Having thus described the invention what is
desired to be secured under a Letters Patent is
1. A mobile machine for the production of metal siding for a structure from continuous metal sheet stock at a job site, said machine comprising,
2. A machine as claimed in claim 1 additionally including roller means for supporting a roll of sheet stock, guide means adjustably mounted on said frame receiving a run of continuous sheet stock from said roll, said guide means including guide plates positionable laterally and vertically relative to the run of sheet stock, wheels carried by said guide plates for rotatably supporting and guiding said run into the roll elements of the initial station.
3. A machine as claimed in claim 1 wherein said rotating punching dies are freely rotatable for rotation by the passing sheet stock, other of said sets of roll elements being powered by a motor through common power transmission means.
4. The machine as claimed in claim 3 additionally including limit stop switch means remotely positionable rearwardly of said saw table for actuating contact by the leading edge of the continuous siding, said switch means being normally closed and in circuit with the motor and operable upon contact by the leading edge of the siding to open said circuit stopping the motor and said other of said sets of powered roll elements, the distance between said switch means and said saw table determining the length of siding to be cut.
5. The machine as claimed in claim 1 additionally including an extensible frame carried by said main frame of the machine, said frame supporting the pivot means of the saw table, said saw table including a gauge for reading the angular relationship of the saw guideway to the passing metal siding whereby the cut made by the saw may be along an angular course corresponding to the pitch angle of a gable portion of a wall.
6. The machine as claimed in claim 1 wherein said aligned bearing supports are recessed along their bottom wall surfaces to provide a keyway, said machine frame recessed along its uppermost surface to receive a key facilitating alignment of the bearing supports on said machine frame.
7. The machine as claimed in claim 1 wherein said punching dies comprise a pair of male and female rotating dies operable to punch a series of even spaced consecutive openings for later nailing of the siding along one of its marginal areas, additional male and female dies operable to punch intermittent weep holes in the remaining marginal area of the siding at greater intervals than the openings formed by the first mentioned pair of rotating dies.
8. The machine as claimed in claim 1 wherein said mobile base supports a walled enclosure for the remaining components of the machine, said base additionally supports a hoist externally of said housing for the loading of rolled sheet stock into place on the machine through a normally closed opening in said enclosure.
BACKGROUND OF THE INVENTION
The present invention pertains generally to a machine for forming continuous metal sheet stock into siding for application to the exterior surface of a building wall. The invention is embodied in a mobile roll machine transportable to a worksite whereat it provides a complete, operating machine for economical production of metal siding.
Metal siding for houses and other structures has recently found wide acceptance by the general public. Metal siding, particularly the embossed, painted type simulating clapboard wood siding, is attractive, of low original cost and maintenance free for several years. Often such siding is applied over existing wood siding of a structure. In the usual application of metal siding considerably effort is spent in calculating and ordering the quantity and lengths of siding components required. Further effort is required at the job site in the final cutting of siding when the siding is immediately below a pitched roof requiring a bevel end cut be made. Typically panels of metal siding are ordered cut to approximate lengths with final cutting and fitting being required of the workmen at the job site. Obviously the cutting and fitting of precut panels results in wasted material. With the present machine being operational at the job site, siding material may be custom manufactured and cut to the required lengths.
The repeated handling of the siding members greatly increases the likelihood of damage to the thin gauge metal (usually aluminum) which, if dented or creased, is unusable. Similarly the siding is usually pre-painted with a vinyl-type paint which is susceptible to being scratched by repeated handlings of the siding members. The special handling of pre-cut, painted siding results in shipping costs greatly exceeding the shipping cost of a comparable amount of sheet stock in roll form as used in the present machine.
SUMMARY OF THE INVENTION
The present invention is embodied within a roll machine of highly compact design permitting convenient mounting of the machine on a mobile base resulting in numerous advantages some of which were earlier mentioned.
The present machine includes a series of roll sets each located at a station along the machine frame and through which sets passes the continuous metal sheet stock. The sheet stock is of a gauge permitting it to be carried in compact roll form on the machine with reloading of the machine by means of a hoist mounted on the mobile base. The sheet stock is drawn from the roll and sequentially passes through the powered roll sets the latter shaping the metal edges to simulate clapboard siding. The finished siding is momentarily stopped upon its leading end contacting limit stop means, which may be located to stop siding production at any desired interval for its cutting. The continuous siding material is supported as it leaves the machine by a saw table which is swingably positionable relative to the siding material.
The machine embodies adjustable guide means for rotatably supporting and directing the sheet stock as it enters the roll sets. Rolling dies are provided for the punching of weep holes for siding ventilation and also apertures for nailing while an additional roll set is provided for correcting the sheet against any imperfections imparted to the rolled sheet stock during its manufacture and cutting.
An important object of the present invention is the provision of a machine for the production of siding which machine is of a very compact nature. The machine is of a size for mounting on a trailer or the like permitting its convenient transport to a job site whereat the siding may be advantageously produced in a customized manner to the job at hand. The sheet stock is compactly carried in its original roll form further contributing to the convenience of the present machine. Costly handling of pre-cut siding panels is avoided as is the risk of damage during handling to the light gauge metal members.
A further object is the provision of roll sets for sizing and shaping of continuous sheet stock to produce siding material with the desired sectional configuration. The roll sets are of a configuration to initially receive the sheet stock and form same all within the distance of a few feet hence the present machine lends itself to transport on a base such as a small trailer or bed of a small truck.
The machine advantageously includes adjustable means in each bearing support for precise clearance setting of each roll set by means of simple adjustment of a threaded member.
A saw table is adjustably carried by the machine rearwardly of the roll sets and supports a section of siding during cutting of same. The saw table includes a protractor-type gauge and a swingable saw guide for cutting both square and beveled ends the latter for siding terminating along a pitched roof. Cutting is done with a minimum of waste. The machine includes electrical circuitry for automatically stopping the machine after a desired length of siding has been run off by the machine by means of a switch, located remotely from the machine, for actuation by the passing end of the siding. Manually operated switch controls are also provided.
The mobile base may include an enclosure for protection of the machine from the weather with an opening in the enclosure permitting a hoist, also on the mobile base, to periodically resupply the machine with a roll of sheet stock. While the metal stock is usually aluminum, the rolls thereof are of considerable weight making the hoist accessory extremely useful.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings:
FIG. 1 is a perspective view of the present machine in place on a mobile base with an enclosure for the machine shown in phantom lines,
FIG. 2 is a side elevational view of the machine with fragments broken away for purposes of illustration,
FIG. 3 is a plan view of FIG. 2 taken approximately along line 3--3 of FIG. 2,
FIG. 4 is a detail side elevational view of a typical bearing support,
FIG. 5 is a horizontal sectional view of a bearing support taken downwardly along line 5--5 of FIG. 4,
FIG. 6 is an elevational view of a saw table taken along line 6--6 of FIG. 2,
FIG. 7 is a vertical sectional view of the saw table taken along line 7--7 of FIG. 6,
FIG. 8 is a horizontal plan view of sheet metal guide means taken along line 8--8 of FIG. 2,
FIG. 9 is a composite elevational view of the roll sets of the machine at stations S-1 through S-7,
FIG. 9A is a view similar to FIG. 9 showing roll sets at stations S-8 and S-9,
FIG. 10 is a diagrammatic composite view of the sectional configuration of the sheet metal immediately after passing the stations S-1 through S-9 indicated, and
FIG. 11 is an electrical schematic for use with the machine.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With continuing attention to the accompanying drawings wherein applied reference numerals indicate parts similarly identified in the following specification, the reference numeral 1, in FIGS. 1 through 3, indicates generally the present roll machine embodying the instant invention. The machine is disclosed as being supported by a trailer 2 constituting a mobile base which, alternatively, may be in the form of a truck bed or the like.
Mounted lengthwise on the mobile base 2 centrally thereof is a machine frame 3 elevated by supports 4, the frame 3 comprised of pairs of elongate side members which are interconnected by opposite end members. Accordingly a rigid, rectangular frame is provided with the side members being preferably of channel section and grooved 5 (FIG. 4) along their upper surfaces for alignment purposes as later elaborated upon. Located along the frame side members are cooperating bearing supports 6, the latter being in opposing pairs with each pair of bearing supports being located at a station hereinafter identified as S-1 through S-9. The term station is applied to a pair of opposed bearing supports and associated components supported thereby. A typical bearing support 6 is seen in FIG. 4 adjustably mounting upper and lower bearing blocks 7 and 8. Suitably journalled within bearing races at 9 in said bearing blocks are upper and lower roll carrying shafts 10 and 11 each having roll elements as best seen in FIG. 9.
A roll of sheet metal stock is indicated at 12 supported by a pair of flanged rollers 13 which in turn are journalled within bearings 14 mounted atop pairs of bearing supports 6. The roll of sheet metal rotates during machine operation as the several powered roll sets draw the sheet metal through the machine. To retain the initial outward run of sheet metal indicated at 15 in FIG. 1, somewhat tensioned, a drag is provided at 16 (FIG. 2) while a weighted roller at 17 is retained within intermediate pairs of upright guides at 18 and rides upon the inner periphery of the roll 12 to insure the sheet metal retaining its compact roll configuration.
The sheet metal being drawn off the roll is reversed in direction about a forward roller 20 carried by sheet metal guide means indicated generally at 21, said guide means supported by the side members of frame 3 includes means for both vertical and lateral adjusting movement relative to the frame for directing the passing run of sheet metal to the roll sets.
A detail plan view of the guide means is shown in FIG. 8 wherein four threaded supports 22 are provided with internally threaded blocks 23 carrying crosswise extending threaded shafts 24. Carried by shafts 24 are a pair of vertical guide plates 25 which may be additionally adjusted relative to the crosswise shafts 24 by means of nut elements 26 on opposite sides of each guide plate. Freely rotatable guide wheels 27 are carried by the guide plates 25 in upper and lower pairs between which pairs the sheet stock passes. The guide plates by being positionable permit the wheels to guide the passing sheet stock into precise presentation to the roll means of station S-1. The roller 20 of the guide means as well as the flanged rollers 13 carrying the sheet stock are preferably chromed to prevent damage to the vinyl coated surface of the embossed sheet stock.
The following description of a single bearing support 6 is applicable to each bearing support which, as earlier mentioned, are disposed in opposed pairs in stations S-1 through S-9 along the frame 3. The bearing supports are preferably of cast construction machined to receive upper and lower bearing blocks 7 and 8 (typically shown in FIG. 4) with the lower surface of the bearing support 6 being recessed at 6A as seen in FIG. 4 to receive an alignment key indicated at 29. The upwardly extending recess 6A extending along the lower surface of the bearing support constitutes a keyway to insure precise alignment of the bearing support on the frame 3 which, as earlier mentioned, is recessed or grooved along its length at 5. Hold down lugs 30 for each bearing support are biased downwardly by lag bolts 31 to engage foot portions 32 of the casting. A top plate 33 for each casting is held in place by bolts 34 with said plate serving to retain the upper end of adjustment means at 45 shown in the form of a bolt and nut assembly.
The adjustment means 45 of each bearing support downwardly engages the upper bearing block 7 within an internally threaded recess 46 whereby rotation of the bolt member will raise or lower the bearing block 7 relative to its companion bearing block 8. The roll elements on the upper shaft 10 adjacent the bearing block are likewise adjusted relative to their subjacent companion roll elements. Helical springs at 47 are carried within aligned recesses in the opposing top and bottom edges of the blocks 7 and 8 for biasing upper bearing block 7 and adjustment means 45 upwardly against the top plate 33. By way of example, when the sheet stock being rolled is of 0.024 thousandths thickness, the roll elements will be vertically spaced to provide approximately 0.050 thousandths spacing between upper and lower roll elements. The inner race 9 of each bearing is keyed to the ends of shafts 10 and 11 to retain the shafts against axial movement.
Each of the shafts 10 and 11, with the exception of those in the initial station S-1, are driven by means of roller chain drives and shaft mounted sprockets. With reference to FIGS. 2 and 3, wherein a housing 49 for the chains and sprockets has been shown in outline, it will be seen that a motor 50 drives through a reduction drive unit 51 with the latter driving shaft 11 in station S-9 by means of a roller chain 52. With reference to FIG. 9A and station S-9 therein it will be seen that shaft 10 additionally functions to drive a gear 53 in mesh with a gear 54 carried by upper shaft 10. Accordingly both shafts 10 and 11 of station S-9 are powered by motor 50 with sprockets at 55-56 (FIG. 2) being provided at the shafts outer ends for subsequent powering of the shafts 10 and 11 of the remaining stations with the exception of S-1. As viewed in FIGS. 2 and 3, the roller chain drives at C for the upper and lower shafts 10 and 11 is through double tooth sprockets carried by said shafts in stations S-3 through S-8 while single tooth sprockets are carried by said shafts in stations S-2 and S-9. The roll elements in station S-1 are not motor driven but are rotated by the passing sheet stock and are adapted to be manually rotated by a crank (not shown) during passage of the sheet stock leading edge during set-up of the machine for operation.
With attention to FIG. 9 showing the roll sets of each station S-1 through S-9, and particularly the initial set of rolls indicated generally at S-1, a rotating punching die is indicated at 57 with radially projecting punching elements 58 for the cutting of closely spaced openings along one margin of the sheet stock to facilitate later nailing of the panel. Synchronized with the rotating punch 57 is a companion die 60 for rolling support of the sheet and having radially disposed slots 61 for step-like reception of the punching elements 58. Timing gears at 62, keyed to shafts 10 and 11, insure synchronization of the two dies. Accordingly, a section of sheet stock passing station S-1 is apertured along one edge while the opposite edge of the sheet stock is rotatably confined between upper and lower roll elements indicated at 63-64 which also embody punch means in the form of a single cutter for piercing the other sheet edge at spaced apart intervals of several inches. These latter openings provide "weep" holes for condensation escape which occurs interiorly of applied siding. The lower roll 64 is provided with a recess to receive the punch 63A in a synchronized manner.
With continuing attention to composite FIG. 9, wherein all the roll sets are viewed from the approaching side of the sheet stock, the next set of rolls is indicated at S-2 and may be termed compensating rolls as either the right hand or left hand rolls may function to slightly elongate that marginal edge of the material passing therebetween by means of the adjustment means 45 which may lower or raise the bearing block 7 to thereby position the shaft carried roll elements. This slight elongation will compensate for irregularities imparted to the sheet stock during its manufacture and cutting with the object of such compensation being the production of a siding panel free of any linear curvature. Once the shaft carrying the upper rolls in station S-2 is adjusted further adjustment is unnecessary unless substantial changes in the gauge of the metal are encountered. As seen in FIG. 10 the metal shown passing stations S-1 and S-2 is still planar in section but having "weep" openings and nail receiving openings therein.
Initial shaping of the sheet stock into siding configuration occurs at station S-3 with the passing sheet stock being thereat configured to the sectional configuration indicated at S-3 in FIG. 10. The right hand side of each of the siding sections shown in FIG. 10 will be the uppermost edge of the simulated clapboard siding when applied to a wall, while the left hand edge of the sections will simulate the thickest or lower edge of the siding. The initial forming of the continuous sheet starts, as aforesaid, at S-3 with both edges being roll formed while at S-4 additional forming provides a vertically depending tab 68 at the left hand edge while the angularity of the right hand edge is increased.
With reference to FIGS. 9 and 10 station S-4.5 includes a pair of horizontally disposed cooperating rolls 65 and 66 acting on the depending tab with the right hand edge of the sheet remaining unchanged. The tab 68 is confined for continuous passage between the horizontal rollers by means of an idler roll 67 all of which rolls are supported by frame 3.
With attention to FIGS. 9 and 10, at S-5 formation of a flange 69 is initiated along the left hand side of the moving sheet stock while the angularity of the right hand edge is simultaneously increased.
At S-6 an inclined roll 70 forms a convoluted right hand edge 74 on the sheet stock by crowding said edge against an upper roller having a vertical surface. A support 71 adjustably carries the roll to permit precise setting of same.
At S-7 the right hand edge is inclined inwardly while the opposite left hand edge is formed by a horizontally disposed roll 72 in cooperation with a roll carried by the upper shaft. Roll 72 is adjustably mounted by a crosswise support 73 attached to the frame side members.
At S-8, the flange 69 extending along the left hand edge of the sheet stock, is moved inwardly while along the right hand edge the convoluted portion is further inclined.
At S-9 the convoluted portion is bent still further inward with a portion of said edge being returned to its original horizontal position.
Indicated generally at 75 is a saw table positionably mounted on an extensible frame 76 which frame is slidably mounted in brackets 77 on the main frame 3. At the rearward end of the extensible frame are crosswise plates 78 (FIG. 6) within which a sleeve-type bearing 80 is secured. Said bearing swingably mounts a horizontal support for the continuous siding produced by the machine which support is further adapted to receive a conventional power saw at S for cutting of the siding. A post 81 is removably mounted within the sleeve bearing 80 and is provided with a flanged portion 82 constituting a load bearing surface for the remaining components of the saw table. A framework comprises welded tubular members 83 and 84 (FIG. 7) which have end mounted plates 85 and 86. End plate 85 is attached to and supported by post 81 by a section of rectangular tubing at 87 welded to said post. For the purpose of supporting and passing siding a lower angle iron 88 is secured intermediate the upper end of the post 81 and end plate 86 while an upper angle iron member 90 is secured to tubular member 83. To prevent marring of the siding as it passes between the angle irons 88 and 90, upper and lower strips of a durable plastic are mounted thereon in closely confining relationship to the passing siding material.
A guide way for the conventional power saw S is provided by a pair of vertical flanges 91-92 extending upwardly from the two tubular members 83--84 of the framework. Accordingly, manual horizontal movement of the saw will be along the uppermost surfaces of the tubular members 83-84 to cause the rotating saw blade at B to cut the siding as seen in FIG. 7.
The post 81, being pivotally retained within sleeve 80, permits the saw guide to swing horizontally about an upright axis A which is perpendicular to one edge of the siding. Accordingly, saw cuts are made by passes of the saw S along the guideway which may be positioned normal to the siding to be cut or in angular relationship thereto for a beveled cut as would be the case for siding for a gable. For cutting beveled ends on the siding a semi-circular shaped gauge is provided at 93 over which a pointer 94 moves for indicating the angularity of the saw table to the siding. The gauge 93 is of planar shape with indices thereon indicating saw table settings for various pitched roofs.
With attention to FIG. 11 a schematic is shown for one suitable electrical circuit for the present machine. A socket receptacle 95 provides an electrical outlet for powering of the saw S. A sheet actuated limit switch 96 is put in circuit with a relay 97 by means of a three-pronged plug 98 and socket 99 which enables the limit switch to open relay operated, normally closed contacts 100-101 for opening a circuit to the reversible electric motor 50 (FIG. 3). A drum switch control is provided at 102 having three positions OFF-REVERSE-FORWARD enabling the operator to manually control the starting and stopping of motor 50 or alternatively manually start the motor 50 with limit switch 96, upon sheet contact, breaking the circuit to the motor. The limit switch 96 for operation in this manner is attached to a sheet supporting stand 102 with the arm 96A of the switch disposed in the path of the siding. The distance of switch arm 96A from the saw table guide will determine the length of the projected segment of siding to be cut. The stand 102 with switch 96 may be spaced to provide the approximate length of projected siding with the extensible frame 76 for the saw table being moved for a final setting. Once positioned all siding of a particular length may be run off with manual starting of motor 50 with stopping being by sheet actuation of limit switch 96.
For loading new rolls 12 of sheet stock into place on supporting rollers 13 a hoist 104 is provided. The upper portion of the hoist stanchion is rotatable within the lower part of the hoist to permit pick-up of a roll and subsequent positioning over an opening 105 in the trailer enclosure E and ultimately setting of the roll in place on rollers 13. A supply of sheet stock in roll form may periodically be supplied to the machine operator with the hoist facilitating transfer from a supply truck to the rollers 13.
Upon completion of the manufacturing of siding at a job site the machine is configured for travel by removal of the saw table 75 from frame 76 by lifting of post 81 from the bearing sleeve 80. Holders (not shown) are provided alongside the machine frame 3 on the trailer bed to hold the saw table in place during transport. The slidable frame 76 is then telescoped inwardly to lie alongside the machine frame to permit a removable closure to be attached in place closing the rear of the trailer.
The electrical components earlier set forth are further identified as follows and which identification is not intended to imply that other equivalent components may not be substituted for those identified: limit switch 96 as Cutler-Hammer part No. 10316H568; limit switch arm 96A as Cutler-Hammer part No. 10316H 533; relay 97 as Cutler-Hammer part No. 9575H 2683; and drum switch 102 as Cutler-Hammer part No. 9441H 268.
While I have shown but one embodiment of the invention it will be apparent to those skilled in the art that the invention may be embodied still otherwise without departing from the spirit and scope of the invention.