurality of roller die assemblies downstream of said shear apparatus operable to roll length wise bends in said strip.
2. A multi-function strip sheet metal processing apparatus as claimed in claim wherein said punch control means is operable to discontinue punching while permitting said strip to pass through said punch apparatus, untouched.
3. A multi-function strip sheet metal processing apparatus as claimed in claim wherein the rotary punch apparatus is mounted on transverse movement means, whereby said rotary punch apparatus can be moved transversely out of alignment with said strip.
4. A multi-function strip sheet metal processing apparatus as claimed in claim wherein said rotary punch apparatus incorporates upper and lower rotors each carrying respective dies, and being rotatable in a forward direction for forming said strip, and being rotatable in a reverse direction, for positioning said dies .
5. A multi-function strip sheet metal processing apparatus as claimed in claim wherein said rotors are guided by cam follower rollers, and guide cams, and incorporating moveable gates on said guide cams for controlling said cam follower rollers.
6. A multi-function strip sheet metal processing apparatus as claimed in claim wherein there are two said pairs of rotors and two said pairs of dies, a first pair of said dies punching openings at spaced intervals in said strip and a second pair of said dies forming edge flanges around said openings.
7. A multi-function strip sheet metal processing apparatus as claimed in claim wherein said punch control means is operable to speed up rotation of said rotors just prior to closing of said dies on said strip, and thereafter slowing down said rotation, as said dies close on said strip, and thereafter speeding up said rotors as said dies begin to open from said strip.
8. A multi-function strip sheet metal processing apparatus as claimed in claim wherein said punch control means is operable to stop rotation of said rotors and permit said strip to pass there between without contacting said dies.
9. A multi-function strip sheet metal processing apparatus as claimed in claim wherein said shear is operable to shear said strip at a predetermined length, and including length sensing meas. sensing the length of said strip and operable to deliver a shear signal to said shear.
10. A multi-function strip sheet metal processing apparatus as claimed in claim 9 and further including feed rolls positioned between said punch rotors and said shear for providing a positive feed of said strip .
11. A multi-function strip sheet metal processing apparatus as claimed in claim 10 wherein form rolls are incorporated with said feed rolls, said forming rolls engaging parts of said flanges and forming the same with longitudinal bends.
12. A multi-function strip sheet metal processing apparatus as claimed in claim 11 wherein said feed rolls and form rolls are mounted together on transverse rails , and adjustment mechanism for moving them transversely relative to said strip.
13. A multi-function strip sheet metal processing apparatus as claimed in claim 12 wherein said roller die assemblies consist of lower rolls and upper rolls, and means for adjusting the spacing between said lower and upper rolls in response to variations in thickness of the work pieces.
14. A multi-function strip sheet metal processing apparatus as claimed in claim 13 wherein there are right and left hand sets of lower and upper rolls, and wherein said right and left hand sets are moveable transversely away from and towards one another, to accommodate work pieces of varying width.
15. A multi-function strip sheet metal processing apparatus as claimed in claim 14 wherein there are two sets of angle rolls and including swingable mounting blocks for supporting said angle rolls and adjustment means for adjusting the angular position of said mounting blocks.
16. A method of forming work pieces from a strip sheet metal supply and in which the strip is processed by repeatedly punching formations at spaced intervals, repeatedly bending spaced apart flanges at spaced intervals, repeatedly shearing the strip into work pieces, and roll forming continuous flanges along the work pieces by roll forming dies between adjacent said formations.
17. The method as claimed in claim 16 including the step of repeatedly bending said flanges parallel to said strip.
18. The method as claimed in claim 17 including the step of repeatedly discontinuing punching to define a space between adjacent formation.
19. The method as claimed in claim 18 including the step of continuously sensing the length of said strip and adjusting the gaps between said roll forming dies.
20. The method as claimed in claim 19 including the step of forming inturned bends along side edges of said work pieces.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2643248 CA2643248A1 (en) | 2008-11-05 | 2008-11-05 | Multi function metal forming apparatus and method |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2643248 CA2643248A1 (en) | 2008-11-05 | 2008-11-05 | Multi function metal forming apparatus and method |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2643248A1 true CA2643248A1 (en) | 2010-05-05 |
Family
ID=42154760
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2643248 Abandoned CA2643248A1 (en) | 2008-11-05 | 2008-11-05 | Multi function metal forming apparatus and method |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2643248A1 (en) |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2016004474A1 (en) * | 2014-07-07 | 2016-01-14 | Rockhouse International Pty Ltd | Frame systems for building structures |
| CN108097781A (en) * | 2018-01-23 | 2018-06-01 | 广东新科炬机械制造有限公司 | A kind of tin bar cutting machine |
| CN111715785A (en) * | 2020-06-28 | 2020-09-29 | 洛阳市优能自动化设备有限公司 | Full-automatic production line for stamping and shearing metal plates and use method |
-
2008
- 2008-11-05 CA CA 2643248 patent/CA2643248A1/en not_active Abandoned
Cited By (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2016004474A1 (en) * | 2014-07-07 | 2016-01-14 | Rockhouse International Pty Ltd | Frame systems for building structures |
| US10151100B2 (en) | 2014-07-07 | 2018-12-11 | Rockhouse International Pty Ltd | Frame systems for building structures |
| US10895072B2 (en) | 2014-07-07 | 2021-01-19 | Rockhouse International Pty Ltd | Frame systems for building structures |
| CN108097781A (en) * | 2018-01-23 | 2018-06-01 | 广东新科炬机械制造有限公司 | A kind of tin bar cutting machine |
| CN108097781B (en) * | 2018-01-23 | 2024-04-30 | 广东新科炬机械制造有限公司 | Tin bar cutting machine |
| CN111715785A (en) * | 2020-06-28 | 2020-09-29 | 洛阳市优能自动化设备有限公司 | Full-automatic production line for stamping and shearing metal plates and use method |
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