U.S. patent application number 09/783247 was filed with the patent office on 2002-08-15 for forming machine for sheets of formable material.
Invention is credited to Cunningham, David H..
Application Number | 20020108421 09/783247 |
Document ID | / |
Family ID | 25128632 |
Filed Date | 2002-08-15 |
United States Patent
Application |
20020108421 |
Kind Code |
A1 |
Cunningham, David H. |
August 15, 2002 |
Forming machine for sheets of formable material
Abstract
A forming machine for receiving an elongated sheet of formable
material to form a desired profile has a rigid framework supporting
a sheet drive that includes a plurality of pairs of co-acting
rollers to advance the sheet through the framework from an upstream
entrance to a downstream exit. A drive assembly interconnects at
least one roller in each of the pairs to rotatably drive the roller
and advance the sheet in the downstream direction. Each of a
plurality of carriage rails extends transversely along the
framework and has first and second carriage mounts slideably
disposed thereon. First and second tool rails are secured,
respectively, to each of the first and second carriage mounts
permitting the tooling rails to move laterally within the
framework. Each tooling rail supports a plurality of forming
elements defining at least two forming stations to bend the sheet
as desired while it advances through the framework.
Inventors: |
Cunningham, David H.; (Fort
Lupton, CO) |
Correspondence
Address: |
TIMOTHY J MARTIN, PC
9250 W 5TH AVENUE
SUITE 200
LAKEWOOD
CO
80226
US
|
Family ID: |
25128632 |
Appl. No.: |
09/783247 |
Filed: |
February 13, 2001 |
Current U.S.
Class: |
72/176 |
Current CPC
Class: |
B21D 5/08 20130101 |
Class at
Publication: |
72/176 |
International
Class: |
B21D 005/08 |
Claims
I claim:
1. A forming machine adapted to receive an elongated sheet of
formable material and operative to form a desired profile thereon,
comprising: (a) a rigid framework including side frames rigidly
interconnected to one another by transverse members to form a rigid
cage having an interior and a width between said side frames, said
cage extending about a forming region through which the elongated
sheet may be advanced from an upstream entrance to a downstream
exit; (b) a sheet drive supported by said framework and operative
to advance the elongated sheet therethrough, said sheet drive
including a plurality of pairs of co-acting rollers, each of said
pairs being longitudinally spaced from an adjacent one of said
pairs in a downstream direction from the entrance to the exit; (c)
a drive assembly interconnected to at least one roller in each of
said pairs or co-acting rollers and operative to rotatably drive
said one roller whereby each of said pairs of co-acting rollers is
operative to engage a portion of the elongated sheet and advance
the elongated sheet in a downstream direction through said
framework to discharge the elongated sheet at the exit; (d) a
plurality of pairs of carriage rails supported by said framework
and extending transversely thereof, each of said carriage rails
having opposite ends secured to said framework at a location
proximately to a respective side frame so as to extend a majority
of the width of said framework; (e) first and second carriage
mounts slideably disposed on each of said carriage rails; (f) a
first tooling rail secured in a mounted state to the first carriage
mounts on each said pair of carriage rails and a second tooling
rail secured in a mounted state to the second carriage mounts on
each said pair of carriage rails whereby said tooling rails may be
moved laterally within said cage; and (g) a plurality of forming
elements supported by each said tooling rail to define at least two
forming stations located in a longitudinally spaced relation to one
another along said tooling rail, said forming stations positioned
to receive an edge portion of the elongated sheet when in the
mounted state whereby said forming stations are operative to bend
the elongated sheet into the desired profile as the elongated sheet
is advanced through the forming region by said drive assembly.
2. A forming machine according to claim 1 including upper ones of
said transverse members and lower ones of said transverse
members.
3. A forming machine according to claim 2 wherein each of said
pairs of co-acting rollers includes a driven roller and a
free-wheeling roller.
4. A forming machine according to claim 3 wherein each said
free-wheeling roller is rotatably supported by upper ones of said
transverse members and wherein rotation of one of said driven
rollers imparts an equal counter-rotation of its associated
free-wheeling roller.
5. A forming machine according to claim 1 wherein each of said
pairs of co-acting rollers includes a driven roller and a
free-wheeling roller.
6. A forming machine according to claim 1 including a plurality of
pairs of opposed primary rail mounts secured to said framework in
parallel spaced-apart relation to one another, one primary rail
mount of each pair extending alongside one of said side frames and
another primary rail mount of each pair extending alongside another
one of said side frames.
7. A forming machine according to claim 6 including lower pairs of
said transverse members disposed in parallel spaced-apart relation
to one another, the primary rail mounts of each of said pairs of
opposed primary rail mounts extending longitudinally between
respective ones of said lower pairs of said transverse members.
8. A forming machine according to claim 6 including a first
intermediate tooling rail mount secured in an affixed state between
the first carriage mounts on each said pair of carriage rails and a
second intermediate tooling rail mount secured in an affixed state
between the second carriage mounts on each said pair of carriage
rails.
9. A forming machine according to claim 8 wherein each said tooling
rail is removably secured to a respective intermediate tooling rail
mount.
10. A forming machine according to claim 1 wherein said tooling
rails are movable laterally and independently of one another in the
interior of said cage.
11. A forming machine according to claim 1 wherein said carriage
mounts each include a body portion having a bore extending
therethrough and a mounting head, said body portion including slots
formed therein that intersect the bore thereby to form a clamping
arm operative to extend around a respective carriage rail, said
clamping arm having an associated fastener operative to selectively
clamp its respective said carriage mount at a selected location
along said carriage rail.
12. A forming machine according to claim 1 wherein said carriage
rails have markings thereon to correspond to selected positions for
said carriage mounts.
13. A forming machine according to claim 1 including at least one
movable limit stop member disposed on each carriage rail, each said
limit stop member adjustably positionable along its respective
carriage rail and operative when in a secured state to restrict
movement of a respective carriage mounts in at least one lateral
direction.
14. A forming machine adapted to receive an elongated sheet of
formable material and operative to form a desired profile thereon,
comprising: (a) a rigid framework including side frames rigidly
interconnected to one another by transverse members to form a rigid
cage having an interior and a width between said side frames, said
cage extending about a forming region through which the elongated
sheet may be advanced from an upstream entrance to a downstream
exit; (b) a sheet drive supported by said framework and operative
to advance the elongated sheet therethrough, said sheet drive
including a plurality of pairs of co-acting rollers wherein one of
said co-acting rollers is a driven roller and another of said
co-acting rollers is a free-wheeling roller, each of said pairs
being longitudinally spaced from an adjacent one of said pairs in a
downstream direction from the entrance to the exit; (c) a drive
assembly interconnected to at least one roller in each of said
pairs or co-acting rollers and operative to rotatably drive said
one roller whereby each of said pairs of co-acting rollers is
operative to engage a portion of the elongated sheet and advance
the elongated sheet in a downstream direction through said
framework to discharge the elongated sheet at the exit; (d) a
plurality of pairs of opposed primary rail mounts secured to said
framework in parallel spaced-apart relation to one another, one
primary rail mount of each pair extending alongside one of said
side frames and another primary rail mount of each pair extending
alongside another one of said side frames; (e) a plurality of pairs
of carriage rails supported by respective ones of said primary rail
mounts and extending transversely of said framework; (f) first and
second carriage mounts slideably disposed on each of said carriage
rails; (g) a first tooling rail secured in a mounted state to the
first carriage mounts on each said pair of carriage rails and a
second tooling rail secured in a mounted state to the second
carriage mounts on each said pair of carriage rails whereby said
tooling rails may be moved laterally and independently of one
another in the interior of said cage; and (h) a plurality of
forming elements supported by each said tooling rail to define at
least two forming stations located in a longitudinally spaced
relation to one another along said tooling rail, said forming
stations positioned to receive an edge portion of the elongated
sheet when in the mounted state whereby said forming stations are
operative to bend the elongated sheet into the desired profile as
the elongated sheet is advanced through the forming region by said
drive assembly.
15. A forming machine according to claim 14 wherein each said
free-wheeling roller is rotatably supported by upper ones of said
transverse members and wherein rotation of one of said driven
rollers imparts an equal counter-rotation of its associated
free-wheeling roller.
16. A forming machine according to claim 14 including lower pairs
of said transverse members disposed in parallel spaced-apart
relation to one another, the primary rail mounts of each of said
pairs of opposed primary rail mounts extending longitudinally
between respective ones of said lower pairs of said transverse
members.
17. A forming machine according to claim 14 including a first
intermediate tooling rail mount secured in an affixed state between
the first carriage mounts on each said pair of carriage rails and a
second intermediate tooling rail mount secured in an affixed state
between the second carriage mounts on each said pair of carriage
rails, and wherein each said tooling rail is secured to a
respective intermediate tooling rail mount.
18. A forming machine according to claim 14 wherein said carriage
mounts each include a body portion having a bore extending
therethrough and a mounting head, said body portion including slots
formed therein that intersect the bore thereby to form a clamping
arm operative to extend around a respective carriage rail, said
clamping arm having an associated fastener operative to selectively
clamp its respective said carriage mount at a selected location
along said carriage rail.
Description
FIELD OF THE INVENTION
[0001] The present invention generally relates to material
fabricating machines, but more particularly relates to forming
machines wherein an elongated strip of material is advanced through
the machine against forming elements in order to progressively
shape the strip of material into a desired cross-sectional
configuration. Specifically, the present invention concerns metal
forming apparatus that receives an elongate strip of material,
either as a panel or from a continuous spool, to fabricate a shaped
member for the construction industry. This invention is
particularly concerned with a machine that is adjustable to alter
profile dimensions on a strip of material as well as a machine that
can be easily custom configured for different profiles.
BACKGROUND OF THE INVENTION
[0002] Material forming machines play a significant role in modern
industry and include, for example, machines which stamp, roll,
form, cut and extrude metal, to name a few. One type of machine,
and a type to which the present invention is directed, receives an
elongated strip of material at an entry way, advances the strip of
material progressively through the machine and against laterally
positioned forming elements to configure longitudinal margins of
the strip into desired useful cross-sections. After formation, the
strip is discharged at an exit location, and a shear may be
positioned at the exit in order to cut the formed material into
selected lengths. The strips of material that are fed into the
machine may either be fed as discrete lengths or, as is more
typically the case, a continuous feed is provided from a coil, such
as a coil of metal to be formed, and the formed strip is cut into
usable lengths at the exit location or in the machine. Specific
examples of such machines for which the present invention is
particularly useful include, roof panel and siding panel forming
machines.
[0003] Existing material forming machines typically have a
framework which supports a drive assembly for advancing the
elongated strip of material from the entrance to the exit. The
drive assembly is coupled to one or more pairs of co-acting rollers
centrally located along the pathway of the strip. It has long been
thought necessary that the coacting pairs include two driven
rollers each journaled for synchronous rotation about first and
second axes, respectively, which rollers were located above and
below the strip as it passed through the frame work. However, as
set forth in U.S. Pat. No. 5,740,687 issued 21 Apr. 1998 to Meyer
et al and assigned to the assignee of the present invention, a
forming apparatus was disclosed wherein the pairs of coacting
rollers each comprise a driven roller connected to the drive
assembly and a free wheeling roller that was adjustably mounted
relative to its associated driven roller.
[0004] In any event, in material forming machines, it is known to
provide a plurality of forming rollers that are disposed along the
pathway of the strip to configure one or both margins into a
desired profile. This is accomplished by progressively bending the
margins into a particular shape. Sometimes these forming rollers
are each independently mounted to the framework at selected
locations, but in other technique involves a group of forming
elements together in forming station sets along the pathway of the
strip. For example, in U.S. Pat. No. 5,425,259 issued Jun. 20, 1995
to Coben et al discloses a forming machine for bending strips
wherein an elongated rail structure is secured within the interior
of the framework of the machine and is removable out of one
entrance or exit of the frame work. The rail structure was mounted
at discrete mounting locations spaced laterally of the drive
mechanism, and a plurality of forming elements were disposed on the
rail structure to define at least two longitudinally spaced forming
stations. The rail structure was removable from the framework
without detaching the mounting stations. Alternative sets of rail
structures were then interchangeably mounted in the framework as
forming sets to allow formation of different profiles without
individually changing each forming station.
[0005] While all of these existing machines are quite useful and
effective in fabricating metal strips into shaped members, such as
panels and gutters, many machines can only form a single profile so
that the fabricator must acquire separate machines for each profile
desired to be configured or each change of dimensions.
Alternatively, the entire set of forming elements need to be
replaced by individually detaching each forming element or, in
certain cases, by replacing a forming station box comprising a set
of forming rollers. In U.S. Pat. No. 5,394,722 issued Mar. 7, 1995
to Meyer, apparatus for forming profiles on strip materials is
disclosed wherein a standard profile can be formed of two different
sizes or physical dimensions. The machine shown in the '722 Patent
utilizes rollers that may position toward and apart from one
another for selected spacing between two relative positions thereby
to selectively vary the profile formed.
[0006] Nonetheless, there remains a need for material forming
machines of improved design wherein greater flexibility of
fabrication may be achieved. There is a need for machines that are
easily adjustable to vary the profile dimensions including such
dimensions as profile height and profile separation with a minimum
of down time for the machine. There is a further need for machines
which can easily be customized for different profiles. The present
invention is directed toward satisfying such needs.
SUMMARY OF THE INVENTION
[0007] It is an object of the present invention to provide a new
and useful material forming machine that is operative to form
elongated strips of material, such as metal, into desired
cross-sectional profiles as the strip of material is advanced
through the machine.
[0008] Another object of the present invention is to provide a
forming machine that can form cross-sectional profiles that may be
easily varied in shape and dimensions.
[0009] A further object of the present invention is to provide a
material forming machine wherein forming rollers may be
interchanged as sets without the need to mount and demount each
individual forming roller set independently from one another.
[0010] Still a further object of the present invention is to
provide a material forming machine for strips of material, such as
metal, of simplified construction with enhanced ease of
adjustability for the profiles on the strips formed thereby.
[0011] It is still a further object of the present invention to
provide a material forming machine that is compact in size yet
versatile in use.
[0012] Yet another object of the present invention is to provide a
material forming machine that is capable of providing a wide
variety of profiles while being readily transportable.
[0013] According to the present invention, then, a forming machine
is adapted to receive an elongated sheet of formable material and
is operative to form a desired profile on that sheet. The forming
machine includes a rigid framework that has side frames rigidly
interconnected to one another by transverse members to form a rigid
cage having an interior and a width between the side frames. The
cage extends about a forming region through which the elongated
sheet may be advanced from an upstream entrance to a downstream
exit. A sheet drive is supported by the framework and is operative
to advance the elongated sheet therethrough. The sheet drive
includes a plurality of pairs of coacting rollers with each of the
pairs of rollers being longitudinally spaced from an adjacent pair
in the downstream direction from the entrance to the exit. A drive
assembly is then interconnected to at least one roller in each of
the pairs of co-acting rollers. The drive assembly operates to
rotatably drive such roller whereby each of the pairs of co-acting
rollers is operative to engage a portion of the elongated sheet and
advance the elongated sheet in a downstream direction through said
framework and thereafter discharge the elongated sheet after
forming the profiles thereon at the exit of the frame work.
Preferably, each of the pairs of co-acting rollers includes a
driven roller and a free wheeling roller. The free wheeling roller
is rotatably supported by an upper transverse member. Rotation of
the driven roller imparts an equal counter rotation to its
associated free wheeling roller.
[0014] A plurality of pairs of carriage rails are supported by the
framework and extend transversely thereof. Each of the carriage
rails has opposite ends secured to the framework at a location
proximately to a respective side frame so as to extend a majority
of the width of the frame work. First and second carriage mounts
are then slideably disposed on each of the carriages. A first
tooling rail is secured in a mounted state to the first carriage
mount on each said pair of carriage rails and a second tooling rail
is secured in a mounted state to the second carriage mounts on each
said pair of carriage rails whereby the tooling rails may be moved
laterally within the cage defined by the frame work. A plurality of
forming elements is then supported by each tooling rail to define
at least two forming stations with the forming stations located in
a longitudinally spaced relation to one another along the tooling
rail. These forming stations are positioned to receive an edge
portion of the elongated sheet when in the mounted state whereby
the forming stations are operative to bend the elongated sheet into
the desired profile as the elongated sheet is advanced through the
forming region by the drive assembly.
[0015] A plurality of pairs of opposed primary rail mounts are
secured to the framework in parallel spaced-apart relation to one
another. One primary rail mount on each pair extends alongside one
of the side frame while the other primary rail mount of each pair
extends alongside the other of the side frames. The primary rail
mounts of each pair preferably extend longitudinally between
respective ones of the lower transverse members which thereby
define lower pairs to support the opposed primary rail mounts. A
first intermediate tooling rail mount may be secured in an affixed
state between the first carriage mounts on each pair of carriage
rails and a second intermediate tooling rail mount may be secured
in an affixed state between a second carriage mount on each pair of
carriage rails. With this configuration, each tooling rail is
removably secured to respective intermediate tooling rail mount.
Moreover, the tooling rails are movable laterally and independently
of one another in the interior of the cage by sliding the
respective carriage mounts to and fro on the carriage rails. The
carriage rails may have index markings to correspond to selected
positions for the carriage mounts whereby the carriage mounts may
be registered with the index markings to determine the dimensions
of the profile to be formed. One or more movable limit stop members
in the form of locking collars may be disposed on each carriage
rail. Here, the limit stop member is adjustably positionable along
its respective carriage rail and operates in a secured state to
restrict movement of a respective carriage rail mount in at least
one lateral direction.
[0016] The carriage rail mounts preferably include a body portion
that has a bore extending therethrough. A mounting head is
supported on the body portion and acts to mount the intermediate
tooling rail mount and tooling rail. The body portion includes
slots formed therein that intersect the bore and each other thereby
to form a clamping arm that is integral with the body. The clamping
arm is operative to extend around a perspective rail. Each clamping
arm has an associated fastener operative to selectively clamp the
respective carriage mount at a selected location along the
respective carriage rail.
[0017] These and other objects of the present invention will become
more readily appreciated and understood from a consideration of the
following detailed description of the exemplary embodiment of the
present invention when taken together with the accompanying
drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a perspective view, partially cut-away, of a
forming machine according to the exemplary embodiment of the
present invention;
[0019] FIG. 2 is a top plan view of the forming apparatus of FIG. 1
with the outer panel coverings removed therefrom;
[0020] FIG. 3 is a side view in elevation and in partial
cross-section showing a representative construction of the
co-acting pair of rollers (one drive and one free wheeling)
according to the exemplary embodiment of the present invention;
[0021] FIG. 4 is an end view in elevation, looking upstream of a
first representative pair of co-acting rollers of FIG. 3 and
showing the elongated strip of material passing therethrough;
[0022] FIG. 5 is a perspective view of the entryway guide of the
present invention;
[0023] FIG. 6 is a perspective view of the drive system, driven
rollers and free wheeling rollers according to the exemplary
embodiment of the present invention;
[0024] FIG. 7 is a perspective view of a carriage rail, carriage
mount and tooling rail assembly used with the exemplary embodiment
of the present invention showing a pair of opposed forming stations
mounted thereon;
[0025] FIG. 8 is a top view in elevation showing the carriage rail,
carriage mount and tooling rail assembly of FIG. 6 mounted in the
framework of the machine and adjusted to a representative
orientation for forming profiles on the edge margins of an
elongated margin sheet of material passing therethrough;
[0026] FIG. 9 is an end view in elevation showing the carriage
rail, carriage mounts and tooling rail assembly and frame of FIG.
7;
[0027] FIG. 10 is an exploded end view in elevation and in partial
cross-section showing the assembly of the carriage rail, carriage
mount and tooling rail structure according to the present
invention;
[0028] FIG. 11(a) is a perspective view of a first embodiment of a
carriage mount according to the present invention and FIG. 11(b) is
a perspective view of an alternative embodiment of the carriage
mount according to the present invention;
[0029] FIG. 12 is a perspective view of a representative carriage
rail according to the present invention with a pair of limit stops
thereon;
[0030] FIG. 13 is a top plan view of the carriage rail, carriage
mount and tooling rail assembly according to the exemplary
embodiment of the present invention; and
[0031] FIGS. 14(a) and 14(b) show alternate rail structures for use
with the material forming machine of FIGS. 1-13 of the present
invention.
DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS
[0032] The present invention is directed to material forming
machines specifically adapted to bend one or both longitudinal
margins of a flat strip of metal into a desired profile. While the
present invention may be employed with elongated strips of material
cut at discrete lengths, it is contemplated that the present
invention may be primarily used with a continuous feed structure
wherein formed strips having a desired longitudinal profile are cut
out of continuous strip of material that fed into the forming
machine. Specifically, the present invention is constructed to
receive a variety of different sets of metal forming stations
mounted as sets on rail structures so that the different sets may
be easily interchanged to allow fabrication of different panel
profiles. In addition, it is a particular feature of the present
invention to provide improved structure for lateral adjustment of
the different sets of forming stations so that the profile
dimensions can be easily and precisely altered thereby to minimize
the down time of the machine. To this end, it should be understood
that the phrase "panel" when used in the context of a formed strip
can include, for example, a standing seam panel, siding, guttering,
structural or nonstructural framing members and the like, as would
be understood by the ordinarily skilled person in the material
forming art. Moreover, while the present machine is specifically
adapted to form metal panels, it should be understood that it is
within the context of this invention to form profiles of other
types and on other types of formable materials.
[0033] By way of explanation, then, a representative material
forming apparatus 10 is introduced in FIGS. 1 and 2. Here, forming
apparatus 10 is constructed as a machine that may, for example, be
used to fabricate roof panels, siding panels, gutters and the like.
Forming apparatus 10 includes a framework 12 formed as a plurality
of longitudinally extending beams 14 interconnected by means of
upper transverse beams 16, lower transverse beams 17 and upright
beams 18. Frame 12 is encased by an outer panel covering 20 which
extends therearound. Forming apparatus 10 has an entryway 22
located at a first end and an exit 24 located at a second end which
is in a longitudinally positioned at a downstream location from the
first end of frame 12. A shear 100 may be located at exit 24 to cut
selected lengths of formed materials, as is known in the art.
[0034] Forming apparatus 10 is particularly adapted to receive an
elongate flat sheet of formable material, such as metal, and to
shape the sheet of material 27 into a shaped member which may be
used, for instance, in the construction industry. In particular,
forming apparatus 10 is adapted to form roof panels or siding
panels wherein mating profiles are formed on the opposite edge
margins of the sheet of material so that, after the panels are
formed, adjacent panels may interlocked together as is known in the
art. To this end, the elongated sheet 27 enters the forming
apparatus 10 at an upstream location defined by entrance 22 and
initially comes in contact with a guide assembly 26 described more
thoroughly below in reference to FIG. 5.
[0035] With reference to FIG. 2, it may be seen in that forming
apparatus 10 includes a drive assembly 50 that will be described in
greater detail below with reference to FIG. 6. Drive assembly 50
includes a plurality of drive stations 51, 52 and 53 which are each
located at longitudinally spaced-apart downstream regions from each
other within framework 12. Drive stations 51-53 are mechanically
coupled to one another and powered by a chain assembly best shown
in FIG. 6. The preferred construction for a representative drive
station 51 is shown with reference to FIGS. 3 and 4. However, it
should be appreciated by one skilled in the art that drive station
52 would be constructed similarly. A representation example of
these drive stations is shown in FIG. 4 wherein drive station 51
includes a pair of co-acting rollers 54 and 56 each respectfully
journaled for rotation around first axle 55 and second axle 57.
First axle 55 and second axle 57 define axes for rollers 54 and 56
that are oriented transversely to the downstream direction in which
the sheet of material is advanced and are parallel to that sheet as
it passes through forming apparatus 10. Axles 55 and 57 are each
mounted to frame 12 by means of bearing blocks 46 and 48, as is
shown in FIG. 2.
[0036] Drive stations 51-53 are constructed substantially in U.S.
Pat. No. 5,740,687, the disclosure and teachings of which are
specifically incorporated herein by reference especially that in
FIGS. 1-4 and 6. In FIGS. 3 and 4, it may be seen that upper roller
54 is a freewheeling roller, while lower roller 56 is a driven
roller. Preferably each of these rollers is covered by a
circumferential layer of polyurethane, 75 and 77, as is shown in
FIG. 3. Free wheeling roller 54 and driven roller 56 co-act with
one another to grip a central portion 29 of sheet 27 as it is
advanced in the downstream direction.
[0037] Both free wheeling roller 54 and driven roller 56 are
disposed in housings 58 and 59, respectively. Housing 59 for driven
roller 56 is stationary relative to frame 12, and it includes
plates 47 secured to angle bars 49 mounted to longitudinal rails
14. Housing 58 for free wheeling roller 54 is adjustably mounted to
frame 12 by screws 76 and jack-screws 78 which permit vertical
adjustment of the free wheeling roller 54 relative to driven roller
56. It should be understood, then, that as sheet 27 is advanced
from the upstream region proximate entrance 22, its lateral margins
28 and 30 will be subjected to the forming stations, as discussed
below. Central portion 32 of sheet 27 is sandwiched between free
wheeling roller 54 and driven roller 56.
[0038] In order to introduce sheet 27 into the first driven station
51, guide assembly 26 is provided at entryway 22. Guide assembly 26
is seen best in FIG. 5 where it may be seen that a pair of brackets
37 are mounted longitudinal beams 14 and support a pair of
spaced-apart parallel round bars 31 and 32. A first guide plate 33
is slideably disposed on bars 31 and 32 and is secured to a
cylindrical clamp 38 that is slideably received on bar 31. Guide
plate 33 has a pair of oppositely projecting wings 34. Similarly, a
second guide plate 35 is slideably disposed on bars 31 and 32 and
is fastened to a cylindrical clamping piece 39. An upwardly arcuate
strap 40 is secured to guide plate 33 and an upwardly arcuate strap
41 is secured to guide plate 35. A smaller strap 42 is secured to
guide plate 33 and, together with strap 40, forms a converging
region 44 into which a leading edge of sheet 27 may be inserted.
Likewise, a smaller strap 43 is mounted on plate 35 and, together
with arcuate strap 41, forms a converging region 45 for the leading
edge of sheet 22. Each of clamps 38 and 39 may be released for
lateral adjustment of each of plates 33 and 35 and, when secured,
act to retain plates 33 and 35 in the desired orientation.
Preferably, this orientation is the width of the sheet 27 that is
to be processed by forming apparatus 10.
[0039] FIG. 6 shows the construction and operation of the drive
assembly 50 according to the exemplary embodiment of the present
invention. Here it may be seen that drive assembly 50 is empowered
by a driver in the form of a motor 43 which is connected to gear
box 45 to provide rotary power to each of the drive stations 51-53.
Motor 43 drives sprocket wheels 88 and 90, which are coupled
together by chain 61, in a counterclockwise direction as sown in
FIG. 6. Sprocket gear 90 is disposed about second axle 83 of driven
roller 82 and, thereby, causes sprocket wheels 92 and 94 to also
rotate in a counterclockwise direction. Sprocket wheel 92 is
coupled by a second chain 62 to sprocket wheel 64 which is disposed
about second axle 57 of driven roller 56. Located beneath a lower
portion of chain 62 between sprocket wheels 92 and 64 are a pair of
polyurethane chain tighteners 84 and 85.
[0040] It should be understood that the counterclockwise rotation
of sprocket wheel 92 causes sprocket wheel 64 to also rotate in a
counterclockwise direction, thereby permitting rotation of driven
roller 56. Driven roller 56 is thus rotatably driven in a
counterclockwise direction; the counterclockwise rotation of driven
roller 56 imparts a clockwise rotation of free wheeling roller 54
about first axis 55 to advance sheet 27 downstream. Likewise,
driven roller 67 of driven station 53 rotates in the
counterclockwise direction by virtue of its mechanical coupling to
sprocket wheel 94. To illustrate, as sprocket 94 rotates
counterclockwise, it causes sprocket wheel 96 to rotate by virtue
of its mechanical coupling thereto by chain 63. A similar
counterclockwise rotation is imparted to sprocket wheel 98 which is
adjoined to sprocket wheel 96 by axle 97. As sprocket wheel 98
rotates counterclockwise, the second axle 70 of driven roller 67 in
drive station 53 is also caused to rotate in the same manner.
Moreover, free wheeling roller 65 rotates in the clockwise
direction. From the foregoing, it should be understood by one of
ordinary skill that the chain coupling discussed above enables each
of the co-acting pairs of roller in drive stations 51-53 to
cooperate in unison with one another.
[0041] With reference now to FIGS. 7-10, the structure of the
carriage rail, carriage mount and tooling rail assembly used with
the exemplary embodiment of the present invention is shown. In
these Figures, assembly 110 is shown to include a pair of rail
mounts 112 and 114 which are in parallel spaced-apart relation to
one another so that they may be mounted alongside longitudinal
beams 14 at a lower portion of framework 12. Rail mounts 112 and
114 are the primary mounts for assembly 110 and are supported by
lower pairs of transverse members in the form of lower beams 17. To
this end, primary rail mount 1 12 has oppositely projecting arms
113 adapted to rest on a pair of lower beams 17. Likewise, rail
mount 114 has a pair of oppositely projecting arms 115 also adapted
to rest on a pair of lower beams 17. A pair of carriage rails 116
and 118 extend between opposite ends of rail mounts 112 and 114 so
as to be in parallel spaced-apart relation to one another. Thus,
carriage rails 116 and 118 extend transversely of framework 12 and
the direction of advancement of material through forming apparatus
10.
[0042] A first carriage mount 120 and a second carriage mount 122
are slideably disposed on each of carriage rails 116 and 118. The
structure of carriage mounts 120 and 122 are described more
thoroughly below. A first pair carriage mounts 120 supports an
intermediate tooling rail mount 124 which is in the form of an
elongated rectangular bar of sufficient length to extend
longitudinally between and preferably beyond carriage mounts 120 in
both the upstream and downstream direction. A tooling rail 126 is
then secured by means of bolts or other fasteners, to tooling rail
126 to form a rigid structure that will slide in the direction of
arrow "A" (FIG. 8) on slide mounts 120. Similarly, an intermediate
tooling rail mount 128 extends in the longitudinal direction
between a pair of carriage mounts 122. Intermediate tooling rail
mount 128 is structured similarly as intermediate tool rail mount
124. Here again, tooling rail mount 128 supports a tooling rail 130
with tooling rail 130 also extending in the longitudinal direction.
Thus, tooling rail 130 may be moved laterally in the direction of
arrow "B" (FIG. 8).
[0043] As is shown in FIGS. 7 and 8, tooling rail 124 supports at
least one but preferably a plurality of forming stations 150. To
this end, an upright mounting block 132 rotatably supports, for
example, a pair of forming rollers 134 and 135 on axles, as is
known in the art. To give further support to mounting stations 150,
a guide bar 136 is provided and is supported on inwardly projecting
posts 138 so that guide bar 136 is parallel to tooling rail 126.
Similarly, tooling rail 130 supports a plurality of forming
stations 152 on mounting blocks 140. Forming station 152 is formed
by a pair of forming rollers 142 and 143 which are rotatably
mounted on respective axles. Positioning blocks 144 and 145 are
provided to position forming roller 143. A second guide bar 146 is
associated with rail 130 and is mounted in parallel spaced-apart
relation thereto by means of posts 148. Guide bars 136 and 146 act
to strengthen the support of the forming stations 150 and 152, for
example, by supporting an end of the axle for forming rollers 135
and 142 that is opposite the respective mounting block 132 and 140.
Guide bars 136 and 146 also act to support the sheet-like material
as it is advanced through forming apparatus 10. As is shown in FIG.
8, in phantom, a plurality of forming stations 150 may be provided
on rail 126 and, likewise, a plurality of forming stations 152 may
be supported by tooling rail 130.
[0044] In order to more fully understand the construction just
described, an exploded view of a representative rail mount,
carriage rail and tooling rail assembly is shown in FIG. 10. Here,
it may be seen that rail mount 112 may be mounted to lower beams 17
by means of a bolt 154 extending through bore 155 in arm 113 and
mated with threaded opening 156 in beam 17. Carriage rail 116 is
then secured to rail mount 112 by means of a bolt 158 extending
through bore 159 and received in threaded bore 160 of the end of
carriage 116. Prior to the attachment of carriage 116, carriage
mounts 120 and 122 are slideably positioned thereon.
[0045] Intermediate tool rail mount 124 is fastened to carriage
mount 120 by means of a bolt 162 extending through a bore in
intermediate rail mount 124 and received by threaded bore 163 in a
head portion 164 of carriage mount 120. Tooling rail 126 is then
mounted by means of bolt 166 extending through bore 167 and
threadably received in intermediate tooling rail mount 124.
Mounting block 140 is then secured to tooling rail 126 by means of
bolt 170 extending through bore 171 and received in bore 172 of
mounting block 140. Here, it may be appreciated that bolt 170 may
be suitably dimensioned to engage an end of the axle of forming
station 150.
[0046] The structure of carriage mount 120 (and corresponding
carriage mount 122) is best shown in FIG. 11(a). As is seen in this
Figure, carriage mount 120 includes a body portion 174 which has a
longitudinally extending bore 176 extending through the length
thereof. Head portion 164 may be formed integrally with body
portion 174 but, as is shown in FIG. 11(a), may be an independent
piece that is bolted to body portion 174 by means of bolt 178. If
desired, bolt 178 may be countersunk in recess 180. Alternatively,
bolt 178 may be dimensioned so that it fastens intermediate tool
rail mount 124, head 164 and body portion 174 together. In any
event, a transverse slot 182 is cut in body portion 174 and
intersects bore 176. A second slot 184 is cut longitudinally in
body portion 174 and intersects both slot 182 and bore 176. In this
manner, a clamp arm 186 is configured and provides a means for
securing carriage mount 120 at a selected location along its
carriage rail 16. To this end, the free end 188 of clamp arm 186
has a bore 190 extending vertically therethrough and aligned with
threaded bore 192. A screw 194 may then be inserted through bore
190 and threadably received in bore 192. When tightened, screw 194
operates to reduce the diameter of bore 176 in a region adjacent
clamp arm 186 so that carriage mount 120 may be selectively
positioned and retained on a respective carriage rail.
[0047] An alternative construction of the carriage mount 120 is
shown in FIG. 11(b). Here, carriage mount 220 includes a body
portion 224 and an end block 226 that is secured thereto. Body
portion 124 is cylindrical and has a cylindrical bore 228 extending
therethrough. A transverse slot 230 is cut to intersect bore 228,
and a longitudinal slot 232 intersects both bore 228 and slot 230
in a manner similar to that described above. In this manner, clamp
arm 234 is formed similarly to clamp arm 186. Here, however, a pair
of flanges 236 may be provided and project radially outwardly of
slot 232 at arm 234 and may be secured together by means of screw
238 extending in hole 240. It should be understood that the
operation of the carriage mount 220 is the same as carriage mount
120.
[0048] With reference now to FIGS. 8, 9 and 12, it may be seen that
a representative carriage rail 116 (as well as carriage rails 118)
may be provided with index markings 200 to help facilitate lateral
adjustment of carriage mounts 120 to a desired lateral position.
Thus, the tooling rails and the tooling stations may be laterally
moved within framework 12 to accommodate different widths of sheet
material or to alter the dimensions of the selected profile that
will be formed by forming stations 150 and 152. Once in position,
clamping arm 186 of each mounting block 120 is secured by
tightening its respective screw 194 so that carriage mount 120 is
properly positioned and virtually retained on its respective
carriage rail. To further facilitate this, a limit stop in the form
of a locking collar 202 has a bore 203 sized so that each locking
collar 202 may be slideably received on a carriage rail 116, 118.
Locking collar 202 is provided with a locking set screw 204 so
that, when locking collar 202 is positioned, set screw 204 may be
tightened to lock collar 202 at the selected position. Locking
collar 202 may be released by loosening screw 204 and repositioning
the locking collar in the directions of arrows "C" (FIG. 12). In
addition to providing further support for carriage mounts 120,
locking collars 202 may be set at a desired location so that they
provide limit stops for quick adjustment of the carriage mounts.
For example, when the carriage mounts are positioned in a first
selected location for the dimensions of the profile to be formed,
locking collars 202 may be preset at a second desired location.
Then, when the user desires to change the profile dimensions,
he/she simply loosens screws 194 and slides the mounting blocks
against the respective locking collars 202.
[0049] With reference now to FIG. 13, it may be seen that framework
12 provides a plurality of pairs of carriage rails 116 and 118 each
with carriage mounts 120, 122. A pair of longitudinally extending
tooling rail mounts 124 and 128 are mounted on framework 12. Here,
an intermediate tooling rail mount 124 extends between a pair of
carriage mounts 120 on a respective pair of carriage rails 116,
118. Likewise, a second intermediate tooling rail mount 128 extends
between a pair of carriage mounts 122 on a respective pair of
carriage rails 116,118.
[0050] With FIG. 13 in mind, and with reference to FIGS. 14(a) and
14(b), it should now be appreciated that tooling rails 126 and 130
with their associated forming stations 150 and 152 may be mounted
as sets. Tooling rails 126 mounts form one lateral rail structure
for forming one margin of the sheet of material while tooling rails
130 form a second rail structure that carries forming stations 152
to configure a second lateral margin of the sheet to be formed.
This is similar to that disclosed in U.S. Pat. No. 5,425,259 which
is incorporated herein by reference, particularly FIGS. 12(a) and
12(b) and the related text. It should be appreciated that each rail
structure carries a plurality of forming stations mounted thereon
and that alternative rail structures may be interchanged to provide
different forming stations whereby different edge profiles may be
fabricated. For example, as is shown in FIG. 14(a), a first rail
structure 340 includes a first rail section 342, a second rail
section 343 and a third rail section 344 which may be
longitudinally aligned with one another. Rail section 342 carries
forming stations A1-A3 on respective mounting blocks 370 while rail
section 343 carries forming stations A4-A6 on mounting blocks 370.
Rail section 344 carries forming stations A7-A9 on mounting blocks
370. Removal of rail sections 342, 343 and 344 would allow removal
of all of forming stations A1-A9 without removing the forming
stations from the respective rail section. Similarly, second rail
structure 440, shown in FIG. 14(a), is formed of three rail
sections 442, 443 and 444. Rail section 442 carries forming
stations B1-B3 respectively mounted on plates 470 while rail
section 443 carries a plurality of forming stations B4-B6 on
mounting plates 470. Rail section 444 carries forming stations
B7-B9 on plates 470. Again, removal of each of rail sections 442,
443 and 444 allows removal of all of forming stations B1-B9 from
the forming region. Likewise in FIG. 14(b), first rail structure
540 has aligned rail sections 542, 543 and 544 which respectively
mount forming stations C1-C3, C4-C6 and C7-C9; second rail
structure 640 has aligned rail sections 642, 643 and 644 which
mount forming stations D1-D3, D3-D6 and D7-D9, respectively, on
plates 570 and 670.
[0051] It should now be appreciated with the structure described
above, alternative sets of forming elements may be removed from the
forming machine 10 without detaching the respective pairs of
forming elements that define the forming stations from the
respective rails. Therefore, a fabricator may fabricate different
profiles by using different sets of first and second rail
structures without the need to use a different forming machine.
That is, the various forming elements that define the forming
stations may be inserted and removed from the machine as easily
mounted sets without removing those forming elements from their
respective rails. Since the attachment of each rail is accomplished
by simply bolting the rail to its respective intermediate tooling
rail mount, very little time is necessary to complete this
process.
[0052] Accordingly, the present invention has been described with
some degree of particularity directed to the exemplary embodiment
of the present invention. It should be appreciated, though, that
the present invention is defined by the following claims construed
in light of the prior art so that modifications or changes may be
made to the exemplary embodiment of the present invention without
departing from the inventive concepts contained herein.
* * * * *