U.S. patent application number 12/811593 was filed with the patent office on 2012-05-31 for arching metallic profiles in continous in-line process.
This patent application is currently assigned to ALLIED TUBE & CONDUIT CORPORATION. Invention is credited to William Cromer, Jack Curless, John Martinez, Dan Nelson, William Smyth, Theodore Thomas Wilk.
Application Number | 20120131974 12/811593 |
Document ID | / |
Family ID | 40755904 |
Filed Date | 2012-05-31 |
United States Patent
Application |
20120131974 |
Kind Code |
A1 |
Curless; Jack ; et
al. |
May 31, 2012 |
ARCHING METALLIC PROFILES IN CONTINOUS IN-LINE PROCESS
Abstract
A method and apparatus for manufacturing an arched metallic
profile, in a continuous in-line process. The method comprises
forming the metallic profile; and arching the formed metallic
profile in a continuous in-line process. The apparatus includes a
roll forming station configured to receive flat metallic
composition and output a given profile. An arching device is
configured to receive the metallic profile and bend the metallic
profile having a desired radius of curvature wherein a portion of
the arching device is displaced with respect to said roll forming
station vertically and/or horizontally.
Inventors: |
Curless; Jack; (Peoria,
AZ) ; Smyth; William; (Harlingen, TX) ;
Martinez; John; (Glendale, AZ) ; Nelson; Dan;
(Brookfield, CT) ; Cromer; William; (Phoenix,
AZ) ; Wilk; Theodore Thomas; (Phoenix, AZ) |
Assignee: |
ALLIED TUBE & CONDUIT
CORPORATION
Harvey
IL
|
Family ID: |
40755904 |
Appl. No.: |
12/811593 |
Filed: |
December 12, 2008 |
PCT Filed: |
December 12, 2008 |
PCT NO: |
PCT/US2008/086655 |
371 Date: |
August 13, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61012929 |
Dec 12, 2007 |
|
|
|
Current U.S.
Class: |
72/199 ; 72/324;
72/362 |
Current CPC
Class: |
B21D 5/08 20130101 |
Class at
Publication: |
72/199 ; 72/362;
72/324 |
International
Class: |
B21B 1/08 20060101
B21B001/08; B21D 43/28 20060101 B21D043/28; B21D 31/00 20060101
B21D031/00 |
Claims
1. A method for manufacturing an arched metallic profile in a
continuous in-line process comprising the steps of: forming the
metallic profile; and, arching the formed metallic profile.
2. The method of claim 1, further comprising the step of
stabilizing the steel profile.
3. The method of claim 2, wherein the step of stabilizing the steel
profile is preformed in conjunction with a Turkshead.
4. The method of claim 2, wherein the step of stabilizing the steel
profile is preformed in conjunction with a cutoff assembly.
5. The method of claim 1, further comprising the step of: forming
holes within the strip steel prior to forming the steel
profile.
6. The method of claim 1, wherein the metallic profile is selected
from the group of a steel profile, and aluminum profile, and
combinations thereof.
7. The method of claim 6, wherein the step of forming the metallic
profile includes the step of: forming a steel profile from a strip
steel in a continuous roll forming process.
8. The method of claim 6, wherein the bent formed steel profile
forms multiple arches.
9. The method of claim 6, wherein the bent formed steel profile
forms multiple arches within two or more distinct planes.
10. The method of claim 9, wherein the bent formed steel profile
forms different arches in the same direction.
11. The method of claim 9, wherein the bent formed steel profile
forms different arches in different directions.
12. The method of claim 1, further comprising the step of: cutting
the bent steel profile within the in-line continuous process.
13. An apparatus for bending metallic profiles within a continuous
in-line process comprising: a roll forming station configured to
receive flat metallic composition and output a given profile; and
an arching device configured to receive said metallic profile and
bend the metallic profile having a desired radius of curvature
wherein a portion of said arching device is displaced with respect
to said roll forming station.
14. The apparatus for bending metallic profiles of claim 13 wherein
said roll forming station comprises a plurality of roll stations,
each of said roll stations including rollers configured to receive
the metallic composition and successively bend the composition into
the given profile.
15. The apparatus for bending metallic profiles of claim 13 wherein
said arching device comprises at least one Turkshead.
16. The apparatus for bending metallic profiles of claim 13 further
comprising a cutting assembly configured to receive said arched
profile and cut said profile into particular lengths.
17. The apparatus for bending metallic profiles of claim 15 further
comprising a support guide disposed within said Turkshead about
which said metallic profile is arched.
18. The apparatus for bending metallic profiles of claim 13 wherein
said arching device is displaced linearly with respect to said roll
forming station.
19. The apparatus for bending metallic profiles of claim 13 wherein
said arching device is displaced angularly with respect to said
roll forming station.
20. The apparatus for bending metallic profiles of claim 15 wherein
said Turkshead is a first Turkshead, said arching device further
comprising a second Turkshead disposed between said first Turkshead
and said roll forming station.
21. The apparatus for bending metallic profile of claim 20 wherein
said second Turkshead includes an insert roller device
corresponding to a shape of said profile, said insert roller device
configured to equalize a longitudinal stress incident on the
profile during arching.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional
Application No. 61/012,929 filed Dec. 12, 2007 which is herein
incorporated by reference in its entirety.
BACKGROUND
[0002] 1. Field of the Invention
[0003] The present invention generally relates to a method and
apparatus for roll forming steel. More particularly, the present
invention relates to a process and machine for forming arch
configurations of metallic profiles from roll-formed steel during a
continuous in-line process.
[0004] 2. Discussion of Related Art
[0005] Continuous in-line processing of steel provides an efficient
and relatively quick method for transforming flat strip steel into
steel profiles to accommodate high volume production with greater
uniformity and consistency. This continuous in-line process is well
known in the art as disclosed in, for example, U.S. Pat. Nos.
3,122,114 and 3,696,503, both to Krengel et. al.; 3,468,145 to
Ostrowski; and 3,667,095 to Ostrowski et. al., the disclosures of
which are incorporated herein by reference. In particular, U.S.
Pat. No. 3,122,114 disclosed the continuous formation of steel
profiles and the galvanized treatment of the external surfaces of
the formed profiles. U.S. Pat. No. 3,696,503 disclosed a method for
continuously galvanizing strip steel in which a forming roll
operation, a galvanizing section and a reforming roll operation
were used to produce steel profile having all exposed surface areas
of the strip steel galvanized. In U.S. Pat. No. 3,468,145, a method
is disclosed for processing steel having a relatively thick
cross-section and producing steel having a desired cross-section by
moving the stock through a mill multiple times. U.S. Pat. No.
3,667,095 disclosed an apparatus for the continuous forming,
galvanizing and application of a protective coating to steel
profiles.
[0006] Generally, a continuous in-line process first forms strip
steel into a desired profile having a cross-section configuration,
for example, C-shaped, "U" shaped, etc. The particular steel
profile is formed as straight pieces within a continuous in-line
machine and cut to a desired length. If the cut steel profiles
require a particular radius of curvature, the cut profile sections
undergo a separate secondary process to form arched sections using,
for example, a standard three roll bending machine. However,
several drawbacks are associated with performing the arching
process after cutting. First, this additional arching step of the
formed and cut profile sections requires additional labor, separate
process machines and consumes valuable process time. Secondly, if
the steel profiles are produced with a plurality of equally spaced
mounting holes along its longitudinal axis, the subsequent arching
process may produce undesirable hole elongation along the bend
radius area. Thirdly, warping may occur along the bend profile of
the steel profile once sections are arched. Moreover, the
cross-section at the end of the steel profile may change after the
steel is bent. For example, a steel profile having a "U" shaped
cross-section essentially comprises a pair of vertically opposed
wall members connected by a lower transverse member. At each
longitudinal (i.e. lengthwise) end portion of the steel profile,
these vertically opposed wall members ideally have a common
transverse plane. Once this "U" shaped profile is arched, one of
the vertically opposed wall members extends beyond this transverse
plane. An additional cutting step is required to ensure that each
of the "U" shaped wall members ends on the same transverse plane.
This adds labor, time and unwanted material waste to the
manufacturing process. Thus, there is a need for a method and
apparatus for manufacturing roll formed steel into a particular
profile, arching the formed profile and cutting the arched profile
all within a continuous in-line process.
SUMMARY OF THE INVENTION
[0007] Exemplary embodiments of the present invention are directed
to an apparatus and method for manufacturing arched metallic
profiles, particularly steel profiles, using a continuous in-line
process. The method includes forming the metallic profile; and
arching the formed metallic profile in a continuous in-line
process. The apparatus includes a roll forming station configured
to receive flat metallic composition and output a given profile. An
arching device is configured to receive the metallic profile and
bend the metallic profile having a desired radius of curvature
wherein a portion of the arching device is displaced with respect
to the roll forming station vertically and/or horizontally.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1A is a block diagram illustrating the steps included
in a continuous in-line process in accordance with the present
invention.
[0009] FIG. 1B illustrates a diagrammatic view of a continuous
in-line arrangement for forming an arch in a steel profile
embodying the various steps shown in FIG. 1A;
[0010] FIG. 2A is a side view of a process for bending a steel
profile in a continuous in-line process in accordance with the
present invention;
[0011] FIG. 2B is a top plan view of the process for bending a
steel profile in a continuous in-line process shown in FIG. 2A in
accordance with the present invention;
[0012] FIG. 2C is a top plan view of the process for bending a
steel profile in a continuous in-line process shown in FIG. 2A in
accordance with the present invention;
[0013] FIG. 2D illustrates a cross sectional view of a portion of
an arching device including an exemplary top insert roller in
accordance with the present invention; and,
[0014] FIGS. 3A and 3B are perspective views of arched metallic
profiles formed as part of a continuous in-line forming process in
accordance with the present invention.
DESCRIPTION OF EMBODIMENTS
[0015] The present invention will now be described more fully
hereinafter with reference to the accompanying drawings, in which
preferred embodiments of the invention are shown. This invention,
however, may be embodied in many different forms and should not be
construed as limited to the embodiments set forth herein. Rather,
these embodiments are provided so that this disclosure will be
thorough and complete, and will fully convey the scope of the
invention to those skilled in the art. In the drawings, like
numbers refer to like elements throughout.
[0016] The present invention is directed to a method and apparatus
for manufacturing an arched or curved steel profile as part of a
continuous in-line forming process. As such, the method roll forms
a steel profile from strip steel and bends this formed steel
profile during the continuous movement of the steel through the
in-line process in a desired cross-section configuration.
Applications of the present continuous in-line process include, for
example manufacture of profiles for storage buildings, greenhouses,
boat hulls, canopies, awnings, garages, ponds, swimming pool,
structural enclosure elements, furniture, etc. FIG. 1A generally
illustrates the continuous in-line roll forming process or method
in accordance with the present invention. The method includes the
functions of roll forming strip steels into a desired profile at
step 100, bending the formed steel profile at step 200 and shearing
or cutting the arched steel profile into individual units for
shipping at step 300. The bending step 200 employs apparatus 200A
and forming device 200B. FIG. 1B illustrates a diagrammatic view of
a continuous in-line arrangement for forming an arch in a steel
profile embodying the various steps shown in FIG. 1A. In
particular, step 100 in which strip steel is roll formed into a
desired profile may be accomplished through the use of an uncoiler
102, end welder 104, accumulation pit 106, punching station 108 and
roll forming station 110. Uncoiler 102 is configured to stream out
long sections of steel sheet or strips from coils. The end welder
104 is used to mate the individual steel sheet sections into a
continuous steel sheet length. The accumulation pit 106 provides
excess length of steel sheet for end welder 104 to work. The
punching station 108 is configured to punch holes or other voids
into the continuous steel sheet if desired. The formed profile may
be an open or closed profile. Typical open profiles include, for
example, "C" shape (most common), "U" shape and angled
configurations. Typical closed profiles may include such
configurations as polygons, e.g., square, rectangle, triangle and
the like, or curved configurations such as oval, circle, and the
like. The formed profile may be either welded or non-welded. The
roll forming station 110 roll forms the continuous steel sheet into
a particular steel profile.
[0017] The step of bending or arching the steel profile includes
utilizing Turkshead 202, Turkshead 204 and cutoff guide 206. The
step of shearing or cutting 300 the bent steel profile is
accomplished using, for example, a flying cutoff assembly 302. As
will be described in more detail below with reference to FIGS.
2A-2C, a Turkshead may remain stationary in an angular or
vertically displaced position relative to roll forming station 110
as the steel is feed through the process line to provide a constant
radius of curvature to the formed steel profile prior to cutting.
Alternatively, the Turksheads 202 and 204 may be synchronized for
linear and/or angular displacement with respect to the roll forming
station 110 as the steel profile is shaped, providing a variable
radius of curvature. As such, variable radii may be formed within a
single cut steel profile or different radii may be formed in
different cut lengths of steel profile. The bent formed steel
profile forms an arch, which may include either a singular arch or
multiple arches. Multiple arches may also be formed where the
arches are within the same plane having different radii, or arches
within different planes of formations, whether the arch has the
same radius or different radii than other arches in different
planes. In addition, the steel profile may be arched by the bending
profile step 200 to form: (i) a consistent arch, (ii) multiple
arches within more than two dimensions, (iii) different arches in
the same direction, (iv) different arches in different directions,
or (v) a spiral configuration. In this manner, various combinations
or arch radii, profile forms and section lengths may be implemented
using the present invention as described below.
[0018] FIG. 2A illustrates an exemplary process line 10 mounted on
a base 5 for forming steel profiles from strip steel. In
particular, strip steel is supplied by an uncoiler which rotates to
feed the continuous flat steel 111 to roll forming station 110. The
strip steel may include a plurality of holes, varying in hole
location, size, shape, or combinations thereof. Roll forming
station 110 defines a steel profile forming device and includes a
plurality of roll forming stands 115.sub.1-115.sub.N in which the
strip steel is roll formed to a profile. The roll forming stands
are positioned along the process line aligned with a central axis
(denoted as "A" in FIG. 2B) to produce a straight rolled steel
profile. Each roll forming stand includes a plurality of rolls
which engage both the upper and lower surfaces of the strip steel
111 and apply pressure thereto to bend the steel. The axis of
rotation of each roll is transverse to the direction that the strip
steel moves through process line 10. Certain of the plurality of
roll forming stands 115.sub.1-115.sub.N may be configured to have
either an upper or lower combination of rolls which remain fixed
relative to the direction of movement through the process line. The
number of roll forming stands 115.sub.1-115.sub.N will depend on
the desired shape of the steel profile where each stand works or
bends the flat steel progressively until the desired shape or
profile is achieved. For example, strip steel 111 is supplied to
first roll forming stand 115.sub.1 where it is rolled and output as
steel 111.sub.1. The next roll forming stand in the process
115.sub.2 receives the formed steel 111.sub.1 where it is again
rolled to output steel 111.sub.2. The next roll forming stand in
the process 115.sub.3 receives the formed steel 111.sub.2 where it
is again rolled to output steel 111.sub.3. As can be seen in FIG.
2A, the steel outputted by each roll forming stand produces a
changed profile which is rolled in progressive increments by the
next successive roll forming stand in station 110. This process
continues until the desired cross-section of steel profile
111.sub.N is outputted by the last roll forming stand 115.sub.N in
the process line 10. By way of example, a simple "U" shaped steel
profile or cross-section may require six roll forming stands
(115.sub.1-115.sub.6) and a more complex shape such as a "U" shape
with channel edges may require twelve to 18 roll forming stands
(115.sub.1-115.sub.18). In addition to forming the desired profile
of the formed steel, the rollers in each stand also act to move or
advance the strip steel through the process line 10.
[0019] Once the steel has been formed into a desired profile, a
pair of Turksheads 202 and 204 are disposed between the last roll
forming stand 115.sub.N and the cutoff assembly 302. The Turksheads
202 and 204 define an arch forming device (200B of FIG. 1A). In
particular, Turkshead 202 receives the formed steel profile
111.sub.N from roll forming stand 111.sub.N. The Turksheads 202 and
204 impart sufficient force to the steel profile to arch the
profile in a desired direction. Each Turkshead 202 and 204 includes
individual rollers or roll clusters rigidly held within a rotary
housing. Representative Turksheads include, for example without
limitation, Turksheads similar to Model Number TH-500-SSU available
from Addison Machine Engineering Inc. of Reedsburg, Wis. The formed
steel profile 111.sub.N is arched by the Turksheads 202 and 204 to
a desired bend radius to form profile 111.sub.T. The arched steel
profile 111.sub.T is then cut to desired lengths by cutoff assembly
302 to form cut steel profile section 111.sub.C. In order to
perform the bending step 200, either Turkshead 202 and/or Turkshead
204 may be disposed linearly in the vertical Y direction through
the use of movable platforms 225 and 228 respectively. In
particular, as steel profile 111.sub.T engages Turkshead 204 at the
desired location along the profile's longitudinal axis, platform
228 displaces Turkshead 204 vertically with respect to Turkshead
202 which remains stationary. This displacement of Turkshead 204
defines a bend point incident on Turkshead 202 causing an arching
of steel profile 111.sub.T along its longitudinal axis to produce
profile 111A. Similarly, Turkshead 202 may be disposed on a movable
platform 226 such that Turkshead 202 is disposed linearly in the
vertical Y direction with respect to roll station 111.sub.N and
Turkshead 204. This displacement of Turkshead 202 defines a bend
point incident on the last roll stand 111.sub.N. The displacement
(linearly or angularly) of either Turkshead 202 and/or 204 with
respect to last roll station 111.sub.N causes an arching of steel
profile 111.sub.T along its longitudinal axis to produce steel
profile 111.sub.A which is supplied to cut-off assembly 302 where
it is cut into desired lengths.
[0020] Turksheads 202 and 204 may also be configured to be
displaced angularly a distance in direction X off the central axis
"A" formed by the roll forming stands 115.sub.1 . . . 115.sub.N in
process line 10 as described in greater detail with reference to
FIGS. 2B and 2C. In this manner, the Turksheads 202 and 204 provide
a constant radius of curvature for the steel profile formed by roll
forming station 110 prior to cutting by cut-off assembly 302 within
the continuous in-line process. Alternatively, the Turksheads 202
and 204 may be synchronized to move as the steel profile is shaped
by the roll assembly 110 thereby providing a variable radius of
curvature. In addition, cut-off assembly 302 is also movable on
platform 301 such that cut-off assembly 302 must be in-line with
Turkshead 204 to provide an end cut along a common transverse
plane. In other words, cutoff assembly 302 is perpendicular to the
steel profile being roll formed by station 110. An exemplary
C-shaped steel profile was formed using the above described
continuous in-line process with a web width of 70 mm, a leg height
of 50 mm, and a return length of 10 mm. Once formed, and as a part
of the in-line continuous process, the steel profile was driven
through a Turkshead to create an arch with an outer radius of 12.5
meters, and an overall length of 4.2 meters. Once bent, the steel
profile was cut to the desired length.
[0021] The Turkshead 202 and/or 204 may also include a forming
device 200B to provide support and/or restrain the desired profile
in critical locations during the arching process. In particular,
when the arching process engages the movement of Turkshead 204
while Turkshead 202 remains stationary, the stress on the profile
about its bend point may compromise the integrity of the formed
profile. Thus, a support guide or guide plate is used to alleviate
these bend forces incident on the formed profile. For example, a
guide plate or a Turkshead guide roll cut device has the
corresponding shape of profile 111.sub.N undergoing the arching
process and may be positioned within Turkshead 202. This device is
used to support the steel profile during arching while avoiding
damage to the given cross-section of the profile as it passes
through the process line. In this manner, the forming device (200B)
is positioned to best enhance the structural integrity of the steel
profile and provides a stabilizing effect while the steel profile
is being arched or bent. These forming devices may be provided in
specified shapes, or contact along specified locations of the steel
profile and are generally used in the formation of bends in open
profiles, such as being shaped to fit in, and conform to, a given
internal space within the steel profile. This forming device 200B
may be separate from or incorporated into the Turkshead(s) to
contribute to the forming of the prescribed curve while maintaining
the desired profile. Alternatively, the forming device 200B may be
part of or in juxtaposition to cutoff assembly 302 to contribute to
the forming of the prescribed curve while maintaining the desired
profile and to promote the unimpeded operation of the cutoff
assembly 302. For example, a forming device may be used in bending
a C-shape in conjunction with a Turkshead by providing a resistive
force to pull against the inside of the C-shape during bending,
e.g., having four rolls providing pressure on a side member of the
steel profile to force it in a certain direction while minimizing
wrinkles in the steel profile.
[0022] FIG. 2B is a top plan view of the process line 10 shown in
FIG. 2A having a plurality of roll forming stands
115.sub.1-115.sub.N centrally disposed along axis A to better
illustrate the angular displacement feature of bending or arching
step 200. Strip steel 111 is supplied to first roll form stand
115.sub.1 and the process of roll forming proceeds as described
above to produce a desired steel profile 111.sub.N. Turkshead 202
remains stationary and Turkshead 204 is displaced angularly a
distance .DELTA. from the central axis "A" such that a bend radius
"R" is formed in the steel profile. The distance may be varied
during the forming of the steel profile using roll forming station
110 to form a profile with multiple radius of curvatures. As
Turkshead 204 is displaced, a different degree of arch is imparted
into the steel profile. This movement is controlled to account for
the speed of the process, amount of bend within a steel profile,
and repetition of the process to reproduce similar steel profiles
consecutively having corresponding degrees of arch therein.
Preferably, the process may be used to create dissimilar sets of
steel profiles, where each set of profiles are formed as a set,
that may be used together, e.g., the left and right rails (mirror
sides) of a slide, etc. In this manner, the constituents of a
particular steel profile set are manufactured with a high degree of
accuracy for use together. Once the profile is arched, the profile
is supplied to cut-off assembly 302 which is angularly aligned with
Turkshead 204 to cut the arched steel profiles into desired
lengths.
[0023] FIG. 2C is a top plan view of the process line 10 shown in
FIG. 2B where both Turksheads 202 and 204 are displaced angularly
with respect to axis "A" to form another arched configuration of
steel profile. In particular, Turkshead 202 is displaced angularly
a distance .DELTA..sub.1 from the central axis "A" such that a bend
radius is formed in the steel profile with respect to bend station
115.sub.N. Turkshead 204 may also be displaced angularly a distance
.DELTA..sub.2 from the central axis "A". In this manner, a steel
profile having an arching radius of curvature "R" may be tailored
to a particular configuration. Cutoff assembly 302 receives the
arched steel profile and cuts the profiles into desired lengths.
Again, cutoff assembly 302 is aligned with Turkshead 204 to provide
an end cut along a common transverse plane of the steel profile.
The relationship of the distances .DELTA..sub.1 and .DELTA..sub.2
will depend on the desired radius of curvature of the profile to be
arched. FIG. 2D illustrates a cross sectional view of a profile
through Turkshead 204 and an exemplary top insert roller 250
disposed with Turkshead 204. Insert roller 250 is included in the
top section of Turkshead 204 to maintain the shape of the roll
formed profile 111.sub.T during the arching step to equalize the
longitudinal stress on the profile during arching to prevent
kinking/warping thereof. In particular, roll formed profile 111T is
disposed between Turkshead side rollers 251A and 251B for bending.
Insert roller 250 is configured to engage profile 111T such that as
the profile is being arched, end 250A of insert roller 250
cooperates with the profile to maintain shape thereof. Insert
roller 250 shown in FIG. 2D is an exemplary shape for profile 111T
and may be exchanged within Turkshead 204 to accommodate other
profile shapes.
[0024] The degree of bend or arch within the steel profile is
determined by the vertical and/or angular displacement of Turkshead
202 and/or Turkshead 204. Representative bends include, for
example, arch ranges in radius from about 3 meters to about 24
meters. As seen in FIGS. 3A and 3B, the formed arch may include a
bend along the sides of the steel profile, such as that shown as a
simple arch in FIG. 3A, or a reverse arching structure with varying
degrees of arch, shown in FIG. 3B. Representative dimensions of the
steel profile may include a web width of from about 1.5 inches to
about 6 inches. Representative arch ranges have a radius from about
3 meters to about 24 meters. Although bends within the steel
profile may include a variety of configurations, the bent formed
steel profile preferably forms an arch. The formed arch preferably
has a consistent radius. Consistent radius include those radii
having a minimal deviation along a given length of formed steel
profiled with representative deviations ranging from about
1/8.sup.th of an inch to about 1/2 inch. The arch may be in the
form of a singular arch or multiple arches, with a singular arch
preferred. Representative multiple arches include multiple arches
within more than two dimensions, different arches in the same
direction and different arches in different directions. The arch
may be formed into a full circle structure, which may be formed
using guides that offset the feed out of the bending steel profiles
outside of the plane of the circle, prior to being cut. Examples of
the final steel profiles, include for example without limitation,
spirals, circles, slides, S-shapes, and the like.
[0025] During the in-line continuous process the arched steel
profile is cut or severed by assembly 302 after the steel profile
has been arched. This avoids drawbacks associated with prior
methods where the steel profiles were first cut to length and then
arched or bent to a desired radius of curvature pursuant to a
secondary process. Accordingly, the method and apparatus of the
present invention forms a bent steel profile product continuous
in-line at high production rates. Representative production rates
include, for example, from about 50 ft/min to about 500 ft/min,
with rates of from about 60 ft/min to about 2040 ft/min preferred,
and rates from about 60 ft/min to about 90 ft/min most preferred.
Supports at the cutoff assembly may be located on the side rail to
move the weight load of the steel profile off of the blade.
Additionally, these supports may be used to push at the bottom or
top of the steel profile to reduce twist, or increase the arch.
Although steel profiles are preferred and referred to herein, other
metallic compositions may be used in the formed profiles to be
arched. For example, when aluminum profiles are manufactured,
formed profiles may result from an extrusion process prior to being
bent in the continuous in-line process. Other metals may be used,
which are generally designed as specific functional components.
[0026] While the present invention has been disclosed with
reference to certain embodiments, numerous modifications,
alterations and changes to the described embodiments are possible
without departing from the sphere and scope of the present
invention, as defined in the appended claims. Accordingly, it is
intended that the present invention not be limited to the described
embodiments, but that it has the full scope defined by the language
of the following claims, and equivalents thereof.
* * * * *