U.S. patent application number 10/234359 was filed with the patent office on 2003-01-02 for rollforming machine and methods.
Invention is credited to Hedman, Norman J., Jinkens, Joseph A., Pacalo, John M. III, Patty, Alfred C., Stimpert, Larry E. II.
Application Number | 20030000271 10/234359 |
Document ID | / |
Family ID | 25109020 |
Filed Date | 2003-01-02 |
United States Patent
Application |
20030000271 |
Kind Code |
A1 |
Patty, Alfred C. ; et
al. |
January 2, 2003 |
Rollforming machine and methods
Abstract
Rollforming machines and methods for adjusting a forming roll
for forming components from materials of different thicknesses. The
rollforming machines and methods may also provide for overbending
the component being rollformed.
Inventors: |
Patty, Alfred C.; (Portage,
IN) ; Pacalo, John M. III; (Pittsburgh, PA) ;
Hedman, Norman J.; (Hilliard, OH) ; Stimpert, Larry
E. II; (Ashland, OH) ; Jinkens, Joseph A.;
(New Albany, OH) |
Correspondence
Address: |
KIRKPATRICK & LOCKHART LLP
535 SMITHFIELD STREET
PITTSBURGH
PA
15222
US
|
Family ID: |
25109020 |
Appl. No.: |
10/234359 |
Filed: |
September 4, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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10234359 |
Sep 4, 2002 |
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09777015 |
Feb 5, 2001 |
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Current U.S.
Class: |
72/176 |
Current CPC
Class: |
B21D 5/08 20130101 |
Class at
Publication: |
72/176 |
International
Class: |
B21D 005/08 |
Claims
What is claimed is:
1. A rollforming apparatus for overbending a generally C-shaped
component with a web, a pair of legs connected to the web, and a
lip protruding from an end of each leg, said apparatus comprising:
a support stand; a lower forming roll rotatably supported on said
stand for supporting a portion of the web thereon; a backup roll
pivotably supported on said stand for engagement with an outer
portion of one of the legs, said backup roll being selectively
independently pivotable relative to said lower forming roll without
contacting the lips on the legs; and an angled forming roll
positioned for selective engagement with a junction between an
inner portion of the web and an inner portion of one of the legs
without contacting any of the lips protruding from the legs.
2. A rollforming apparatus for overbending a generally C-shaped
component with a web and a pair of legs connected to the web, said
apparatus comprising: a support stand; a lower forming roll
rotatably supported on said stand for supporting a portion of the
web thereon; a backup roll pivotably supported on said stand for
engagement with an outer portion of one of the legs, said backup
roll being selectively independently pivotable relative to said
lower forming roll; and an angled forming roll positioned for
selective engagement with a junction between an inner portion of
the web and an inner portion of one of the legs.
3. A rollforming apparatus, comprising: a vertically extending
support stand; a forming roll supported on a spindle; an adjustment
block movably supported on said support stand, said spindle
rotatably supported by said adjustment block; and a slide assembly
in cooperative engagement with said support stand and said
adjustment block to provide for selective angular movement of said
forming roll upon moving said adjustment block vertically on said
support stand.
4. The apparatus of claim 3, wherein said slide assembly is
positioned between said support stand and said adjustment
block.
5. The apparatus of claim 3, wherein said slide assembly includes a
rail member and a bearing member, said rail member and bearing
member in cooperative engagement to provide relative movement
therebetween.
6. The apparatus of claim 5, wherein the movement between said rail
member and said bearing member is linear movement.
7. The apparatus of claim 6, wherein the linear movement between
said rail member and said bearing member is along an axis that
extends at an angle of greater than 0 degrees and less than 90
degrees with respect to a generally horizontal axis.
8. The apparatus of claim 3, wherein said rail member is connected
to one of said support stand and said slide assembly, and said
bearing member is connected to the other of said support stand and
said slide assembly.
9. The apparatus of claim 5, wherein slide assembly further
includes an inner gage block mounted to said adjustment block, and
wherein one of said rail member and said bearing member is attached
to said inner gage block.
10. The apparatus of claim 9, wherein slide assembly further
includes an outer gage block mounted to said support stand, and
wherein one of said rail member and said bearing member is attached
to said outer gage block.
11. The apparatus of claim 10, wherein said inner gage block moves
relative to said outer gage block.
12. The apparatus of claim 3, wherein said forming roll is affixed
directly to said spindle for rotation with said spindle.
13. The apparatus of claim 3, wherein said forming roll is affixed
directly to a sleeve, said sleeve being slideably connected to said
spindle for rotation with said spindle.
14. The apparatus of claim 3, further comprising a screw jack
assembly connected to said adjustment block for driving movement of
said adjustment block.
15. The apparatus of claim 14, wherein said screw jack assembly is
mounted to said support stand.
16. The apparatus of claim 3 wherein said support stand includes a
base having a first leg and a second leg extending therefrom, said
slide assembly in cooperative engagement with at least one of said
first leg and said second leg.
17. The apparatus of claim 3, wherein said forming roll is
contained in a plane that is generally perpendicular to a
longitudinal axis of said spindle.
18. A rollforming apparatus, comprising: a support stand; a forming
roll supported on a spindle; an adjustment block, said spindle
rotatably secured to said adjustment block; and a slide assembly in
cooperative engagement with said support stand and said adjustment
block to provide movement of said forming roll in a direction that
is the resultant of normal and axial components of motion of said
spindle.
19. A rollforming apparatus, comprising: a support stand; a forming
roll supported on a spindle; an adjustment block, said spindle
rotatably secured to said adjustment block; and a slide assembly
including an inner gage block mounted to said adjustment block and
an outer gage block mounted to said support stand, said slide
assembly further including a rail member and a bearing member, one
of said rail member and said bearing member attached to said inner
gage block and the other of said rail member and said bearing
member attached to said outer gage block, said rail member and
bearing member in cooperative engagement to facilitate movement
between said support stand and adjustment block to provide movement
of said forming roll axially along an axis of rotation of said
spindle and transversely to said axis of rotation of said
spindle.
20. A rollforming machine, comprising: a plurality of rollforming
stations, at least one of said plurality of rollforming stations
comprising: a support stand; a forming roll supported on a spindle;
an adjustment block, said spindle rotatably secured to said
adjustment block; and a slide assembly in cooperative engagement
with said support stand and said adjustment block to provide
movement of said forming roll axially along an axis of rotation of
said spindle and transversely to said axis of rotation of said
spindle.
21. A method of forming a component, comprising: feeding a sheet of
material to a rollforming station having a forming roll supported
by a spindle rotatably secured to an adjustment block to form said
component; and adjusting the position of the forming roll by
employing a slide assembly in cooperative engagement with the
adjustment block to facilitate movement of the forming roll in a
direction that is the resultant of normal and axial components of
motion of the spindle.
22. A method of forming a structural component from a flat piece of
sheet metal comprising: bending a portion of the sheet metal to
form a leg portion and a web portion such that the leg portion is
oriented at an angle relative to the web portion; supporting the
web portion along a horizontal plane; engaging a junction formed
between the leg portion and the web portion with a member; and
applying a further bending force to the leg in a direction which
reduces the angle between the leg portion and the web portion while
said engaging the junction between the leg portion and web portion
with the member.
23. The method of claim 22 wherein the angle relative to the web
portion is reduced to an angle within the range of eighty-four to
ninety-one degrees upon said applying a further bending force to
the leg.
24. The method of claim 22 wherein said engaging a junction formed
between the leg portion and web portion further comprises engaging
the junction with an angled roller.
25. The method of claim 22 further comprising removing at least
some camber in the component after said applying a further bending
force.
26. The method of claim 22 further comprising removing at least
some twist in the component after said applying a further bending
force.
27. The method of claim 22 further comprising removing at least
some bow in the component after said applying a further bending
force.
28. A method of forming a structural component from a flat piece of
sheet metal having a pair of lateral sides, said method comprising:
bending portions of the flat piece of sheet metal along each
lateral side to form lip portions that each protrude at an angle
relative to a remaining portion of the piece of sheet metal;
bending the remaining portion of the piece of sheet metal to form a
leg portion corresponding to each lip portion such that the lip
portion protrudes from the corresponding leg portion at an angle
and such that each leg portion forms a corresponding junction with
a web portion extending between the leg portions, each leg portion
oriented at an angle relative to the web portion; supporting the
web portion along a horizontal plane; engaging the junction formed
between one of the leg portions and the web portion with a member;
applying a further bending force to the one of the leg portions in
a direction which reduces the angle between the one of the leg
portions and the web portion while said engaging the junction
between the one of the leg portions and web portion with the
member; engaging another junction formed between another of the leg
portions and the web portion with another member; and applying
another further bending force to the another of the leg portions in
a direction which reduces the angle between the another of the leg
portions and the web portion while said engaging the junction
between the another of the leg portions and web portion with the
another member.
29. The method of claim 28 wherein the angle of one of the leg
portions relative to the web portion is reduced to an angle within
the range of eighty-four to ninety-one degrees upon said applying a
further bending force to the one of the leg portions.
30. The method of claim 28 wherein the angle of the another of the
leg portions relative to the web portion is reduced to another
angle within the range of eighty-four to ninety-one degrees upon
said applying another further bending force to the another of the
leg portions.
31. The method of claim 28 wherein said engaging a junction formed
between the one of the leg portions and web portion further
comprises engaging the junction with an angled roller.
32. The method of claim 31 wherein said engaging another junction
formed between the another of the leg portions and web portion
further comprises engaging the another junction with another angled
roller.
33. The method of claim 28 further comprising removing at least
some camber in the component after said applying another further
bending force.
34. The method of claim 28 further comprising removing at least
some twist in the component after said applying another further
bending force.
35. The method of claim 28 further comprising removing at least
some bow in the component after said applying another further
bending force.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Divisional Patent Application of U.S.
patent application Ser. No. 09/777,015, filed Feb. 5, 2001.
FEDERALLY SPONSORED RESEARCH
[0002] Not applicable.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The invention relates to rollforming machines and, more
particularly, to adjustable rollforming machines for forming
components from materials of different thicknesses and rollforming
machines having the capability to overbend the component being
formed.
[0005] 2. Description of the Invention Background
[0006] Rollforming is a well-know process of bending a continuous
strip or cut to length strip of metal through a series of shaped
rolls. Common rollforming processes gradually form a strip of metal
into a predetermined shape. The shapes may include, for example,
generally C-shaped cross sections or generally U-shaped cross
sections, or may include relatively complex formations being formed
along the length of the material.
[0007] Rollforming processes are widely used because they are
regarded as being a highly efficient means for continuously forming
metal strip. Any number of other operations may be performed while
the metal is taking shape. These other operations may include, for
example, punching, tabbing, cutting to length, perforating,
drawing, lancing, embossing, knurling, edge conditioning and
curving. One particular benefit of rollforming is that strength and
function are added to the metal as a result of the rollforming
process. Rollforming, therefore, provides for many advantages in
comparison to other known processes for forming metal
materials.
[0008] The marketplace for shaped, rollformed sections has expanded
into virtually every field of industry thereby replacing other
known processes such as extrusions, brake forming and punch press
operations in the areas such as the aircraft industry and the
automotive industry. Another industry that heavily relies on
rollforming is the architectural industry, and more specifically,
the metal frame construction industry. As an alternative to
traditional wood construction components, a variety of metal frame
constructions and associated components have been developed for use
in the residential and/or commercial building industry. The
components needed for the metal frame construction industry are
greatly varied and thus can be time consuming and expensive to
manufacture using conventional rollforming techniques. For example,
the needed components must be manufactured in an assortment of
sizes, gauges and shapes depending upon the particular need for an
assortment of different residential and/or commercial structures in
which the components will be utilized. In addition, such components
must be manufactured to relatively close tolerances to ensure that
they will fit together properly and can easily be assembled and
installed.
[0009] Rollforming machines for producing components used, for
example, in the metal frame construction industry, are well known
and typically include a plurality of sets of forming rolls arranged
in upper and lower pairs and spaced apart along the length of the
rollforming machine on rollforming support stands. As is also well
known, the forming rolls at one stand will produce a continuous
formation in the material and the forming rolls of the next stand
will produce another formation, or for example, increase the angle
of the formation which has already been started at the previous
stand and so on. Examples of such rollforming machines are
disclosed, in U.S. Pat. Nos. 5,970,764 and 5,829,295.
[0010] When rollforming a strip of metal to produce a component, it
is advantageous for the rollforming machine to be capable of
working on materials of different thicknesses, also referred to as
the "gauge" of the material in the metals industry. In order to
achieve this flexibility of working on materials of different
thicknesses, early rollforming machines required that the forming
rolls be replaced entirely or substantially changed when it was
desirable to form a material having a different thickness. As can
be appreciated, this practice of completely replacing the forming
rolls was very costly in terms of material costs to provide
numerous different forming rolls, labor costs for the added time of
installing and reinstalling the forming rolls, and the
manufacturing costs in view of the time that the rollforming
machine could not be in operation during replacement of the forming
rolls. More modem rollforming machines provide for automatic
adjustment of the forming rolls to accommodate the materials of
different thicknesses. For example, the aforementioned U.S. Pat.
No. 5,970,764 discloses a first rack and pinion arrangement in
combination with an eccentrically mounted shaft for adjusting the
clearance between forming rolls in a first plane and a second rack
and pinion arrangement in combination with an additional
eccentrically mounted shaft for adjusting the clearance between the
forming rolls in a second plane. While apparently effective at
adjusting the clearance between the forming rolls for materials of
different thicknesses, such an arrangement still has many
disadvantages and shortcomings. For example, many mechanical parts
are necessary to achieve the desired adjustment resulting in
increased costs for manufacturing and maintaining the rollforming
machine, and also resulting in the increased likelihood of
mechanical failure leading to down time and lost operating revenue
for the rollforming machine. In addition, such arrangement is
apparently unable to accurately and consistently maintain the
required tolerances when rollforming a component.
[0011] When performing a rollforming process to produce a component
of a particular shape, it is desirable for the component to
maintain the desired shape after the rollforming process is
completed and the component exits the rollforming machine. One
problem that can occur when rollforming products is commonly
referred to in the rollforming industry as "springback". The
bending process that takes place during rollforming is a complex
process which seeks to avoid stress concentration at the points of
bending. Because the material being rollformed has a modulus of
elasticity, the material tries to assume a shape having a bend of
lesser extent than was desired. Therefore, springback is generally
defined as the elastic recovery of metal after a stress has been
applied. Other properties of the metal which may affect and
contribute to springback are, for example, tensile strength, yield
strength and Rockwell hardness. As can be appreciated, the amount
of springback that may occur will vary for different materials and
for different shapes depending upon the degree of bending.
[0012] One solution to correcting springback is to rework the
rollformed component to mitigate the effects of the springback.
However, to rework the component greatly increases the unit cost
for the component and, therefore, is not an effective solution.
Another solution to springback is to employ additional rollforming
stands on the rollforming machine that include forming rolls cut to
specific angles in order to overbend the component once the desired
shape has been achieved. However, this also greatly increases the
costs of rollforming by requiring additional rollforming stands and
increased material and labor costs to install and replace the
forming rolls depending upon the particular angle that is needed in
order to achieve the necessary overbend to compensate for the
springback.
[0013] There is identified, therefore, a need for an improved
rollforming machine that overcomes limitations, shortcomings and
disadvantages of known rollforming machines.
[0014] There is also a need for an improved rollforming machine
that is capable of accommodating materials of different
thicknesses.
[0015] There is a further need for an improved rollforming machine
that can be easily and efficiently adjusted for materials of
different thicknesses and profiles.
[0016] There is a further need for an improved rollforming machine
that is capable of producing a component of a desired shape or
configuration wherein the component maintains the desired shape or
configuration once the rollforming is completed and the component
is removed from the rollforming machine.
[0017] Still another need exists for an improved rollforming
machine with effective overbending capabilities for ensuring that
the component formed by the rollforming machine maintains the
desired shape or configuration once the rollforming is completed
and the component is removed from the rollforming machine.
[0018] A need also exists for an improved rollforming machine that
includes overbend capabilities wherein the desired and necessary
amount of overbending can easily be adjusted and maintained while
running production and during non-production.
SUMMARY OF THE INVENTION
[0019] The embodiments of the invention meet the above-identified
needs, as well as other needs, as will be more fully understood
following a review of this specification and drawings.
[0020] An embodiment of the invention includes a rollforming
apparatus comprising a moveable support stand, a first forming
roll, a second forming roll and a third forming roll. The first
forming roll is rotatably mounted to a first spindle, wherein the
first spindle is moveably connected to the support stand to provide
for angular movement of the first forming roll. The second forming
roll is mounted to a second spindle that extends through a central
aperture defined by the first forming roll. The second spindle is
moveably connected to the support stand to provide for movement of
the second forming roll relative to the angular movement of the
first forming roll. The third forming roll is rotatably supported
by the support stand for movement therewith.
[0021] The rollforming apparatus may be utilized in conjunction
with a rollforming machine that is structured and arranged to form
components of different shapes and configurations, such as, for
example, components having a generally C-shaped cross section,
components having a generally U-shaped cross section or components
with other cross sections as may be needed for particular
applications. Advantageously, the first, second and third forming
rolls of the rollforming apparatus are structured and arranged to
perform, for example, overbending of the component to counter the
effects of springback that may occur during the rollforming
process.
[0022] A further embodiment of the invention includes a method of
forming components of different shapes and configurations, such as,
for example, a component having a generally C-shaped cross section,
a component having a generally U-shaped cross section or a
component having other cross sections depending upon the particular
shape needed for a particular application of the component. The
method includes feeding a sheet or coil of material to a
rollforming station structured and arranged to form a portion of
the component. The method also includes feeding the sheet of
material to an additional rollforming station having a plurality of
forming rolls supported by a plurality of spindles. The method
further includes adjusting the position of at least one of the
forming rolls resulting in moving the position of at least one of
the spindles. Advantageously, the method may further include
employing the roll station having a plurality of forming rolls
supported by a plurality of spindles for overbending of a sheet of
material to compensate for springback conditions that may develop
in the component being formed.
[0023] An additional embodiment of the invention includes a
rollforming apparatus comprising a support stand, a forming roll
supported on a spindle, an adjustment block and a slide assembly.
The spindle is rotatably secured to the adjustment block. The slide
assembly is in cooperative engagement with the support stand and
the adjustment block to provide movement of the forming roll
axially along an axis of rotation of the spindle and transversely
to the axis of rotation of the spindle.
[0024] The slide assembly may include an inner gage block mounted
to the adjustment block and an outer gage block mounted to the
support stand. The slide assembly may further include a rail member
and a bearing member such that one of the rail member and the
bearing member is attached to the inner gage block and the other of
the rail member and the bearing member is attached to the outer
gage block. The rail member and the bearing member are positioned
for cooperative engagement to facilitate movement between the
support stand and adjustment block to provide for movement of the
forming roll. Advantageously, the rollforming apparatus provides
for easy and efficient adjustment of the forming roll for materials
of different thicknesses.
[0025] In another embodiment of the invention, the rollforming
apparatus having a support stand, a forming roll supported on a
spindle, an adjustment block and a slide assembly may be utilized
in conjunction with a rollforming machine having a plurality of
rollforming stations to form a component of a desired shape and
configuration.
[0026] An additional embodiment of the invention includes a method
of forming a component that includes feeding a sheet or coil of
material to a rollforming station having a forming roll supported
by a spindle rotatably secured to an adjustment block to form the
component. The method also includes adjusting the position of the
forming roll by employing a slide assembly in cooperative
engagement with the adjustment block to facilitate movement of the
forming roll in a direction that is the resultant of normal and
axial components of motion of the spindle.
BRIEF DESCRIPTION OF THE DRAWING
[0027] FIG. 1A is a top-plan view of a rollforming machine in
accordance with an embodiment of the invention.
[0028] FIG. 1B is a top-plan view illustrating a portion of the
rollforming machine shown in FIG. 1A.
[0029] FIG. 1C is a side-elevational view of the rollforming
machine as illustrated in FIG. 1B.
[0030] FIG. 1D is a top-plan view of an embodiment of rollforming
stations 12a-12c of the rollforming machine shown in FIG. 1A.
[0031] FIG. 2 is a side-elevational view taken along line 2-2 of
FIG. 1A.
[0032] FIG. 3A is an isometric view of a component C capable of
manufactured by the rollforming machine shown in FIG. 1A.
[0033] FIG. 3B is a front-elevational view taken along line 3B-3B
of FIG. 3A.
[0034] FIGS. 4A-4M are partial front-elevational views of the
rollforming stations 12a-12m of the rollforming machine illustrated
in FIG. 1A.
[0035] FIG. 5 is a partial sectional view taken along line 5-5 of
FIG. 1A.
[0036] FIGS. 6A is an exploded isometric view of a typical support
stand, adjustment block and slide assembly in accordance with an
embodiment of the invention.
[0037] FIGS. 6B is an isometric view illustrating the exploded view
of FIG. 6A as assembled.
[0038] FIG. 7 is a front-elevational view of an embodiment of an
adjustment block of the invention.
[0039] FIG. 8 is a sectional view taken along line 8-8 of FIG.
7.
[0040] FIG. 9 is a side-elevational view of a rollforming apparatus
employed at, for example, rollforming stations 12-1 and/or 12m of
the rollforming machine shown in FIG. 1A.
[0041] FIG. 10 is a partial sectional view taken along line 10-10
of FIG. 9.
[0042] FIG. 11 is a rear-elevational view of the rollforming
apparatus shown in FIG. 9.
[0043] FIG. 12 is an isometric view of the rollforming apparatus
shown in FIG. 9.
[0044] FIG. 13 is a side-elevational view of the rollforming
apparatus shown in FIG. 9, with the rolls in a different
position.
[0045] FIG. 14 is a partial rear-elevational view of the
rollforming apparatus shown in FIG. 9.
[0046] FIG. 15 is a partial sectional view taken along line 15-15
of FIG. 14.
[0047] FIG. 16 is a rear-elevational view of a pivot plate assembly
of the rollforming apparatus shown in FIG. 9.
[0048] FIG. 17 is a partial sectional view taken along line 17-17
of FIG. 16.
[0049] FIG. 18 is a partial, exploded isometric view of the
rollforming apparatus shown in FIG. 9, and that is similar to FIG.
6A.
[0050] FIG. 19 is an isometric view illustrating FIG. 18 as
assembled.
[0051] FIG. 20 is a partial sectional view of rollforming station
12j of the rollforming machine in FIG. 1A.
[0052] FIG. 21 is a partial sectional view of rollforming station
12k of the rollforming machine in FIG. 1A.
[0053] FIG. 22 is an isometric view of a typical straightener for
use in accordance with an embodiment of the invention, and as shown
in FIG. 1A.
[0054] FIG. 23 is a partial sectional view of the straightener
shown in FIG. 22.
DETAILED DESCRIPTION OF THE INVENTION
[0055] Referring to FIGS. 1A-1D and 2, there is illustrated a
rollforming machine 10 in accordance with the invention. In
general, rollforming machines are well known machines and they
include numerous parts and components for the assembly and
operation thereof. Many of these numerous parts and components that
make up rollforming machines that are well known to those skilled
in the art of manufacturing and operating rollforming machines will
not be described in detail herein. Rather, the rollforming machine
10 will be described in general details with specific emphasis on
the inventive aspects and the various embodiments of the
invention.
[0056] The rollforming machine 10 includes a plurality of
rollforming stations 12a-12m. The plurality of rollforming stations
12a-12m are positioned along the length of the rollforming machine
10 for gradually forming a strip or coil of metal into a
predetermined shape or profile such as the component C, shown in
FIGS. 3a and 3b, having a generally C-shaped cross section. Other
components may be formed having different shapes or profiles such
as, for example, a generally U-shaped cross section or other more
relatively complex cross sections or formations that may be
desired. The component C may be, for example, a metal stud member
used, for example, in the metal frame construction industry. The
component C generally includes a web 14, a pair of legs 16
connected to the web 14, and a pair of lips 18 connected to the
legs 16. For purposes of illustration only, the rollforming machine
10 will be described in conjunction with the rollforming of the
component C.
[0057] The rollforming machines 10 may also include a plurality of
corresponding transmissions 20a-20m connected to the plurality of
rollforming stations 12a-12m by a plurality of corresponding upper
drive shafts 22a-22i for stations 12a-12i and lower drive shafts
23a-23m for stations 12a-12m. The plurality of transmissions
20a-20m may be integrally connected and driven by a common drive
motor 17 that transmits a driving force to the transmissions
20a-20m via drive chain 19 or drive belt. The drive motor 17 may be
of an appropriate size and capacity for providing the appropriate
driving force to the plurality of rollforming stations 12a-12m. The
drive shafts 22a-22i and 23a-23m will be discussed in more detail
herein.
[0058] The rollforming machine 10 also includes moveable support
frames 24 and 25 to which the plurality of rollforming stations
12a-12m are mounted. The support frames 24 and 25 are connected to
a respective plurality of linear slides 26 and 27 to provide for
lateral adjustment of the plurality of rollforming stations 12a-12m
in order for the rollforming machine 10 to accommodate a particular
component C having a web 14 of different widths. The linear slides
26 and 27 are mounted to a base assembly 28 which serves as the
foundation for the rollforming machine 10.
[0059] Referring to FIGS. 1A-1C, the support frame 24 is laterally
adjustable in the directions indicated by arrow 2, while the
support frame 25 is laterally adjustable in the directions
indicated by arrow 3. In order to facilitate the lateral adjustment
of the support frames 24 and 25, the rollforming machine 10 may
include lateral adjustment assemblies 4 and 5 that are connected to
the base assembly 28. The lateral adjustment assembly 4 may be
connected to a drive motor 6 for actuation thereof. The lateral
adjustment assembly 4 may be connected by, for example, a drive
belt 7 to the lateral adjustment assembly 5. Many types of lateral
adjustment assemblies may be employed, as is well known, for moving
the support frames 24 and 25 laterally. The lateral adjustment
assemblies 4 and 5 include, for example, pneumatic cylinders,
hydraulic cylinders, powered and/or unpowered screw closure
devices, including ball screws, acme screws or oppositely threaded
screws for providing the desired lateral adjustment of the support
frames 24 and 25. In addition to accommodating materials of
different widths, the lateral adjustment of the support frames 24
and 25 also provide for formation of components C having legs 16 of
unequal length.
[0060] The rollforming machine 10 may also include a support bridge
8 having a plurality of rollers 9 for contacting the web 14 of the
component C being formed in order to prevent deflection of the web
14. The support bridge 8 may be mounted to the base assembly 28 or
may be mounted to one of the support frames 24 and 25.
[0061] Referring to FIGS. 1D, the rollforming machine may include a
split platform design to allow for enhanced lateral adjustment
capabilities. This may be achieved by, for example, mounting
rollforming stations 12a-12c on support frames 24' and 25' to
increase the overall lateral adjustment capabilities. This is
particularly advantageous for sheets of material entering the
rollforming station 10 when the lips are being initially formed to
accommodate the overall width of the sheet of material or when
producing a component C having legs 16 of unequal lengths.
[0062] As can be seen in FIG. 1A, the rollforming machine 10 may
also include a pair of straighteners 30, which will be described
and shown in more detail herein. Generally, straighteners are well
known components that are used in association with rollforming
machines in order to correct, for example, bow, twist or camber
that may result in the component C as it is being rollformed.
[0063] Referring to FIGS. 4A-4I, the operation of the plurality of
rollforming stations 12a-12i will be described in more detail. Each
of the rollforming stations 12a-12i include a pair of upper forming
rolls mounted on a spindle and a pair of lower forming rolls
mounted on a spindle. A strip of material is fed to the rollforming
stations 12a-12i which progressively form the component C, and more
specifically, form the legs 16 and lips 18 thereof.
[0064] Referring to FIG. 4A, rollforming station 12a includes upper
forming rolls 40a and 41a and lower forming rolls 42a and 43a.
Rollforming station 12a initiates the formation of the component C
by bending the end of the strip of material to begin to form the
lips 18. As shown in FIG. 4A and as will be described in more
detail herein, the forming rolls 40a, 41a, 42a and 43a are
laterally adjustable, as shown in dotted line, to accommodate
forming components C that have webs 14 of different widths.
[0065] FIG. 4B illustrates rollforming station 12b having a pair of
upper forming rolls 40b and 41b and a pair of lower forming rolls
42b and 43b. Rollforming station 12b continues the formation of the
lips 18 of the component C.
[0066] Referring to FIG.4C, there is illustrated rollforming
station 12c having a pair of upper forming rolls 41c and 42c and a
pair of lower forming rolls 43c and 44c. Rollforming station 12c
completes the formation of the lips 18 of the component C such that
the lips 18 are positioned generally perpendicular to the web
14.
[0067] Referring to FIGS. 4D-4I, there is illustrated rollforming
stations 12d-12i, respectively. Each of the rollforming stations
12d-12i include a pair of upper forming rolls and a pair of lower
forming rolls configured to form the legs 16 of the component C.
The remaining rollforming stations 12j-12m are illustrated
respectively in FIGS. 4J-4M and will be described in more detail
herein.
[0068] Referring to FIG. 5, there is illustrated a view of
rollforming station 12i. Rollforming station 12i is typical of the
preceding rollforming stations 12a-12h. It will be appreciated, as
explained in detail herein and illustrated in FIGS. 4A-4H, that
each of the preceding rollforming stations 12a-12h include
differently configured forming rolls in order to progressively form
a specific portion of the component C.
[0069] Still referring to FIG. 5, the rollforming station 12i (for
purposes of simplification of the description of rollforming
station 12i, the suffix "i" will not be repeatedly used herein but
may be shown in the drawings) includes a pair of support stands 32
and 33 each having a base 34 and 35, respectively, for connecting
the support stands 32 and 33 to the support frames 24 and 25 (shown
in FIG. 1) of the rollforming machine 10. An upper spindle 36 and a
lower spindle 38 are rotatably secured to the support stands 32 and
33. The upper spindle 36 supports the pair of upper annular forming
rolls 40 and 41, while the lower spindle 38 supports the pair of
lower annular forming rolls 42 and 43. More particularly, the
forming roll 41 is mounted on a sleeve 44 for rotation therewith
and the sleeve 44 is moveably connected to the upper spindle 36 for
rotation therewith. The sleeve 44, for example, may include a key
for cooperating with an elongated keyway formed in the upper
spindle 36 to allow for sliding, longitudinal movement between the
sleeve 44 and the upper spindle 36. Similarly, the forming roll 43
is mounted on a sleeve 45 for rotation therewith and the sleeve 45
is moveably connected, by the described key and keyway arrangement,
for rotation with the lower spindle 38.
[0070] As shown in FIG. 5, the upper spindle 36 is rotatably
secured to the support stand 32 by an adjustment block 46. The
adjustment block 46 includes a pair of spaced apart bearing
assemblies 48 that permit the rotatable motion of the upper spindle
36. Similarly, an adjustment block 47 rotatably supports the sleeve
44 which supports the upper spindle 36 therein. The adjustment
block 47 includes an additional pair of spaced-apart bearing
assemblies 49 that cooperate with the sleeve 44 to allow the
rotatable motion thereof. In addition, the lower spindle 38 is
rotatably secured to the support stand 33 by an adjustment block 50
having a pair of spaced apart bearing assemblies 52 therein to
allow the rotatable motion of the lower spindle 38 relative to the
support stand 33. The sleeve 45 and lower spindle 38 are rotatably
secured to the support stand 33 by an additional adjustment block
51 having a pair of spaced apart bearing assemblies 53. Each of the
bearing assemblies 48, 49, 52 and 53 are essentially identical and,
therefore, only bearing assembly 48 will be described in detail.
Bearing assembly 48 is, for example, a pair of opposed tapered
roller bearings having an inner race or cone 48' that is secured to
the spindle 36 for rotation therewith and an outer race or cup 48"
that is stationary within the adjustment block 46 with the roller
48'" positioned therebetween. The bearing assembly 48 may be, for
example, available from The Timken Company of Canton, Ohio as Part
Nos. 47487 and 47420. However, other conventional bearings may be
employed.
[0071] Referring to FIGS. 6a, 6b, 7 and 8, there is illustrated in
more detail one embodiment of the support stand 33 and the
adjustment block 47. The support stand 33 includes a first leg 54
and a second leg 55 extending from the base 35. A pair of
structural flanges 56 may be connected to the base 35 and the legs
54 and 55 to provide structural support for the legs 54 and 55. The
adjustment block 51 is received in a bottom portion of the support
stand between the legs 54 and 55. Specifically, the adjustment
block 51 includes tabs 58 for receipt in slots 59 (only one slot 59
shown in FIG. 6a) formed on inner, bottom portion of the legs 54
and 55. The adjustment block 47 is received in an upper portion of
the support stand 33 between the legs 54 and 55. The adjustment
block 51 remains stationary with respect to the support stand 33,
while the adjustment block 47 is moveably connected to the support
stand 33.
[0072] In this embodiment, to provide for the moveable connection
of the adjustment block 47 to the support stand 33, there is
provided a first slide assembly 60 and a second slide assembly 61.
It will be appreciated that the first slide assembly 60 and the
second slide assembly 61 are essentially identical. The slide
assembly 60 includes an outer gage block 62 and an inner gage block
64. The second slide assembly 61 also includes an outer gage block
63 and an inner gage block 65. The first slide assembly 60 and the
second slide assembly 61 each include a bearing member 66 and 67,
respectively, that is rigidly secured to the respective outer gage
blocks 62 and 63. Specifically, the bearing member 66 is received
in a bearing slot 68 and the bearing member 67 is received in a
bearing slot 69 and, for example, a plurality of fasteners (not
shown) may be utilized for rigidly securing the bearing members 66
and 67 to the outer gage blocks 62 and 63. The first slide assembly
60 further includes a rail member 70 that is received in a rail
slot 72 formed on the inner gage block 64. A plurality of fasteners
(not shown) may also be provided for rigidly securing the rail
member 70 to the inner gage block 64. Similarly, the second slide
assembly 61 also includes a rail member 71 received in a rail slot
(not shown in FIG. 6a).
[0073] The first slide assembly 60 is assembled such that the
bearing member 66 is in cooperative engagement with the rail member
70 to allow movement therebetween. Similarly, the second slide
assembly 61 is assembled such that the bearing member 67 is
positioned for cooperative engagement with the rail member 71 to
allow movement therebetween. The bearing member 66 and rail member
70 and the bearing member 67 and rail member 71 are commercially
available components and may be, for example, a THK Miniature LM
Guide Type RSR . . . Z manufactured by THK.
[0074] The first slide assembly 60 is mounted to the adjustment
block 47 by rigidly securing the inner gage block 64 to a first
side 74 of the adjustment block 47 using, for example, a plurality
of fasteners (not shown) that extend through the apertures 76
formed in the inner gage block 64. Similarly, the second slide
assembly 61 is connected to a second side 75 of the adjustment
block 47 by rigidly securing the inner gage block 65 to a second
side 75 using, for example, a plurality of fasteners (not shown)
that extend through the plurality of apertures 77 formed in the
inner gage block 65.
[0075] After the first slide assembly 60 and the second slide
assembly 61 are mounted to the adjustment block 47, the adjustment
block 47 is positioned between the legs 54 and 55 of the support
stand 33 in the direction of arrow 78. As shown, the outer gage
block 62 is at least partially received in a generally U-shaped
receptacle 80 formed in the first leg 54 and the outer gage block
63 is at least partially received in a generally U-shaped
receptacle 81 formed in the second leg 55. The outer gage block 62
is positioned such that a plurality of apertures 82 formed in the
outer gage block 62 are aligned with a corresponding plurality of
apertures 84 formed in the first leg 54. A plurality of fasteners
(not shown) extend through the apertures 82 and 84 to rigidly
secure the outer gage block 62 to the first leg 54. Similarly, the
outer gage block 63 includes a plurality of apertures 83 that are
aligned with a corresponding plurality of apertures 85 formed in
the second leg 55. A plurality of fasteners (not shown) extend
through the apertures 83 and 85 to rigidly secure the outer gage
block 63 to the second leg 55 of the support stand 33. As will be
appreciated, the described arrangement allows for linear movement
of the adjustment block 47 in an angled direction, and specifically
in a direction corresponding to an angle at which the bearing
members 66 and 67 are in cooperative engagement with the rail
members 70 and 71 for movement therebetween, as will be described
in more detail herein.
[0076] Referring to FIGS. 6a, 6b, 7 and 8, the adjustment block 47
will be described in more detail. It will be appreciated that the
adjustment block 48 is essentially identical to the adjustment
block 47. As previously described, the adjustment block 47 includes
a first side 74 for attaching the inner gage block 64 thereto and a
second side 75 for attaching the inner gage block 65 thereto. The
adjustment block 47 also includes a central opening 86 extending
therethrough. The opening 86 is generally circular for receipt of
the sleeve 44 and the upper spindle 36 therein, or in the case of
the adjustment block 48 for receipt of the upper spindle 36 only
therein. As best shown in FIG. 8, the adjustment block 47 includes
bearing pockets 88 for receipt of the bearing assemblies 49. The
bearing assemblies 49, as previously described, rotatably secure
the sleeve 44 and upper spindle 36 to the support stand 33. The
adjustment block 47 includes an annular bearing support 90
positioned between and about the bearing pockets 88 in order to
maintain the position of the bearing assemblies 49 within the
bearing pockets 88. The adjustment block 47 also includes an inner
bearing plate 92 and an outer bearing plate 93 for further securing
and maintaining the bearing assemblies 49 in the bearing pockets
88.
[0077] In addition, the adjustment block 47 includes an opening 94
therethrough for receiving a clevis pin 96. The adjustment block 47
also includes an additional opening 98 that extends generally
transverse to the opening 94. A clevis with bushing 97 extends into
the opening 98 and is slideably connected at one end to the clevis
pin 96 and at the other end is attached to a shaft 99 (see FIG. 5
and FIG. 10) of a screw jack assembly 100 which provides a driving
movement to the adjustment block 47, as will be described in more
detail herein.
[0078] As shown in FIGS. 1A and 2, each rollforming station 12a-12k
includes a screw jack assembly 100a-100k that are interconnected by
linkage arrangements 101. The linkage arrangements 101 are in turn
connected to a drive motor 107 to actuate each of the individual
screw jack assemblies for operation of the adjustment blocks, as
described herein. Rollforming stations 12-l and 12m include drive
motors 400 for actuating the adjustment block that controls
movement of the angled roll 244.
[0079] Referring to FIGS. 1A and 5, the transmission 20 is
connected to an upper drive shaft 22 by a conventional universal
coupling, generally designated by reference number 102, and the
upper drive shaft 22 is connected to the upper spindle 36 by an
additional universal coupling, generally designated by reference
number 103. The described arrangement provides for rotation of the
upper spindle 36. The upper drive shaft 22 is a telescoping type
drive shaft to allow for the individual segments of the drive shaft
22 to telescope in the directions indicated by arrow 104. Such
drive shafts are well known components. Similarly, drive shaft 23
is connected to the transmission 20 by a universal coupling 105 and
the lower spindle 38 is connected to the lower drive shaft 23 by
additional universal coupling 106. The lower drive shaft 23 is also
a telescoping type for movement in the directions indicated by
arrow 108.
[0080] The support stands 32 and 33 may be simultaneously adjusted
in an inward direction, as indicated by arrows 110 or may be
simultaneously adjusted in an outward direction as indicated by
arrows 112 in order for the rollforming machine 10 to accommodate a
component C having a web 14 of different widths. The movement of
the support stands 32 and 33 is accomplished by simultaneously
moving the support frames 24 and 25, to which the support stands 33
and 32 are respectively connected, in the direction of arrows 110
or arrows 112. During movement of the support stands 32 and 33, the
transmission 20i remains stationary. Movement of the support stand
32 in the inward direction of arrow 110 results in the expansion or
extension of the drive shafts 22 and 23 because the upper spindle
36 and lower spindle 38 are rotatably secured to the support stand
32 by respective adjustment blocks 46 and 50, and more specifically
by the pairs of bearing assemblies 48 and 52. During inward
movement of the support stand 33, the sleeves 44 and 45, which are
rotatably secured to respective adjustment blocks 47 and 51, also
move inward with respect to the upper spindle 36 and lower spindle
38. As previously described, the sleeve 44 is moveably connected to
the upper spindle 36 by a key and keyway arrangement and similarly
the sleeve 45 is moveably connected to the lower spindle 38 by a
key and keyway arrangement. The inward movement of the spindles 36
and 38 results in the inward movement of forming rolls 40 and 42
and the inward movement of sleeves 44 and 45 results in the inward
movement of forming rolls 41 and 43.
[0081] During outward movement of the support stand 32 as,
indicated by arrow 112, the drive shafts 22 and 23 collapse in
order to accommodate the outward movement. In addition, outward
movement of the support stand 33, as indicated by arrow 112,
results in the sleeve 44 moving with respect to the upper spindle
36 and the sleeve 45 moving with respect to the lower spindle 38.
The described movement results in outward movement of the forming
rolls 40, 41, 42 and 43.
[0082] In addition to adjusting the rollforming stations 32 and 33
inwardly and outwardly for a component C having a web 14 of
different widths, the invention includes adjusting the forming
rolls 40 and 41 relative to the forming rolls 42 and 43,
respectively, to accommodate forming a component C of a material
having different thicknesses or different gauges. To make the
necessary adjustments for materials of different thicknesses, it is
necessary to adjust each of the forming rolls 40 and 41 in two
different planes. Specifically, it is necessary to adjust the
forming roll 40 in the direction of an axis of rotation of the
upper spindle 36, as indicated by arrow 114, and in a direction
transversely to the axis of rotation of the upper spindle 36, as
indicated by arrow 115. Similarly, it is necessary to adjust
forming roll 41 axially in the direction of an axis of rotation of
the upper spindle 36, as indicated by arrow 116, and in a direction
of transversely to the axis of rotation of the upper spindle 36, as
indicated by arrow 117. Advantageously, the previously described
arrangements of adjustment blocks 46 and 47 each having the first
slide assembly 60 and second slide assembly 61, allows for one
continuous movement of the forming roll 40 in the direction of
arrow 118 and for one continuous movement of the forming roll 41 in
the direction of arrow 119. As can be appreciated, the direction of
arrow 118 is in a direction that is the resultant of the axial
component 114 and the normal component 115 of motion of upper
spindle 36, as illustrated in FIG. 5. Likewise, the direction of
arrow 119 is in a direction that is the resultant of the axial
component 116 and the normal component 117 of motion of the upper
spindle 36, as illustrated in FIG. 5. It will be appreciated that
the direction of arrow 119 is essentially along the same line of
action as movement between the bearing member 66 and rail member 70
of the first slide assembly 60 and the bearing member 67 and rail
member 71 of the second slide assembly 61. To achieve adjustment of
the forming rolls 40 and 41 in two planes for materials of
different thicknesses while maintaining equal axial and transverse
movement, the direction of arrows 118 and 119 should be generally
45 degrees with respect to the horizontal or the axial components
114 and 116. However, it should be appreciated that the angular
position of the arrows 118 and 119 may be at any desired angle by
altering the position of the bearing members 66 and 67 and rail
members 70 and 71 of the first slide assembly 60 and the second
slide assembly 61.
[0083] The structural arrangement of support stand 33 in order to
achieve the adjustment of forming roll 41 in the direction of arrow
119 will now be described in more detail. It will be appreciated
that the structural arrangement of support stand 32 is similar to
support stand 33 and that operation of the same to achieve
adjustment of forming roll 40 in the direction of arrow 118 is
essentially the same. As previously described, support stand 33
includes a screw jack assembly 100, which is a generally well known
component. The screw jack assembly 100 includes the shaft 99 that
is connected to the clevis with bushing 97 which in turn is
moveably connected to the dowel pin 96 which is supported in the
aperture 94 of the adjustment block 47. The screw jack assembly 100
is preferably rigidly mounted to the support stand 33. Actuation of
the screw jack assembly 100 in a generally upward direction results
in the shaft 99 moving the clevis with bushing 97 in a generally
upward direction as well. As a result of this upward movement of
the screw jack 100 and clevis with bushing 97, the adjustment block
47 must also move as a result of the slideable connection between
the clevis with bushing 97 and the clevis pin 96. The resulting
movement of the adjustment block 47 is in the direction of arrow
119. This movement results from the relative movement between the
bearing member 66 and rail member 70 and the relative movement
between the bearing member 67 and the rail member 71. The rail
members 70 and 71, which are rigidly secured to the inner gage
blocks 64 and 65, respectively, which are in turn rigidly secured
to the adjustment block 47, move with respect to the bearing
members 66 and 67 in the direction of arrow 119. Because of the
described structural arrangement, this is the only direction in
which the adjustment block 47 can move in response to actuation of
the screw jack assembly 100. Actuation of the screw jack assembly
100 in the opposite direction, i.e., a generally downward
direction, will result in movement of the adjustment block 47 in
the angular orientation of arrow 117, only in the opposite
direction from the previously described movement. Accordingly,
actuation of the screw jack assembly 100 in a generally upward
direction will result in adjustment of the forming roll 41 in a
direction for materials having a greater thickness while actuation
of the screw jack assembly 100 in a generally downward direction
will result in adjustment of the forming roll 41 in a direction for
materials having a lesser thickness.
[0084] During movement of the adjustment block 47, one of the
bearing assemblies 49, and specifically the inner race or cup 49'
thereof, acts against a first shoulder 118 formed on the sleeve 44
and the other bearing assembly 49, and specifically the other inner
race or cup 49' thereof, acts against a bearing nut 120 attached to
the sleeve 44. The action of the bearing assemblies 49 against the
shoulder 118 and bearing nut 120 causes the sleeve 44, which has
the forming roll 41 attached thereto, to move in the desired
direction with respect to the upper spindle 36.
[0085] Rollforming stations 12-l and 12m, as will be described in
detail herein, provide for both rollforming of the component C and
overbending of the component C to compensate for springback that
may develop during the rollforming process. In this embodiment,
rollforming stations 12-l and 12m are essentially identical except
that the rollforming apparatus 200 at each of the stations is
located on opposite sides of the rollforming line. Referring to
FIGS. 9-19, a rollforming apparatus 200 of this embodiment employed
by rollforming stations 12-l and 12m will be described in detail
(for purposes of simplification of the description, the suffixes
"l" or "m" will not be repeated herein, but may be shown in the
drawings).
[0086] Rollforming apparatus 200 includes a support stand 233, that
is similar to the support stand 33 described herein, having a base
235 and a first leg 254 and a second leg 225 extending from the
base 235 (see FIG. 11). The rollforming apparatus 200 also includes
a first support member 202 connected to the first leg 254 and a
second support member 203 connected to the second leg 255. The
first support member 202 and the second support member 203 are
rigidly secured to the first leg 254 and the second leg 255,
respectively, of the support stand 233. The rollforming apparatus
200 also includes the structural flanges 256 for providing
structural support to the first leg 254 and the second leg 255.
[0087] The rollforming apparatus 200 further includes a pivot plate
assembly, generally designated by reference number 204, that is
moveably connected to the first and second support members 202 and
203. The pivot plate assembly 204 includes an overbend roll 206
rotatably mounted thereto. As shown and described herein, roll 206
is an idle roller that is rotated by contact with the component C
passing through the rollforming station. However, roll 206 could be
positively driven, if desired. Movement of the pivot plate assembly
204 with respect to the first and second support members 202 and
203 provides for angular movement of the overbend roll 206 for
overbending and/or the component C.
[0088] Referring to FIGS. 16 and 17, the pivot plate assembly 204
and overbend roll 206 of this embodiment will be described in more
detail. In this embodiment, the pivot plate assembly 204 includes a
first pivot plate 208 moveably connected to the first support
member 202 and a second pivot plate 209 moveably connected to the
second support member 203. A connector plate 210 extends between
the first pivot plate 208 and second pivot plate 209 for supporting
the overbend roll 206. To provide for the moveable connection
between the first pivot plate 208 and the first support member 202
and the moveable connection between the second pivot plate 209 and
the second support member 203, the first and second pivot plates
208 and 209 each include a plurality of rollers 212 mounted thereto
for receipt in corresponding arcuate slots 214 formed in the first
support member 202 and the second support member 203 (see FIG. 12).
The plurality of rollers 212 provide for a structurally stable
connection between the pivot plate assembly 204 and the first and
second support members 202 and 203 while providing for relative
movement therebetween.
[0089] To adjust the positions the pivot plate assembly 204 and the
first and second support members 202 and 203, there is provided a
screw jack assembly 216, best shown in FIG. 11. The screw jack
assembly 216 is mounted to a mounting plate 218 having a first
mounting leg 220 that is secured by a fastener 222 to the first
support member 202. The mounting plate 218 also includes a second
mounting leg 221 that is secured by a fastener 223 to the second
support member 203. The screw jack assembly 216 includes a shaft
224 that is connected to an actuator bar 226. A first fastener 228
secures an end of the actuator bar 226 to the first pivot plate 208
and a second fastener 229 secures another end of the actuator bar
226 to the second pivot plate 209. The actuator bar passes through
an actuator slot 230 formed in the first support member 202 (see
FIGS. 12 and 13) and an additional actuator slot formed in the
second support member 203. As can be appreciated, actuation of the
screwjack assembly 216 results in movement of the shaft 224 which
in turn causes movement of the actuator bar 226. Because the
actuator bar 226 is connected to the first pivot plate 208 by
fastener 228 and to the second pivot plate 209 by fastener 229, the
pivot plate assembly 204 is moved along an arcuate path
corresponding to the arcuate slots 214 which receive the plurality
of rollers 212.
[0090] The embodiment of the rollforming apparatus 200 (see FIG.
11) includes a motor 232 connected by a motor coupling 234 to the
screwjack assembly 216. The rollforming apparatus 200 also includes
a pivot stop 236 connected to the first support member 202 for
cooperation with the first pivot plate 208 and an additional pivot
stop (not shown) positioned for cooperation with the second pivot
plate 209. This prevents overbending that may cause the lip 18 to
contact the roll 244 and distort or bend the shape of the lip
18.
[0091] As best shown in FIGS. 16 and 17, the overbend roll 206 is
rotatably mounted on a spindle assembly, generally designated by
reference number 237, that is mounted to the connector plate 210 of
the pivot plate assembly 204. Specifically, the spindle assembly
237 includes a bearing assembly 238, a bearing retainer 239 and a
seal retainer 240 which mount the overbend roll 206 to a spindle
241 for rotation of the overbend roll 206 thereabout. The spindle
241 is rigidly secured to the connector plate 210. As can be
appreciated, such arrangement enables the overbend roll 206 to be
pivoted, as indicated by arrow 242, when the pivot plate assembly
204 is moved, as described herein.
[0092] Also in this embodiment, the spindle 241 defines a central
aperture 243 which allows for a support structure for an angled
roll 244 to pass therethrough, as will be explained in more detail
herein.
[0093] Referring specifically to FIGS. 14-15 and 18-19, it will be
further appreciated that, in this embodiment, the support stand 233
is similar to the support stand 33, as described herein. The
support stand 233 includes an adjustment block 247 for supporting
the angled roll 244 and an additional adjustment block 251 for
supporting a lower forming roll 252. As shown and described herein,
the roll 244 is an idle roller that is rotated by contact with the
component C. However, roll 244 could be positively driven, if
desired. The adjustment block 247 is structured similarly to the
adjustment block 47 as described herein. The essential difference
between adjustment block 247 and the adjustment block 47 is that
adjustment block 247 does not include the central aperture 86
extending therethrough and, further, does not include the bearing
assemblies 49. Rather, the adjustment block 247 supports a rigid
structural shaft 257 that protrudes from the adjustment block 247
but does not move with respect to the adjustment block 247. The
shaft 257 extends through the central aperture 243 formed in the
overbend roll 206 and has an axis generally designated as "A-A"
(see FIG. 10). The central aperture 243 is sized to permit for
movement of the adjustment block 247 and shaft 257 for adjusting
the position of angled roll 244 for forming components C from
materials of different thicknesses. Positioned at the end of the
shaft 257 is a bearing housing 259 for supporting a pair of spaced
apart bearing assemblies 249. Rotatably supported by the bearing
assemblies 249 is a spindle 236 that has an axis "B-B" and that
rotates within the bearing housing 259. As can also be seen in FIG.
10, spindle 236 may be oriented such that its axis "B-B" is
oriented at an angle relative to axis "A-A" of shaft 257. The
angled roll 244 is rotatably secured to the spindle 236 for
rotation therewith.
[0094] As best shown in FIG. 18, the support stand 233 of this
embodiment also includes a first slide assembly 260 and a second
slide assembly 261, which are similar to the slide assemblies 60
and 61 described herein in conjunction with the support stand 33.
The first slide assembly 260 includes an outer gage block 262, an
inner gage block 264, a bearing member 266 and a rail member 270.
Similarly, the second slide assembly 60 includes an outer gage
block 263, an inner gage block 265, a bearing member 267 and a rail
member 271. The first slide assembly 260 and the second slide
assembly 262 are positioned between the adjustment block 247 and
the first leg 254 and the second leg 255 of the support stand 233
to provide for movement of the adjustment block with respect to the
support stand 233, in essentially the same manner as described
herein for the adjustment block 47 and the support stand 33. Those
of ordinary skill in the art will appreciate that such arrangement
permits the position of the angled roll 244 to be adjusted for
accommodating materials of different thicknesses.
[0095] To achieve this adjustment, it is necessary to adjust the
angled roll 244 axially along longitudinal axis "A-A" of the shaft
257, as indicated by arrow 316, and transversely to the
longitudinal axis "A-A" of the shaft 257, as indicated by arrow 317
(see FIG. 15). This results in movement of the angled roll 244 in
the direction of arrow 319 which is the resultant sum of the axial
component 316 of the shaft 257 and the normal component 317 of the
shaft 257.
[0096] As best shown in FIG. 15, the support stand 233 also
includes the adjustment block 251 which is constructed and arranged
in essentially the same manner as adjustment block 51, as described
herein. The adjustment block 251 includes bearing assemblies 253
that rotatably secure the sleeve 245 to the adjustment block 251
for rotation therein. Spindle 238 is received in the sleeve 245 and
moveably connected thereto by the previously described key and
keyway arrangement.
[0097] A lower support roll 279 (see FIG. 4M) is also attached to
the spindle 238 for supporting the component C during the
rollforming and/or overbending at station 12m. The support roll is
rotatably secured to an additional adjustment block 250 (see FIG.
1) that is similar to the adjustment block 50 described herein. The
support stand 233 and opposing support stand that contains
adjustment block 250 are adjustable in an inward and outward
direction, in essentially the same manner as described hereinabove
for support stands 32 and 33.
[0098] Referring to FIGS. 10 and 13, the rollforming and
overbending of the component C by the rollforming apparatus 200
will be described in more detail. As shown, the overbend roll 206
engages an outer portion of the leg 16 of component C. The angled
roll 244 contacts a junction between an inner portion of the leg 16
and the inner portion of the web 14. The lower forming roll 252
engages an outer portion of the web 14 adjacent the angled roll
244. With the overbend roll 206 in the position shown in FIG. 10
(generally perpendicular to the axis "C-C" of the shaft 238 upon
which the lower forming roll 252 is journaled) the rollforming
apparatus 200 is capable of forming and/or overbending the
component C with the leg 16 generally perpendicular to the web 14.
As can be seen in FIG. 10, the axis "B-B" of the shaft 236 is not
parallel to the axis C-C of the shaft 238. If the material being
used to form the component C lacks properties that might result in
springback, then upon exiting the rollforming apparatus 200 the
component C should remain with the leg 16 generally perpendicular
to the web 14. For materials that do exhibit properties that may
result in springback, angular adjustment of the overbend roll 206,
in the direction of arrow 242 and as shown in FIG. 13, will result
in overbending of the component C. Specifically, additional bending
application is applied to the leg 16 about the junction where the
angled roll 244 contacts the component C such that when the
component C exits the rollforming apparatus 200, the leg 16 should
return, as a result of the springback, to a position that is
generally perpendicular to the web 14. The range of angular motion
of the overbend roll 206 may be about 84 to 91 degrees with respect
to a generally horizontal axis. It will be understood that the
rollforming apparatus 200 is capable of rollforming and/or
overbending the component C such that the leg 16 may be at other
angles than generally perpendicular with respect to the web 14.
[0099] Accordingly, it will be appreciated that the rollforming
apparatus 200 provides an efficient and flexible apparatus for
rollforming and/or overbending the component C. The overbend roll
206, the angled roll 244 and the lower forming roll 252 of the
rollforming apparatus 200 may be adjusted and positioned, as
described herein, to provide for a high degree of flexibility when
rollforming and/or overbending the component C. As can be
appreciated from the description set forth herein and the drawings
attached hereto, the overbend roll 206, as rotatably mounted to the
spindle 241, is independently adjustable from the angled roll 244
and the lower forming roll 252. The angled roll 244, which is
secured to spindle 236 for rotation therewith, is also
independently adjustable of the overbend roll 206 and the lower
forming roll 252. The lower forming roll 252 is laterally
adjustable by moving the stand 233 in an inward or outward
direction which will result in the overbend roll 206 and spindle
241, as well as the overbend roll 244 and spindle 236 also moving
in an inward or outward direction in conjunction with movement of
the support stand 233.
[0100] Referring to FIGS. 4J-4K and 20-21, there is illustrated
rollforming stations 12j and 12k. Rollforming stations 12j and 12k
are essentially identical only positioned on opposing sides of the
rollforming line of rollforming machine 10. Rollforming stations
12j and 12k further progress the formation of the legs 16 of the
component C. Rollforming station 12j includes adjustment block 247j
for supporting shaft 257j which in turn supports angled roller
244j. The adjustment block 247j, the shaft 257j and the angled
roller 244j operate in essentially the same manner as adjustment
block 247, shaft 257 and angled roller 244, as described herein.
The adjustment block 247j allows for adjustment of the angled
roller 244j in the direction of arrow 319j in order to accommodate
materials of different thicknesses for forming the component C.
Similarly, rollforming station 12k includes adjustment block 247k,
shaft 257k and angled roller 244k to provide for adjustment of the
angled roller 244k in the direction of arrow 319k.
[0101] Referring to FIGS. 22 and 23, there is illustrated a typical
straightener 30 for use with the rollforming machine 10. The
straightener 30 may be a conventionally known straightener utilized
to adjust the component C for camber, twist, bow, etc., as is
generally known in the rollforming industry. Generally, the
straightener 30 includes an adjustable top roll 390, an adjustable
bottom roll 391 and a side roll 392. The straightener 30 is mounted
to a linear slide bearing 393 which in turn is mounted to the
support frames 24 and 25. The linear slide bearing 393 allows for
the entire straightener 30 to be laterally adjustable in order to
accommodate the component C having a web of different widths.
[0102] Whereas particular embodiments of the invention have been
described herein for the purpose of illustrating the invention and
not for the purpose of limiting the same, it will be appreciated by
those of ordinary skill in the art that numerous variations of the
details, materials, and arrangement of parts and directional
references, such as, for example, up, down, horizontal, vertical,
top or bottom, may be made within the principle and scope of the
invention without departing from the invention as described in the
appended claims. For example, the described adjustment blocks may
be alternately constructed and arranged to achieve similar movement
thereof by using similar means such as opposed wedges cut on angles
that may be attached internally or externally to the adjustment
block housing for movement with respect to the stand. In addition,
the adjustment blocks for adjustment of the upper spindle and
associated forming rolls may be employed with the lower spindle and
associated forming rolls, if desired.
* * * * *