Title:
Die-stand for roll-forming machine
United States Patent 3914971
Abstract:
A roll-forming machine includes a plurality of roll-stands for moving material along a predetermined path and a plurality of die-stands for progressively transforming the material from an initial configuration to a desired configuration. The die-stands are mounted on and positioned by an elongate, rigid spine which permits conversion of the machine from one roll-forming configuration to another by replacing the spine and the die-stands mounted thereon with a different spine-die-stand assembly. Each die-stand includes at least one roller supporting the material for movement along the path, a toroidal roller engaging the material along the line of a desired bend, at least one primary bend roller engaging the material beyond the toroidal roller and positioned to bend the material toward the toroidal roller, and a guide roller engaging the edge of the material to absorb forces caused by the formation of bends in the material. These rollers are selectively positionable as a group to change the roll-forming configuration of the roll-forming machine. Also, one of the primary bend rollers and the guide roller may be selectively positionable relative to the toroidal roller and the support rollers to further change the roll-forming configuration of the roll-forming machine.
US Patent References:
Rolling-mill for bending angle or channel iron into different angles
Eckenroth - November 1921 - 1397271
Machine for shaping the edges of sheet material
Olson - November 1927 - 1649613
Channel-forming machine
Frahm et al. - June 1928 - 1673787
Arching mechanism
Watkins - September 1931 - 1822984
Cluster roll assembly for tube mills
Ruple - December 1964 - 3159199
Rolling-mill for bending angle or channel iron into different angles
Eckenroth - November 1921 - 1397271
Machine for shaping the edges of sheet material
Olson - November 1927 - 1649613
Channel-forming machine
Frahm et al. - June 1928 - 1673787
Arching mechanism
Watkins - September 1931 - 1822984
Cluster roll assembly for tube mills
Ruple - December 1964 - 3159199
Application Number:
05/473793
Publication Date:
10/28/1975
Filing Date:
05/28/1974
View Patent Images:
Export Citation:
Primary Class:
Other Classes:
72/181
International Classes:
B21D5/06; B21D5/08; B21B35/14; B21B35/00; B21D5/14
Field of Search:
72/178,181,179,182,176
US Patent References:
Primary Examiner:
Mehr, Milton S.
Attorney, Agent or Firm:
Richards, Harris & Medlock
Parent Case Data:
CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of co-pending application Ser. No. 355,673, filed Apr. 30, 1973 now U.S. Pat. No. 3,884,710.
Claims:
What is claimed is
1. For use in a roll-forming machine, a die-stand comprising:
2. The die-stand according to claim 1 wherein the plate supports at least two forming members and further including means for selectively varying the position of one of the forming members supported on the plate relative to the other forming members supported on the plate and thereby changing the roll-forming configuration of the roll-forming machine.
3. The die-stand according to claim 1 further characterized by:
4. For use in a roll-forming machine, a die-stand assembly comprising:
5. The die-stand assembly according to claim 4 further characterized by guide means carried by the elongate rigid spines for guiding material into the roll-forming machine, and wherein the positioning means also positions the guide means to direct materials of various widths into the roll-forming machine.
6. The die-stand assembly according to claim 4 wherein the positioning means is further characterized by:
7. The die-stand according to claim 4 further characterized by:
8. In a roll-forming machine of the type in which material is moved along a predetermined path and at least one bend is progressively formed in the material along a predetermined line, the improvement comprising:
9. The improvement according to claim 8 further including at least one positioning roller mounted at substantially the same point along the path of movement of the material through the roll-forming machine and engaging the edge of the material to absorb forces caused by the formation of bends in the material which might otherwise tend to displace the material from the predetermined path.
10. The improvement according to claim 9 further including means for selectively positioning all of the rollers relative to the path of material movement through the roll-forming machine and thereby changing the roll-forming configuration of the roll-forming machine.
11. The improvement according to claim 10 further including means for selectively positioning at least the positioning roller relative to the remaining rollers and thereby further changing the roll-forming configuration of the roll-forming configuration.
12. A roll-forming machine comprising:
13. The roll-forming machine according to claim 12 wherein each die-stand comprises a plurality of forming members and further including means for selectively locating at least one forming member of each die-stand relative to the path of material movement and relative to the positioning of the remaining forming members comprising the die-stand and thereby further changing the roll-forming configuration of the roll-forming machine.
14. The roll-forming machine according to claim 12 wherein each die-stand further comprises:
15. The roll-forming machine according to claim 12 wherein each die-stand comprises a plurality of rollers mounted on the plate and further including means for selectively varying the positioning of at least one of the rollers relative to the plate.
16. The roll-forming machine according to claim 12 wherein each die-stand is further characterized by:
17. The roll-forming machine according to claim 12 wherein each die-stand further includes at least one lead screw connected between the frame and the plate, and means for selectively rotating the lead screw and thereby varying the positioning of the plate and the forming member supported thereby relative to the frame.
18. The roll-forming machine according to claim 12 wherein each die-stand further includes:
19. The roll-forming machine according to claim 12 wherein the die-stand is further characterized by means for selectively varying the positioning of the forming member with respect to the plate and thereby changing the roll-forming configuration of the roll-forming machine.
20. The roll-forming machine according to claim 19 wherein the means for positioning the forming member relative to the plate comprises servo means connected between the plate and the forming member supported thereon.
21. The roll-forming machine according to claim 12 wherein the die-stand further includes a second plate and a second forming member supported on the second plate for engagement with material passing through the roll-forming machine to at least partially transform the material from an initial configuration to a desired configuration, and wherein the positioning means also positions the second plate.
22. The roll-forming machine according to claim 21 wherein the positioning means comprises means for effecting equal and opposite movement of the two plates relative to the path of material movement through the roll-forming machine.
1. For use in a roll-forming machine, a die-stand comprising:
2. The die-stand according to claim 1 wherein the plate supports at least two forming members and further including means for selectively varying the position of one of the forming members supported on the plate relative to the other forming members supported on the plate and thereby changing the roll-forming configuration of the roll-forming machine.
3. The die-stand according to claim 1 further characterized by:
4. For use in a roll-forming machine, a die-stand assembly comprising:
5. The die-stand assembly according to claim 4 further characterized by guide means carried by the elongate rigid spines for guiding material into the roll-forming machine, and wherein the positioning means also positions the guide means to direct materials of various widths into the roll-forming machine.
6. The die-stand assembly according to claim 4 wherein the positioning means is further characterized by:
7. The die-stand according to claim 4 further characterized by:
8. In a roll-forming machine of the type in which material is moved along a predetermined path and at least one bend is progressively formed in the material along a predetermined line, the improvement comprising:
9. The improvement according to claim 8 further including at least one positioning roller mounted at substantially the same point along the path of movement of the material through the roll-forming machine and engaging the edge of the material to absorb forces caused by the formation of bends in the material which might otherwise tend to displace the material from the predetermined path.
10. The improvement according to claim 9 further including means for selectively positioning all of the rollers relative to the path of material movement through the roll-forming machine and thereby changing the roll-forming configuration of the roll-forming machine.
11. The improvement according to claim 10 further including means for selectively positioning at least the positioning roller relative to the remaining rollers and thereby further changing the roll-forming configuration of the roll-forming configuration.
12. A roll-forming machine comprising:
13. The roll-forming machine according to claim 12 wherein each die-stand comprises a plurality of forming members and further including means for selectively locating at least one forming member of each die-stand relative to the path of material movement and relative to the positioning of the remaining forming members comprising the die-stand and thereby further changing the roll-forming configuration of the roll-forming machine.
14. The roll-forming machine according to claim 12 wherein each die-stand further comprises:
15. The roll-forming machine according to claim 12 wherein each die-stand comprises a plurality of rollers mounted on the plate and further including means for selectively varying the positioning of at least one of the rollers relative to the plate.
16. The roll-forming machine according to claim 12 wherein each die-stand is further characterized by:
17. The roll-forming machine according to claim 12 wherein each die-stand further includes at least one lead screw connected between the frame and the plate, and means for selectively rotating the lead screw and thereby varying the positioning of the plate and the forming member supported thereby relative to the frame.
18. The roll-forming machine according to claim 12 wherein each die-stand further includes:
19. The roll-forming machine according to claim 12 wherein the die-stand is further characterized by means for selectively varying the positioning of the forming member with respect to the plate and thereby changing the roll-forming configuration of the roll-forming machine.
20. The roll-forming machine according to claim 19 wherein the means for positioning the forming member relative to the plate comprises servo means connected between the plate and the forming member supported thereon.
21. The roll-forming machine according to claim 12 wherein the die-stand further includes a second plate and a second forming member supported on the second plate for engagement with material passing through the roll-forming machine to at least partially transform the material from an initial configuration to a desired configuration, and wherein the positioning means also positions the second plate.
22. The roll-forming machine according to claim 21 wherein the positioning means comprises means for effecting equal and opposite movement of the two plates relative to the path of material movement through the roll-forming machine.
Description:
BACKGROUND AND SUMMARY OF THE INVENTION
U.S. Pat. No. 3,748,884 granted to Dan L. Colbath on July 31st, 1973, discloses a roll-forming machine including a plurality of roll-stands each comprising non-forming rollers which function to move material along a predetermined path. The roll-forming machine further includes a plurality of die-stands each comprising non-driven material engaging rollers which function to transform the material from an initial configuration to a desired configuration. The die-stands are mounted on and positioned relative to the path by an elongate, rigid spine. This permits conversion of the machine from one roll-forming configuration to another by removing the spine and the die-stands attached thereto and then installing a different spine/die-stand assembly in the roll-forming machine.
In co-pending application Ser. No. 355,673 there is disclosed a roll-forming machine also including roll-stands for transporting material along a predetermined path and die-stands for progressively transforming the material from an initial configuration to a desired configuration. The roll-forming machine is similar to that described above in connection with U.S. Pat. No. 3,748,884 in that the die-stands are mounted on a rigid spine to facilitate conversion of the roll-forming machine from one roll-forming configuration to another. The major difference between the two roll-forming machines relates to the fact that in the latter machine the roll-stands comprise non-forming lower driving rollers only. Idler rollers are mounted on the spine for cooperation with the lower driving rollers to drive material through the roll-forming machine.
Although roll-forming machines incorporating the above-described inventions have enjoyed substantial commercial success, certain limitations have been encountered in their use. For example, in both machines the positioning of the material driving rollers of the roll-stands transversely relative to the direction of movement of material through the roll-forming machine is fixed. This is somewhat limiting with respect to the width of materials that can be accommodated in the roll-forming machine. Similarly, the positioning of the material engaging rollers of the die-stands of the above-described roll-forming machines is fixed. This requires the substitution of a new spine/die-stand assembly even though the roll-forming configuration represented by the new spine/die-stand assembly differs from that of the prior assembly only to a relatively minor degree.
Co-pending application Ser. No. 458,295, filed Apr. 5, 1974, by Dan L. Colbath for ROLL STAND FOR ROLL-FORMING MACHINE discloses certain improvements relating to both of the above-described roll-forming machines. In one aspect these improvements relate to accommodating roll-forming machines for use in conjunction with materials of various widths. This is accomplished by mounting the rollers of the roll-stands for selective positioning transversely with respect to the path of movement of material through the roll-forming machines.
The present invention relates to improvements in die-stands for roll-forming machines whereby the roll-forming configuration of a roll-forming machine may be changed without the necessity of installing a different spine/die-stand assembly. In accordance with the broader aspects of the invention, all of the material engaging rollers on at least one side of each die-stand are selectively positionable as a group with respect to the path of material movement through the roll-forming machine, thereby changing the roll-forming configuration of the machine. Also, certain rollers of the group may be selectively positionable with respect to the remaining rollers, thereby further changing the roll-forming configuration of the machine.
In accordance with more specific aspects of the invention, certain embodiments of the invention comprise die-stands including a rigid frame depending from the elongate, rigid spine. Plates are positioned on opposite sides of the path of movement of material through the roll-forming machine, and each plate supports at least one material engaging roller. Lead screws are rotatably supported in the frame and are threadedly engaged with members secured to the plate. Thus, upon rotation of the lead screws the plate and the material engaging rollers supported thereby are selectively positioned relative to the path of movement of material through the roll-forming machine.
In accordance with other embodiments of the invention, all of the rollers supporting the plates on one side of the path of material movement through the roll-forming machine are secured to a second elongate, rigid spine. Lead screws are provided for selectively positioning the second elongate, rigid spine and the plates supported thereby relative to the first spine and the plates and the material engaging rollers supported thereby. In either case guide apparatus comprising part of the spine/die-stand assembly is adjusted simultaneously with any change in the positioning of the material engaging rollers relative to the path of movement through the roll-forming machine.
In accordance with another aspect of the invention, each die-stand comprises at least one roller which supports the material for movement through the roll-forming machine. A toroidal roller engages the material along the line of a desired bend in the material. At least one primary bend roller engages the material at a point beyond the toroidal roller and is positioned to bend the material toward the toroidal roller. The toroidal roller is mounted for rotation in a plane which bisects the plane of rotation of the supporting roller and the plane of rotation of the material engaging roller. Finally, a guide roller engages the edge of the material and serves to absorb forces resulting from the formation of bends in the material which might otherwise tend to drive the material out of its path of movement through the roll-forming machine.
DESCRIPTION OF THE DRAWINGS
A more complete understanding of the invention may be had by reference to the following Detailed Description when taken in conjunction with the accompanying Drawings, wherein:
FIG. 1 is an illustration of a typical roll-forming shape;
FIG. 2 is an illustration of a sub-die-stand having a roller grouping arranged in accordance with the present invention;
FIG. 3 is an illustration of a die-stand incorporating a first embodiment of the invention;
FIG. 4 is an illustration of the guide assembly of a spine/die-stand assembly incorporating the first embodiment of the invention;
FIG. 5 is an illustration of a spine/die-stand assembly incorporating the first embodiment of the invention;
FIG. 6 is an illustration of a die-stand incorporating another aspect of the invention;
FIG. 7 is an illustration of a die-stand incorporating a second embodiment of the invention; and
FIG. 8 is an illustration of a spine/die-stand assembly incorporating the second embodiment of the invention.
DETAILED DESCRIPTION
Referring now to the Drawings, and particularly to FIG. 1 thereof, there is shown a workpiece 10 which may be considered as representative of the type of workpiece that is formed in a roll-forming machine. The workpiece 10 includes a base or web 12 and opposed sides or flanges 14. The flanges 14 are separated from the web 12 by bends 16 and extend to edges 18. The workpiece 10 is received in the roll-forming machine in an entirely flat state, and the flanges 14 are progressively formed in the workpiece 10 as the workpiece travels through the roll-forming machine. Those skilled in the art will appreciate the fact that the workpiece 10 illustrated in FIG. 1 is representative only, and in particular that workpieces formed by roll-forming machines incorporating the present invention may be either substantially less complicated or substantially more complicated than the workpiece of FIG. 1. This is particularly true with respect to the flanges of the workpiece, each of which may comprise one or more additional bends to provide inwardly or outwardly turned lips, etc. in accordance with the requirements of a particular application.
In FIG. 2 there is shown a representative sub-die-stand 20 incorporating the present invention. The sub-die-stand 20 includes a supporting plate 22 having a slot 24 formed therein which receives the workpiece 10. A set of rollers 26 is supported on the plate 22 for engagement with a workpiece 10 passing through the slot 24.
The set of rollers 26 of the sub-die-stand 20 includes a pair of support rollers 28 which are rotatably supported on a shaft 30 for engagement with the base 12 of the workpiece 10. The shaft 30 is in turn supported by a bracket 32 which is secured to the plate 22 by means of fasteners 34. A toroidal roller 36 is positioned for engagement with the workpiece 10 along a line corresponding to the bend 16. As used herein the term "toroidal roller" means a roller having a material engaging surface which is curved at right angles to the axis of rotation of the rollers to form the outer surface of a toroid, as opposed to a cylindrical roller which has a material engaging surface which is parallel to the axis of rotation of the roller. The toroidal roller 36 is rotatably supported on a shaft 38 which is in turn supported on the plate 22 by means of a bracket 40 and fasteners 42.
At least one primary bend roller 44 is mounted for engagement with the workpiece 10 at a point beyond the line of engagement of the toroidal roller 36 with the workpiece. The primary bend roller 44 is rotatably supported on a shaft 46 which is in turn secured to the plate 22 by means of a bracket 48 and a pair of fasteners 50. As will be understood by those skilled in the art, the primary bend roller 44 is so positioned as to bend the outer portion of the workpiece 10 towards the toroidal rollers 36, thererby partially forming the flange 14 and the bend 16 on one side of the workpiece. A guide roller 52 is mounted on the plate 22 for engagement with one edge 18 of the workpiece 10. The guide roller 52 is rotatably supported of a shaft 54 which is in turn secured to the plate 22 by means of a bracket 56 and a pair of fasteners 58.
As is well known in the art, the conventional roller arrangement can cause numerous problems in the operation of a roll-forming machine. For example, if a bend is formed on one side only of a workpiece, the forces which are imposed on the workpiece in the formation of the bend typically cause the workpiece to tend to move out of its proper path through the roll-forming machine. Even if identical bends are formed in the opposite sides of the workpiece, the forces which are applied to the workpiece in the formation of the bends can cause buckling of the center portion of the workpiece, particularly in the case of a relatively wide workpiece. Finally, variations in the workpiece such as non-uniformity of thickness, etc. can cause the workpiece to tend to move out of its proper path of travel even though the forces which are applied in the formation of bends in the workpiece are wholly contained.
The roller arrangement 26 of FIG. 2 overcomes these and other problems of the prior art. The toroidal roller 36 is mounted for rotation in a plane which bisects the plane of rotation of the support rollers 28 and the plane of rotation of the primary bend roller 44. This fact together with the toroidal configuration of the roller 36 causes the roller 36 to absorb substantially the entire force which is applied to the workpiece by the primary bend roller 44 in forming the bend 16 and the flange 14. Additionally, the guide roller 52 absorbs any forces not absorbed by the toroidal roller 36 and/or forces resulting from variations in material thickness, etc. and thereby constrains the workpiece to movement along its proper path of travel through the roll-forming machine. In this regard, it will be understood that the roller 52 illustrated in FIG. 2 functions primarily to absorb forces generated on the opposite side of the roll-forming machine and/or forces tending to move the workpiece to the right (FIG. 2) and that a similar guide roller is utilized to absorb forces generated on the illustrated side of the roll-forming machine and/or tending to move the workpiece to the left (FIG. 2).
Referring now to FIG. 3, there is shown a die-stand 60 incorporating a first embodiment of the invention. The die-stand 60 includes a pair of sub-die-stands 20 each constructed substantially as described hereinbefore in connection with FIG. 2. However, it will be understood that the configuration of the sub-die-stands utilized in each die-stand 60 depends entirely upon the configuration of the workpiece to be formed in a particular roll-forming operation. To this end the two sub-die-stands utilized in a particular die-stand may or may not be similar, depending on whether or not the workpiece to be formed is symmetrical.
The die-stand 60 comprises one of a plurality of die-stands all secured to an elongate rigid spine 62 for simultaneous positioning and/or removal of a roll-forming machine. Each stand 60 comprises a rigid frame 64 which is secured to the spine 62 by means of a pair of brackets 66 and a pair of fasteners 68. The brackets 66 are in turn secured to the spine 62 either by means of suitable fasteners or by means of welding.
An upper lead screw 70 is rotatably supported on the frame 64 by means of anti-friction bearings 72 and a lower lead screw 74 is rotatably supported in the frame 64 by means of anti-friction bearings 76. The upper lead screw 70 is provided with a sprocket 78 and the lower lead screw 74 is provided with a sprocket 80. A roller chain 82 is constrained around the sprockets 78 and 80, whereby the upper lead screw 70 is caused to rotate concurrently with the lower lead screw 74.
An input shaft 84 is connected between the lower lead screw 74 and a bevel gear 86. The gear 86 is mounted in mesh with a bevel gear 88 which is secured to an input shaft 90. The shaft 90 extends to a suitable input device, such as a handwheel. Thus, upon rotation of the shaft 90, the upper lead screw and the lower lead screws 74 are caused to rotate through equal angular increments.
The upper lead screw 70 has a left-hand threaded portion 92 and a right-hand threaded portion 94. Similarly, the lower lead screw 74 has a left-hand threaded portion 96 and a right-hand threaded portion 98. A pair of left-hand threaded nuts 100 are threadedly engaged with the left-hand threaded portions of the upper and lower lead screws and are secured to the plate 22 of the right-hand sub-die-stand 20 by means of fasteners 102. A pair of right-hand threaded nuts 104 are threadedly engaged with the right-hand threaded portions of the upper and lower lead screws and are secured to the plate 22 of the right-hand sub-die-stand 20 by means of fasteners 106. Thus, upon rotation of the lead screws 70 and 74 under the action of the input shaft 90, the left-hand and right-hand sub-die-stands 20 of the die-stand 60 are moved toward or away from each other. Assuming that the right-hand and left-hand threaded portions of the upper and lower lead screws are of identical pitch, this movement is equal and opposite with respect to the path of movement of material through the roll-forming machine.
The purpose of moving the sub-die-stands 20 relative to the path of movement of material through the roll-forming machine is to change the roll-forming machine from one roll-forming configuration to another without necessitating removal of the die-stand 60 and the die-stands attached thereto. That is, by moving the sub-die-stands 20 relative to the path of material through the roll-forming machine, the roll-forming machine may be configured to form a workpiece 10 in which the web or base portion 12 is either wider or narrower than was previously the case. It will be understood, however, that this action does not change the dimensions of the sides or flanges 14 of the workpiece 10 that is formed by the roll-forming machine.
Referring to FIG. 4 a guide assembly 110 is also supported on the elongate, rigid spine 62. The guide assembly 110 includes a pair of depending frames 112 each secured to the spine 62 by means of brackets 114 and fasteners 116. The brackets 114 are in turn secured to the spine 62 by suitable means, such as welding.
The frames 112 support a member 118 of inverted U-shaped configurations and having a surface 120 which receives and supports material as the material is guided into a roll-forming machine. A pair of slots 122 are formed in the member 118 and extend transversely with respect to the path of material movement through the roll-forming machine. A plurality of guide rollers 124 extend through the slots 122 and function to guide the material as it enters the roll-forming machine and thereby assure proper entry of the material into the die-stands comprising the roll-forming machine.
A pair of lead screws 126 and 128 are rotatably supported in the member 118 beneath the slots 122. The lead screw 126 has a left-hand threaded portion 130 and a right-hand threaded portion 132. The lead screw 128 has identical left-hand and right-hand threaded portions. A pair of left-hand threaded nuts 134 are threadedly engaged with the left-hand threaded portions of the lead screws and support two of the guide rollers 124. A pair of right-hand threaded nuts 136 are threadedly engaged with the right-hand threaded portions of the lead screws and support the remaining rollers 124.
A shaft 138 extends from the lead screw 126 and has a sprocket 140 secured thereto. A shaft 142 extends from the lead screw 128 and a sprocket 144 is mounted on the shaft 142. A roller chain 146 extends around the sprockets 140 and 144, whereby the lead screws 126 and 128 are constrained to rotation through identical angular displacements. The shaft 142 also supports a bevel gear 148. The gear 148 is mounted in mesh with a bevel gear 150 mounted on the input shaft 90. The shaft 90 extends to a handwheel 152. Thus, upon rotation of the handwheel 152, the lead screws 126 and 128 function to properly position the guide rollers 124 to guide material into the roll-forming machine.
Referring now to FIG. 5, there is shown a complete spine/die-stand assembly 154 incorporating the first embodiment of the invention. It will be noted that the input shaft 90 functions to simultaneously direct an identical input signal from the handwheel 152 to the bevel gear 150 and to all of the bevel gears 88 of the die-stands of the assembly. Thus, upon rotation of the handwheel 152, the positioning of the guide rollers 124 of the guide assembly 110 and the positioning of the plates 22 and the rollers supported thereby comprising the sub-die-stands 20 of all of the die-stands 60 included in the assembly 154 are simultaneously repositioned to change the roll-forming configuration of the roll-forming machine incorporating the assembly.
The spine/die-stand assembly 154 is utilized in conjunction with a roll-forming machine of the type disclosed in U.S. Pat. No. 3,748,884 granted to Dan L. Colbath on July 31st, 1973. Such a device includes a frame which receives the spine 62 of the assembly 154, whereby the spine 62 and the frame of the roll-forming machine function to properly position the guide assembly 110 and all of the die-stands 60 relative to the path of movement of material through the roll-forming machine. The roll-forming machine further includes a plurality of roll-stands which are preferably constructed in accordance with the disclosure of the co-pending application of Dan L. Colbath filed Apr. 5th, 1974, Ser. No. 458,295, for ROLL-STAND FOR ROLL-FORMING MACHINE, and which function to drive material through the roll-forming machine and through the die-stands 60 of the assembly 154. A more complete understanding of the operation of such a roll-forming machine may be had by reference to U.S. Pat. No. 3,748,884 and by reference to co-pending application Ser. No. 458,295, the disclosures of which are incorporated by reference.
A die-stand 60' incorporating another aspect of the invention is illustrated in FIG. 6. Many of the component parts of the roll-stand 60' are equivalent in construction and function to component parts of the roll-stand 60 illustrated in FIG. 3. Such equivalent parts are indicated by reference numerals identical to those utilized hereinbefore in connection with the description of the die-stand 60, but are differentiated from the component parts of the die-stand 60 by means of a prime (') designation.
The primary distinction between the die-stand 60' of FIG. 6 and the die-stand 60 of FIG. 3 relates to the fact that rather than being supported directly on the plates 22' of the sub-die-stands 20', the guide roller 52' and one of the primary bend rollers 44' of each sub-die-stand 20' are mounted on a sub-plate 160. The sub-plates are in turn slidably supported in ways 162 which are secured to the plates 22' by fasteners 164. A nut 166 is secured to each sub-plate 160 by fasteners 168 and is threadedly engaged with a lead screw 170. Each lead screw 170 is rotatably supported on the corresponding plate 22' by a bearing block 172 and a bracket 174 which is secured to the plate 22' by fasteners 176.
Each lead screw 170 extends to a bevel gear 178 which is mounted in mesh with a bevel gear 180 secured to the output of a servo motor 182. The servo motor 182 is mounted on the plate 22' and is utilized to effect selective rotation of its corresponding lead screw 170, thereby positioning the sub-plate 160 and the rollers 44' and 52' mounted thereon relative to the remaining components of the sub-die-stand 20'. As used herein the term servo motor means a device capable of reproducing an input to a predetermined degree of accuracy, and may comprise any of the commercially available electrical, hydraulic, or pneumatic servo motors. Moreover, servo actuators other than the motor-lead screw arrangement illustrated in FIG. 6 may be utilized to position the sub-plates 160 and the components supported thereby.
The use of the die-stand 60' provides the same advantages as the use of the die-stand 60. Thus, upon actuation of the input shaft 90' the lead screws 70' and 74' are actuated to reposition the sub-die-stands 20' relative to the path of movement of the material through the roll-forming machine. By this means the roll-forming configuration of the roll-forming machine is changed with respect to the width of the base or web 12' of the workpiece 10'.
The use of the roll-stand 60' is further advantageous in that the use of the sub-plates 160 and the associated apparatus for controlling the positioning of the sub-plates 160 relative to the plates 22' permits selective repositioning of the guide roller 52' and one of the primary bend rollers 44' of each sub-die-stand 20'. By this means the roll-forming configuration of the roll-forming machine is changed with respect to the dimensions of the flanges 14' of the workpiece 10'. Such a change in the roll-forming configuration of the roll-forming machine may be carried out either simultaneously with or independently of a change in the dimensions of the web 12' of the workpiece 10'. Moreover, the dimensions of the flange 14' on one side of the workpiece 10' may be changed independently of a change in the dimensions of the flange 14' on the opposite side of the workpiece 10'.
Referring now to FIG. 7, there is shown a die-stand 190 incorporating a second embodiment of the invention. The die-stand 190 includes a pair of sub-die-stands 20 each constructed substantially as described hereinbefore in connection with FIG. 2. Moreover, it will be understood that the configuration of the sub-die-stands utilized in the die-stand 190 depends entirely upon the configuration of the workpiece to be formed in a particular roll-forming operation. To this end the two sub-die-stands utilized in a particular die-stand may or may not be similar, depending on whether or not the workpiece to be formed is symmetrical.
The die-stand 190 comprises one of a plurality of die-stands all secured to an elongate rigid spine 192 for simultaneous positioning in or removal from a roll-forming machine. Each die-stand 190 comprises a rigid frame 194 depending from the spine 192 and secured thereto by fasteners 196. The plate 22 of the sub-die-stand 20 on one side of the die-stand 190 is secured directly to the frame 194 by fasteners 198.
The frame 194 rotatably supports an upper lead screw 200 and a lower lead screw 202. The upper lead screw 200 extends to a sprocket 204 and the lower lead screw 202 extends to a sprocket 206. A chain 208 extends around the sprockets 204 and 206 and functions to constrain the lead screw 200 to rotate concurrently with the lead screw 202.
An input shaft 210 is connected between the lead screw 202 and a bevel gear 212. The gear 212 is mounted in mesh with a bevel gear 214 which is secured to an input shaft 216. The shaft 216 extends to a suitable input device, such as a handwheel. Thus, upon rotation of the shaft 216, the lead screws 200 and 202 are caused to rotate through equal angular increments
The die-stand 190 has associated therewith a second elongate, rigid spine 218. A rigid frame 220 is secured to the spine by means of fasteners 222. Each plate 22 of a sub-die-stand 20 located on the opposite side of the roll-forming machine from the frames 194 is secured to a corresponding frame 220 by fasteners 224.
Certain of the plates 22 on the opposite side of the roll-forming machine have nuts 226 connected thereto by means of fasteners 228. The nuts 226 threadedly engage the lead screws 200 and 202. Thus, upon rotation of the shaft 216, the lead screws 200 and 202 cooperate with the nuts 226 to change the positioning of the sub-die-stands 20 relative to the path of movement of material through the roll-forming machine. This causes a change in the roll-forming configuration of the roll-forming machine with respect to the width of the base 12 of the workpiece 10.
In FIG. 8, there is shown a complete spine/die-stand assembly 230 incorporating die-stands 190 of the type illustrated in FIG. 7. At the outset, it will be noted that only certain die-stands 190 of the assembly 230 include lead screws 200 and 202 and nuts 226 threadedly engaged therewith. Upon rotation of the shaft 216 by means of a handwheel 232, the lead screws and the nuts cooperate to change the positioning of the plates 22 of the sub-die-stands 20 on the opposite side of the assembly from the shaft 216. This causes a corresponding change in the relative positioning of the second elongate, rigid spine 218 with respect to the elongate rigid spine 192. Since the remaining plates 22 on the side of the assembly 230 remote from the shaft 216 are all secured to the second elongate rigid spine 218, all such plates and the rollers carried thereby are repositioned simultaneously with the repositioning of the plates 22 having the nuts 226 secured thereto under the action of lead screws 200 and 202.
The spine/die-stand assembly 230 further includes a guide assembly 234. The assembly 234 includes a pair of opposed L-shaped members 236 and 238. The members 236 and 238 have parallel upper surfaces 240 which function to support material as it is guided into a roll-forming machine incorporating the assembly 230. Guide rollers 242 protrude through the surfaces 240 and the members 236 and 238 and function to define the path of material movement into the roll-forming machine.
The member 238 and the guide rollers 242 supported thereby are secured to the spine 192 by means of frames 244. On the other hand, the member 236 and the rollers 242 carried thereby are secured to the second spine 218 by means of frames 246. Thus, the member 236 and the rollers 242 on the side of the assembly 230 remote from the shaft 216 are repositioned simultaneously with the plates 22 of the sub-die-stands 20 on the opposite side of the assembly 230 under the action of the lead screws 200 and 202 and the nuts 226.
The spine/die-stand assembly 230 is utilized in conjunction with a roll-forming machine of the type disclosed in U.S. Pat. No. 3,748,884 granted to Dan L. Colbath on July 31, 1973. Such a roll-forming machine includes a frame which receives the spine 192. The spine and the frame thus function to properly position the die-stands 190 and the guide assembly 234 of the assembly 230 relative to the path of material movement through the roll-forming machine. The roll-forming machine further includes a plurality of roll-stands which function to drive material through the roll-forming machine, and particularly through the forming rollers of the die-stands 190. Such roll-stands are preferably constructed in accordance with the teachings of co-pending application Ser. No. 458,295, filed Apr. 5th, 1974 by Dan L. Colbath for ROLL-STAND FOR ROLL-FORMING MACHINE. A more complete understanding of the operation of such a roll-forming machine and the cooperation of the spine/die-stand assembly 230 therewith may be had by reference to U.S. Pat. No. 3,748,884 and to co-pending application Ser. No. 458,295, the disclosures of which are incorporated herein by reference.
The use of the embodiment of the invention illustrated in FIGS. 7 and 8 provides the same advantages as the use of the embodiment of the invention illustrated in FIGS. 3, 4, and 5. Thus, by means of the invention it is possible to simultaneously reposition all of the forming rollers on one side of the path of movement of material through a roll-forming machine and thereby change the roll-forming configuration of the machine. The use of the second embodiment of the invention is further advantageous in that it requires fewer component parts and is therefore less expensive to manufacture than the first embodiment. Those skilled in the art will appreciate the fact that the aspect of the invention illustrated in FIG. 6 may be utilized in the second embodiment of the invention, if desired.
From the foregoing, it will be understood that the present invention comprises an improvement in die-stands for roll-forming machines incorporating numerous improvements over the prior art. Perhaps the most important advantage deriving from the use of the invention involves the fact that die-stands constructed in accordance therewith are provided with sub-die-stands which are selectively repositionable relative to the path of material movement through a roll-forming machine, thereby changing the roll-forming configuration of the machine. In certain embodiments of the invention, the sub-die-stands include at least one roller which is selectively repositionable with respect to the remaining rollers, thereby further changing the roll-forming configuration of the roll-forming machine. Another advantage deriving from the use of the invention relates to the fact that sub-die-stands constructed in accordance therewith include a toroidal roller shaped and positioned to absorb substantially all of the forces which are applied to the workpiece in the formation of bends therein, and guide rollers which function to retain the workpiece on its proper path of travel through the roll-forming machine.
Although preferred embodiments of the invention have been illustrated in the accompanying Drawings and described in the foregoing Detailed Description, it will be understood that the invention is not limited to the embodiments, but is capable of numerous rearrangements, modifications, and substitutions of parts and elements without departing from the spirit of the invention.
U.S. Pat. No. 3,748,884 granted to Dan L. Colbath on July 31st, 1973, discloses a roll-forming machine including a plurality of roll-stands each comprising non-forming rollers which function to move material along a predetermined path. The roll-forming machine further includes a plurality of die-stands each comprising non-driven material engaging rollers which function to transform the material from an initial configuration to a desired configuration. The die-stands are mounted on and positioned relative to the path by an elongate, rigid spine. This permits conversion of the machine from one roll-forming configuration to another by removing the spine and the die-stands attached thereto and then installing a different spine/die-stand assembly in the roll-forming machine.
In co-pending application Ser. No. 355,673 there is disclosed a roll-forming machine also including roll-stands for transporting material along a predetermined path and die-stands for progressively transforming the material from an initial configuration to a desired configuration. The roll-forming machine is similar to that described above in connection with U.S. Pat. No. 3,748,884 in that the die-stands are mounted on a rigid spine to facilitate conversion of the roll-forming machine from one roll-forming configuration to another. The major difference between the two roll-forming machines relates to the fact that in the latter machine the roll-stands comprise non-forming lower driving rollers only. Idler rollers are mounted on the spine for cooperation with the lower driving rollers to drive material through the roll-forming machine.
Although roll-forming machines incorporating the above-described inventions have enjoyed substantial commercial success, certain limitations have been encountered in their use. For example, in both machines the positioning of the material driving rollers of the roll-stands transversely relative to the direction of movement of material through the roll-forming machine is fixed. This is somewhat limiting with respect to the width of materials that can be accommodated in the roll-forming machine. Similarly, the positioning of the material engaging rollers of the die-stands of the above-described roll-forming machines is fixed. This requires the substitution of a new spine/die-stand assembly even though the roll-forming configuration represented by the new spine/die-stand assembly differs from that of the prior assembly only to a relatively minor degree.
Co-pending application Ser. No. 458,295, filed Apr. 5, 1974, by Dan L. Colbath for ROLL STAND FOR ROLL-FORMING MACHINE discloses certain improvements relating to both of the above-described roll-forming machines. In one aspect these improvements relate to accommodating roll-forming machines for use in conjunction with materials of various widths. This is accomplished by mounting the rollers of the roll-stands for selective positioning transversely with respect to the path of movement of material through the roll-forming machines.
The present invention relates to improvements in die-stands for roll-forming machines whereby the roll-forming configuration of a roll-forming machine may be changed without the necessity of installing a different spine/die-stand assembly. In accordance with the broader aspects of the invention, all of the material engaging rollers on at least one side of each die-stand are selectively positionable as a group with respect to the path of material movement through the roll-forming machine, thereby changing the roll-forming configuration of the machine. Also, certain rollers of the group may be selectively positionable with respect to the remaining rollers, thereby further changing the roll-forming configuration of the machine.
In accordance with more specific aspects of the invention, certain embodiments of the invention comprise die-stands including a rigid frame depending from the elongate, rigid spine. Plates are positioned on opposite sides of the path of movement of material through the roll-forming machine, and each plate supports at least one material engaging roller. Lead screws are rotatably supported in the frame and are threadedly engaged with members secured to the plate. Thus, upon rotation of the lead screws the plate and the material engaging rollers supported thereby are selectively positioned relative to the path of movement of material through the roll-forming machine.
In accordance with other embodiments of the invention, all of the rollers supporting the plates on one side of the path of material movement through the roll-forming machine are secured to a second elongate, rigid spine. Lead screws are provided for selectively positioning the second elongate, rigid spine and the plates supported thereby relative to the first spine and the plates and the material engaging rollers supported thereby. In either case guide apparatus comprising part of the spine/die-stand assembly is adjusted simultaneously with any change in the positioning of the material engaging rollers relative to the path of movement through the roll-forming machine.
In accordance with another aspect of the invention, each die-stand comprises at least one roller which supports the material for movement through the roll-forming machine. A toroidal roller engages the material along the line of a desired bend in the material. At least one primary bend roller engages the material at a point beyond the toroidal roller and is positioned to bend the material toward the toroidal roller. The toroidal roller is mounted for rotation in a plane which bisects the plane of rotation of the supporting roller and the plane of rotation of the material engaging roller. Finally, a guide roller engages the edge of the material and serves to absorb forces resulting from the formation of bends in the material which might otherwise tend to drive the material out of its path of movement through the roll-forming machine.
DESCRIPTION OF THE DRAWINGS
A more complete understanding of the invention may be had by reference to the following Detailed Description when taken in conjunction with the accompanying Drawings, wherein:
FIG. 1 is an illustration of a typical roll-forming shape;
FIG. 2 is an illustration of a sub-die-stand having a roller grouping arranged in accordance with the present invention;
FIG. 3 is an illustration of a die-stand incorporating a first embodiment of the invention;
FIG. 4 is an illustration of the guide assembly of a spine/die-stand assembly incorporating the first embodiment of the invention;
FIG. 5 is an illustration of a spine/die-stand assembly incorporating the first embodiment of the invention;
FIG. 6 is an illustration of a die-stand incorporating another aspect of the invention;
FIG. 7 is an illustration of a die-stand incorporating a second embodiment of the invention; and
FIG. 8 is an illustration of a spine/die-stand assembly incorporating the second embodiment of the invention.
DETAILED DESCRIPTION
Referring now to the Drawings, and particularly to FIG. 1 thereof, there is shown a workpiece 10 which may be considered as representative of the type of workpiece that is formed in a roll-forming machine. The workpiece 10 includes a base or web 12 and opposed sides or flanges 14. The flanges 14 are separated from the web 12 by bends 16 and extend to edges 18. The workpiece 10 is received in the roll-forming machine in an entirely flat state, and the flanges 14 are progressively formed in the workpiece 10 as the workpiece travels through the roll-forming machine. Those skilled in the art will appreciate the fact that the workpiece 10 illustrated in FIG. 1 is representative only, and in particular that workpieces formed by roll-forming machines incorporating the present invention may be either substantially less complicated or substantially more complicated than the workpiece of FIG. 1. This is particularly true with respect to the flanges of the workpiece, each of which may comprise one or more additional bends to provide inwardly or outwardly turned lips, etc. in accordance with the requirements of a particular application.
In FIG. 2 there is shown a representative sub-die-stand 20 incorporating the present invention. The sub-die-stand 20 includes a supporting plate 22 having a slot 24 formed therein which receives the workpiece 10. A set of rollers 26 is supported on the plate 22 for engagement with a workpiece 10 passing through the slot 24.
The set of rollers 26 of the sub-die-stand 20 includes a pair of support rollers 28 which are rotatably supported on a shaft 30 for engagement with the base 12 of the workpiece 10. The shaft 30 is in turn supported by a bracket 32 which is secured to the plate 22 by means of fasteners 34. A toroidal roller 36 is positioned for engagement with the workpiece 10 along a line corresponding to the bend 16. As used herein the term "toroidal roller" means a roller having a material engaging surface which is curved at right angles to the axis of rotation of the rollers to form the outer surface of a toroid, as opposed to a cylindrical roller which has a material engaging surface which is parallel to the axis of rotation of the roller. The toroidal roller 36 is rotatably supported on a shaft 38 which is in turn supported on the plate 22 by means of a bracket 40 and fasteners 42.
At least one primary bend roller 44 is mounted for engagement with the workpiece 10 at a point beyond the line of engagement of the toroidal roller 36 with the workpiece. The primary bend roller 44 is rotatably supported on a shaft 46 which is in turn secured to the plate 22 by means of a bracket 48 and a pair of fasteners 50. As will be understood by those skilled in the art, the primary bend roller 44 is so positioned as to bend the outer portion of the workpiece 10 towards the toroidal rollers 36, thererby partially forming the flange 14 and the bend 16 on one side of the workpiece. A guide roller 52 is mounted on the plate 22 for engagement with one edge 18 of the workpiece 10. The guide roller 52 is rotatably supported of a shaft 54 which is in turn secured to the plate 22 by means of a bracket 56 and a pair of fasteners 58.
As is well known in the art, the conventional roller arrangement can cause numerous problems in the operation of a roll-forming machine. For example, if a bend is formed on one side only of a workpiece, the forces which are imposed on the workpiece in the formation of the bend typically cause the workpiece to tend to move out of its proper path through the roll-forming machine. Even if identical bends are formed in the opposite sides of the workpiece, the forces which are applied to the workpiece in the formation of the bends can cause buckling of the center portion of the workpiece, particularly in the case of a relatively wide workpiece. Finally, variations in the workpiece such as non-uniformity of thickness, etc. can cause the workpiece to tend to move out of its proper path of travel even though the forces which are applied in the formation of bends in the workpiece are wholly contained.
The roller arrangement 26 of FIG. 2 overcomes these and other problems of the prior art. The toroidal roller 36 is mounted for rotation in a plane which bisects the plane of rotation of the support rollers 28 and the plane of rotation of the primary bend roller 44. This fact together with the toroidal configuration of the roller 36 causes the roller 36 to absorb substantially the entire force which is applied to the workpiece by the primary bend roller 44 in forming the bend 16 and the flange 14. Additionally, the guide roller 52 absorbs any forces not absorbed by the toroidal roller 36 and/or forces resulting from variations in material thickness, etc. and thereby constrains the workpiece to movement along its proper path of travel through the roll-forming machine. In this regard, it will be understood that the roller 52 illustrated in FIG. 2 functions primarily to absorb forces generated on the opposite side of the roll-forming machine and/or forces tending to move the workpiece to the right (FIG. 2) and that a similar guide roller is utilized to absorb forces generated on the illustrated side of the roll-forming machine and/or tending to move the workpiece to the left (FIG. 2).
Referring now to FIG. 3, there is shown a die-stand 60 incorporating a first embodiment of the invention. The die-stand 60 includes a pair of sub-die-stands 20 each constructed substantially as described hereinbefore in connection with FIG. 2. However, it will be understood that the configuration of the sub-die-stands utilized in each die-stand 60 depends entirely upon the configuration of the workpiece to be formed in a particular roll-forming operation. To this end the two sub-die-stands utilized in a particular die-stand may or may not be similar, depending on whether or not the workpiece to be formed is symmetrical.
The die-stand 60 comprises one of a plurality of die-stands all secured to an elongate rigid spine 62 for simultaneous positioning and/or removal of a roll-forming machine. Each stand 60 comprises a rigid frame 64 which is secured to the spine 62 by means of a pair of brackets 66 and a pair of fasteners 68. The brackets 66 are in turn secured to the spine 62 either by means of suitable fasteners or by means of welding.
An upper lead screw 70 is rotatably supported on the frame 64 by means of anti-friction bearings 72 and a lower lead screw 74 is rotatably supported in the frame 64 by means of anti-friction bearings 76. The upper lead screw 70 is provided with a sprocket 78 and the lower lead screw 74 is provided with a sprocket 80. A roller chain 82 is constrained around the sprockets 78 and 80, whereby the upper lead screw 70 is caused to rotate concurrently with the lower lead screw 74.
An input shaft 84 is connected between the lower lead screw 74 and a bevel gear 86. The gear 86 is mounted in mesh with a bevel gear 88 which is secured to an input shaft 90. The shaft 90 extends to a suitable input device, such as a handwheel. Thus, upon rotation of the shaft 90, the upper lead screw and the lower lead screws 74 are caused to rotate through equal angular increments.
The upper lead screw 70 has a left-hand threaded portion 92 and a right-hand threaded portion 94. Similarly, the lower lead screw 74 has a left-hand threaded portion 96 and a right-hand threaded portion 98. A pair of left-hand threaded nuts 100 are threadedly engaged with the left-hand threaded portions of the upper and lower lead screws and are secured to the plate 22 of the right-hand sub-die-stand 20 by means of fasteners 102. A pair of right-hand threaded nuts 104 are threadedly engaged with the right-hand threaded portions of the upper and lower lead screws and are secured to the plate 22 of the right-hand sub-die-stand 20 by means of fasteners 106. Thus, upon rotation of the lead screws 70 and 74 under the action of the input shaft 90, the left-hand and right-hand sub-die-stands 20 of the die-stand 60 are moved toward or away from each other. Assuming that the right-hand and left-hand threaded portions of the upper and lower lead screws are of identical pitch, this movement is equal and opposite with respect to the path of movement of material through the roll-forming machine.
The purpose of moving the sub-die-stands 20 relative to the path of movement of material through the roll-forming machine is to change the roll-forming machine from one roll-forming configuration to another without necessitating removal of the die-stand 60 and the die-stands attached thereto. That is, by moving the sub-die-stands 20 relative to the path of material through the roll-forming machine, the roll-forming machine may be configured to form a workpiece 10 in which the web or base portion 12 is either wider or narrower than was previously the case. It will be understood, however, that this action does not change the dimensions of the sides or flanges 14 of the workpiece 10 that is formed by the roll-forming machine.
Referring to FIG. 4 a guide assembly 110 is also supported on the elongate, rigid spine 62. The guide assembly 110 includes a pair of depending frames 112 each secured to the spine 62 by means of brackets 114 and fasteners 116. The brackets 114 are in turn secured to the spine 62 by suitable means, such as welding.
The frames 112 support a member 118 of inverted U-shaped configurations and having a surface 120 which receives and supports material as the material is guided into a roll-forming machine. A pair of slots 122 are formed in the member 118 and extend transversely with respect to the path of material movement through the roll-forming machine. A plurality of guide rollers 124 extend through the slots 122 and function to guide the material as it enters the roll-forming machine and thereby assure proper entry of the material into the die-stands comprising the roll-forming machine.
A pair of lead screws 126 and 128 are rotatably supported in the member 118 beneath the slots 122. The lead screw 126 has a left-hand threaded portion 130 and a right-hand threaded portion 132. The lead screw 128 has identical left-hand and right-hand threaded portions. A pair of left-hand threaded nuts 134 are threadedly engaged with the left-hand threaded portions of the lead screws and support two of the guide rollers 124. A pair of right-hand threaded nuts 136 are threadedly engaged with the right-hand threaded portions of the lead screws and support the remaining rollers 124.
A shaft 138 extends from the lead screw 126 and has a sprocket 140 secured thereto. A shaft 142 extends from the lead screw 128 and a sprocket 144 is mounted on the shaft 142. A roller chain 146 extends around the sprockets 140 and 144, whereby the lead screws 126 and 128 are constrained to rotation through identical angular displacements. The shaft 142 also supports a bevel gear 148. The gear 148 is mounted in mesh with a bevel gear 150 mounted on the input shaft 90. The shaft 90 extends to a handwheel 152. Thus, upon rotation of the handwheel 152, the lead screws 126 and 128 function to properly position the guide rollers 124 to guide material into the roll-forming machine.
Referring now to FIG. 5, there is shown a complete spine/die-stand assembly 154 incorporating the first embodiment of the invention. It will be noted that the input shaft 90 functions to simultaneously direct an identical input signal from the handwheel 152 to the bevel gear 150 and to all of the bevel gears 88 of the die-stands of the assembly. Thus, upon rotation of the handwheel 152, the positioning of the guide rollers 124 of the guide assembly 110 and the positioning of the plates 22 and the rollers supported thereby comprising the sub-die-stands 20 of all of the die-stands 60 included in the assembly 154 are simultaneously repositioned to change the roll-forming configuration of the roll-forming machine incorporating the assembly.
The spine/die-stand assembly 154 is utilized in conjunction with a roll-forming machine of the type disclosed in U.S. Pat. No. 3,748,884 granted to Dan L. Colbath on July 31st, 1973. Such a device includes a frame which receives the spine 62 of the assembly 154, whereby the spine 62 and the frame of the roll-forming machine function to properly position the guide assembly 110 and all of the die-stands 60 relative to the path of movement of material through the roll-forming machine. The roll-forming machine further includes a plurality of roll-stands which are preferably constructed in accordance with the disclosure of the co-pending application of Dan L. Colbath filed Apr. 5th, 1974, Ser. No. 458,295, for ROLL-STAND FOR ROLL-FORMING MACHINE, and which function to drive material through the roll-forming machine and through the die-stands 60 of the assembly 154. A more complete understanding of the operation of such a roll-forming machine may be had by reference to U.S. Pat. No. 3,748,884 and by reference to co-pending application Ser. No. 458,295, the disclosures of which are incorporated by reference.
A die-stand 60' incorporating another aspect of the invention is illustrated in FIG. 6. Many of the component parts of the roll-stand 60' are equivalent in construction and function to component parts of the roll-stand 60 illustrated in FIG. 3. Such equivalent parts are indicated by reference numerals identical to those utilized hereinbefore in connection with the description of the die-stand 60, but are differentiated from the component parts of the die-stand 60 by means of a prime (') designation.
The primary distinction between the die-stand 60' of FIG. 6 and the die-stand 60 of FIG. 3 relates to the fact that rather than being supported directly on the plates 22' of the sub-die-stands 20', the guide roller 52' and one of the primary bend rollers 44' of each sub-die-stand 20' are mounted on a sub-plate 160. The sub-plates are in turn slidably supported in ways 162 which are secured to the plates 22' by fasteners 164. A nut 166 is secured to each sub-plate 160 by fasteners 168 and is threadedly engaged with a lead screw 170. Each lead screw 170 is rotatably supported on the corresponding plate 22' by a bearing block 172 and a bracket 174 which is secured to the plate 22' by fasteners 176.
Each lead screw 170 extends to a bevel gear 178 which is mounted in mesh with a bevel gear 180 secured to the output of a servo motor 182. The servo motor 182 is mounted on the plate 22' and is utilized to effect selective rotation of its corresponding lead screw 170, thereby positioning the sub-plate 160 and the rollers 44' and 52' mounted thereon relative to the remaining components of the sub-die-stand 20'. As used herein the term servo motor means a device capable of reproducing an input to a predetermined degree of accuracy, and may comprise any of the commercially available electrical, hydraulic, or pneumatic servo motors. Moreover, servo actuators other than the motor-lead screw arrangement illustrated in FIG. 6 may be utilized to position the sub-plates 160 and the components supported thereby.
The use of the die-stand 60' provides the same advantages as the use of the die-stand 60. Thus, upon actuation of the input shaft 90' the lead screws 70' and 74' are actuated to reposition the sub-die-stands 20' relative to the path of movement of the material through the roll-forming machine. By this means the roll-forming configuration of the roll-forming machine is changed with respect to the width of the base or web 12' of the workpiece 10'.
The use of the roll-stand 60' is further advantageous in that the use of the sub-plates 160 and the associated apparatus for controlling the positioning of the sub-plates 160 relative to the plates 22' permits selective repositioning of the guide roller 52' and one of the primary bend rollers 44' of each sub-die-stand 20'. By this means the roll-forming configuration of the roll-forming machine is changed with respect to the dimensions of the flanges 14' of the workpiece 10'. Such a change in the roll-forming configuration of the roll-forming machine may be carried out either simultaneously with or independently of a change in the dimensions of the web 12' of the workpiece 10'. Moreover, the dimensions of the flange 14' on one side of the workpiece 10' may be changed independently of a change in the dimensions of the flange 14' on the opposite side of the workpiece 10'.
Referring now to FIG. 7, there is shown a die-stand 190 incorporating a second embodiment of the invention. The die-stand 190 includes a pair of sub-die-stands 20 each constructed substantially as described hereinbefore in connection with FIG. 2. Moreover, it will be understood that the configuration of the sub-die-stands utilized in the die-stand 190 depends entirely upon the configuration of the workpiece to be formed in a particular roll-forming operation. To this end the two sub-die-stands utilized in a particular die-stand may or may not be similar, depending on whether or not the workpiece to be formed is symmetrical.
The die-stand 190 comprises one of a plurality of die-stands all secured to an elongate rigid spine 192 for simultaneous positioning in or removal from a roll-forming machine. Each die-stand 190 comprises a rigid frame 194 depending from the spine 192 and secured thereto by fasteners 196. The plate 22 of the sub-die-stand 20 on one side of the die-stand 190 is secured directly to the frame 194 by fasteners 198.
The frame 194 rotatably supports an upper lead screw 200 and a lower lead screw 202. The upper lead screw 200 extends to a sprocket 204 and the lower lead screw 202 extends to a sprocket 206. A chain 208 extends around the sprockets 204 and 206 and functions to constrain the lead screw 200 to rotate concurrently with the lead screw 202.
An input shaft 210 is connected between the lead screw 202 and a bevel gear 212. The gear 212 is mounted in mesh with a bevel gear 214 which is secured to an input shaft 216. The shaft 216 extends to a suitable input device, such as a handwheel. Thus, upon rotation of the shaft 216, the lead screws 200 and 202 are caused to rotate through equal angular increments
The die-stand 190 has associated therewith a second elongate, rigid spine 218. A rigid frame 220 is secured to the spine by means of fasteners 222. Each plate 22 of a sub-die-stand 20 located on the opposite side of the roll-forming machine from the frames 194 is secured to a corresponding frame 220 by fasteners 224.
Certain of the plates 22 on the opposite side of the roll-forming machine have nuts 226 connected thereto by means of fasteners 228. The nuts 226 threadedly engage the lead screws 200 and 202. Thus, upon rotation of the shaft 216, the lead screws 200 and 202 cooperate with the nuts 226 to change the positioning of the sub-die-stands 20 relative to the path of movement of material through the roll-forming machine. This causes a change in the roll-forming configuration of the roll-forming machine with respect to the width of the base 12 of the workpiece 10.
In FIG. 8, there is shown a complete spine/die-stand assembly 230 incorporating die-stands 190 of the type illustrated in FIG. 7. At the outset, it will be noted that only certain die-stands 190 of the assembly 230 include lead screws 200 and 202 and nuts 226 threadedly engaged therewith. Upon rotation of the shaft 216 by means of a handwheel 232, the lead screws and the nuts cooperate to change the positioning of the plates 22 of the sub-die-stands 20 on the opposite side of the assembly from the shaft 216. This causes a corresponding change in the relative positioning of the second elongate, rigid spine 218 with respect to the elongate rigid spine 192. Since the remaining plates 22 on the side of the assembly 230 remote from the shaft 216 are all secured to the second elongate rigid spine 218, all such plates and the rollers carried thereby are repositioned simultaneously with the repositioning of the plates 22 having the nuts 226 secured thereto under the action of lead screws 200 and 202.
The spine/die-stand assembly 230 further includes a guide assembly 234. The assembly 234 includes a pair of opposed L-shaped members 236 and 238. The members 236 and 238 have parallel upper surfaces 240 which function to support material as it is guided into a roll-forming machine incorporating the assembly 230. Guide rollers 242 protrude through the surfaces 240 and the members 236 and 238 and function to define the path of material movement into the roll-forming machine.
The member 238 and the guide rollers 242 supported thereby are secured to the spine 192 by means of frames 244. On the other hand, the member 236 and the rollers 242 carried thereby are secured to the second spine 218 by means of frames 246. Thus, the member 236 and the rollers 242 on the side of the assembly 230 remote from the shaft 216 are repositioned simultaneously with the plates 22 of the sub-die-stands 20 on the opposite side of the assembly 230 under the action of the lead screws 200 and 202 and the nuts 226.
The spine/die-stand assembly 230 is utilized in conjunction with a roll-forming machine of the type disclosed in U.S. Pat. No. 3,748,884 granted to Dan L. Colbath on July 31, 1973. Such a roll-forming machine includes a frame which receives the spine 192. The spine and the frame thus function to properly position the die-stands 190 and the guide assembly 234 of the assembly 230 relative to the path of material movement through the roll-forming machine. The roll-forming machine further includes a plurality of roll-stands which function to drive material through the roll-forming machine, and particularly through the forming rollers of the die-stands 190. Such roll-stands are preferably constructed in accordance with the teachings of co-pending application Ser. No. 458,295, filed Apr. 5th, 1974 by Dan L. Colbath for ROLL-STAND FOR ROLL-FORMING MACHINE. A more complete understanding of the operation of such a roll-forming machine and the cooperation of the spine/die-stand assembly 230 therewith may be had by reference to U.S. Pat. No. 3,748,884 and to co-pending application Ser. No. 458,295, the disclosures of which are incorporated herein by reference.
The use of the embodiment of the invention illustrated in FIGS. 7 and 8 provides the same advantages as the use of the embodiment of the invention illustrated in FIGS. 3, 4, and 5. Thus, by means of the invention it is possible to simultaneously reposition all of the forming rollers on one side of the path of movement of material through a roll-forming machine and thereby change the roll-forming configuration of the machine. The use of the second embodiment of the invention is further advantageous in that it requires fewer component parts and is therefore less expensive to manufacture than the first embodiment. Those skilled in the art will appreciate the fact that the aspect of the invention illustrated in FIG. 6 may be utilized in the second embodiment of the invention, if desired.
From the foregoing, it will be understood that the present invention comprises an improvement in die-stands for roll-forming machines incorporating numerous improvements over the prior art. Perhaps the most important advantage deriving from the use of the invention involves the fact that die-stands constructed in accordance therewith are provided with sub-die-stands which are selectively repositionable relative to the path of material movement through a roll-forming machine, thereby changing the roll-forming configuration of the machine. In certain embodiments of the invention, the sub-die-stands include at least one roller which is selectively repositionable with respect to the remaining rollers, thereby further changing the roll-forming configuration of the roll-forming machine. Another advantage deriving from the use of the invention relates to the fact that sub-die-stands constructed in accordance therewith include a toroidal roller shaped and positioned to absorb substantially all of the forces which are applied to the workpiece in the formation of bends therein, and guide rollers which function to retain the workpiece on its proper path of travel through the roll-forming machine.
Although preferred embodiments of the invention have been illustrated in the accompanying Drawings and described in the foregoing Detailed Description, it will be understood that the invention is not limited to the embodiments, but is capable of numerous rearrangements, modifications, and substitutions of parts and elements without departing from the spirit of the invention.