Note: Descriptions are shown in the official language in which they were submitted.
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BACKGROUND OF THE INVENTION
This invention relates to package flow systems, and
more particularly to a roller assembly and support frame for
use in package flow systems.
Over the years a number of roller assemblies have
been developed for conveying, supporting and storing various
packages and articles upon frames, flow tracks, racks and con- )
veyor frames. These prior art roller assemblies have met with
varying degrees of success.
One type of prior art roller assembly that has been
developed has one or more rollers extending laterally outward
of the side walls of the flow track or rail. Undesirably, the
arrangement and positioning of these rollers occupy valuable
storage and conv~ying space.
Another type of roller assembly that has been developed
has rollers mounted between the side walls of the channel-shaped
flow track. Typi~ying this type of roller assembly are the
roller assemblies shown in U.S. Patents, Nos. 2,982,387; 3,023,487,
3,063,354 and 3,900,112. These rollers have outwardly extend-
ing spindles, axles and trunnions which are connected or inte-
grally formed with the roller and are supported by the shoulders
o apertures or recesses of the flow track. Some of these
roller assembliés are intricate and sometimes difficult and
expensive to manufacturej assemble or install.
Various fasteners and structural components have
; also been developed for securing the flow track to a support
frame or rack. These features and components include bolts,
such as shown in U.S. Patent No. 2,982,387 hooks, such as
shown in U.S. Patent No. 3,063,354, and tabs, such as shown
in U.S. Patent No. 3,900,112.
It is there~ore desirable to provide an improved
roller assembly which is easier and less expensive to manufacture,
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assemble and install, and to provide an improYed support frame
for firmly supporting the roller assembly.
SUMMARY OF THE INVEN~ION
An improved roller assembly and support frame are
provided for use in a package flow system. The roller assem-
bly is of relatively simple design and construction and is
generally easy and inexpensive to manufacture, assemble and
install.
The roller assembly has a channel-shaped frame or
rail which is operatively connected to and supports at least
one and preferably a plurality of longitudinally spaced rollers.
The rail has a pair of upright side walls wi~h lower edges and
an intermediate section that extends between and connects ~he
side walls. Advantageously, each of the side walls has a rib,
which is preferably longitudinal. Desirably, each rib extends
laterally inwardly to provide an upright grasping surface.
The novel support frame includes a plurality of shelf
members which firmly support the roller assembly. Each shelf
member has rib-engaging feet which snap fit and interlocking
20 engage the ribs of the roller assembly. Each shelf member
; also has a base or base portions which engage and support the
lower edges of the rail.
In one embodiment the shelf member includes an
upright support section having a plurality of T-shaped end
members that extend upwardly from the base. Each of the T-
shaped end members has a laterally extending foot that engages
the ribs.
In another embodiment, the feet of the shelf member
~ are generally horizontal and extend longitudinally above the
; 30 base to engage the ribs.
Desirably, the front shelf member has an inclined
side that extends above the heiyh~ of the base. An abutment
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plate extends downwardly from the upper portion of the inclinedside to provide an abutment stop for the front end of the rail
during installation of the rail in the support frame, and an
abutment stop for packages during use of the package flow system.
Preferably, the rear shelf member has a generally
upright side and a generally horizontal top. An abutment plate
extends downwardly from the horizontal top. In the illustra-
tive embodiment, the upright side o~ the rear shelf member is
of a lesser height than the overall height of the inclined side
of the front shelf member.
In the preferred orm, the rihs and the feet are in
general horizontal alignment with each other and the minimum
distance between the grasping surface of the ribs ~e normally
greater than the minimum distance between the feet prior to
assembling the roller assembly to the support frame, so that
the ribs snap fit against the feet of the shelf members.
In order to assemble t.he roller assembly to the novel
members, the side walls of the roller assembly are temporarily
compressed so as to span a distance less than the minimum dis-
tance between the feet of the shelf members. The roller assem-
bly is then inserted and placed between the feet so that the
ribs are aligned with the feet. Upon releasing the side walls,
the ribs securely engage and are biased against the feet.
While the roller assembly can be manufactured and
assembled by various methods and processes, the preferred
` method and process includes the steps of: providing a gener-
ally continuous imperforate web of metal; providing a~ roller
; having a hub defining a socket; advancing the web through a
series of processing stations including sequentially blanking
or stamping the web to form a series of longitudinally spaced
pairs of side wall openings without completely severing the
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stamped material from the web, arcuately bending the stamped material
to form arcuate surfaces, bending the arcuate surfaces generally
perpendicular to the web to form arcuate shaft sections extending
integrally and laterally from the web, placing the roller adjacent the
web, aligning the axial socket with the arcuate shaft sections,
bending the web to form a channel-shaped rail frame with upright side
walls and an intermediate section extending between and integrally
connecting the upright side walls, and concurrently inserting the
arcuate shaft sections into the axial sockets to provide arcuate
bearing surfaces for the roller as the web is being bent into the
channel-shaped rail frame.
Desirably, longitudinally spaced roller-receiving openings
are sequen~ially blanked or stamped in the web simultaneous with the
side wall openings. Preferably, the roller-receiving openings are
generally rectangular in shape and have a dimension perpendicular to the
lateral axis less than the maximum diameter of the outer cylindrical
suface of the roller.
In the illustrative embodiment the web is indented to form
a pair of generally parallel longitudinal ribs, and the side wall
defining portions of the web are bent to Eorm generally U-shaped
edges.
~ or ease of assembly, the arcuate shaft sections can be
bent at an angle slightly less than 90 degrees from the side walls
to form tapered shaft sections.
The improvement or combination which is defined as the
invention herein is a package flow system comprising a roller assembly
including a channel-shaped frame having a pair of upright side walls
; and an intermediate section extending between and connect:ing the side
; walls, each of the side walls having a longitudinal frame-engaging
rib, a generally upright inner side wall surface and a lower edge
beneath the intermediate section. The assembly also includes a
plurality of rollers operatively connected to the side walls, each
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62
of which rollers includes a cylindrical load-supporting surface for
dynamically supporting the load. Each of the longitudinal frame-
engagLng ribs extends longitudinally along one of the upright side
walls with portions extending longitudinally between the rollers and
having an outer rib wall providing a generally upright grasping surface
in general vertical alignment with one of the upright inner side
wall surfaces and an inner rib wall extending laterally inwardly from
the upright inner side wall surface. A support frame is provided,
having a shelf member including rib-engaging feet with generally upright
portions for snap-fitting interlocking engagement with the upright
grasping surfaces of the longitudinal ribs. Base means is provided
for engaging the lower edges of the side walls to support the roller
assembly.
A more detailed explanation of the invention is provided
in the following description and appended claims taken in conjunction
with the accompanying drawings.
BRIEF DESCRIPTION OF T~IE DRAWINGS
Figure 1 is a schematic representation of a method
of forming a roller assembly in accordance with principles of
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the present invention;
FIGURE 2 iS a perspective view of a package flow
system with a roller assembly supported by a shelf member of
a support ~rame in accordance with principles of the present
; invention;
FIGURE 3 is an enlarged cross-sectional end ~iew of
a package flow system with the roller assembly supported by
another type of shelf member in accordance with principles of
the present invention;
FIGURE 4 is a fragmentary longitudinal view of the
roller assembly taken substantially along lines 4-4 of Figure
3 with parts brsken away ~or ease of illustration and clarity;
FIGURE S is an enlarged perspective view of an
arcuate shaft section that together with a similar, axially
opposed arcuate shaft section supports a roller;
FIGURE 6 is a fragmentary perspective view of the
front shelf m~mber illustrated in Figure ~;
FIGURE 7 is a fragmentary perspective view of a rear
shelf member;
FIGURE 8 is a fragmentary perspective view of the
~ront shelf member illustrated in Figure 3; and
FIGURE 9 is a fragmentary perspecti~e view of another
rear shelf member.
DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMEMT
Figures 2 and 3 of the drawings illustrate package
flow systems 10 and 12, respectively, having an improved
impact-resistant roller assembly 14 which is particularly use-
ful for conveyiny, supporting and storing packages, cartons,
, .s~e/~
containers and other articles upon 6hel~e members of a support
'l
frame, rack or track assembly 16 or 18. The roller assembly
14 can also be useful in gravity conveyor systems and other
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6~?
conveyor assemblies.
Roller assembly 14 includes a plurality of cylindri-
cal rollers 20 which are preferably longitudinally spaced from
each other at equal intervals and made of impact-resistant
plastic having a relatively low coefficient o* friction, such
as nylon or high density polyethylene. In some circumstances
it may be desirable to make the roller 20 out of other materials,
such as metal, wood or rubber.
Each roller 20 has an outer cylindrical load-supporting
l~ surface 22 (Figure 3) for engaging, dynamically supporting and
conveying a load, such as a package, carton, container or other
articles. A plurality of circumferentially spaced ribs 24
extend radially inwardly from the outer load-isupporting surface
22 to a centrally disposed tubular hub 26. In the illustrative
embodiment there are two sets of four circumferentially spaced
ribs 24 which are laterally and angularly offset from each other.
Hub 26 defines an elongated, axial shaft sections-
receiving socket 28 extending along a lateral axis 30. Socket
28 provides a cylindrical bearing surface for the shaft sections
56 and 58. The outer lateral edges or ends 26a of the hub 26
are also rounded or chamfered radially inwardly for ease of inser-
tion of the shaft sections 56 and 58. Desirably, the outermost
portion 26b of the outer lateral edges or ends 26a is gener-
ally upright and serves as a thrust bearing or bearing surface
that ocassionally rotatably engages the side walls 36 and 38 of
the rail 34. Preferably, hub 26 and socket 28 extend laterally
outward of both sides of the outer load-supporting surface 22
as well as ribs 2~, a sufficient amount or length to maintain
adequate clearance between the outer load-supporting surface 22
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and the top 40 of the rail 34 to prevent the roller 20 from
rubbing against the top 40 of the rail.
It is believed that the construction and arrange-
ment of the illustrative roller is less expensive and easier
to mold within closer dimensional tolerances than some prior
art rollers having connected axles, trunnions and spindles.
One of the many advantages of the present invention
is the provision of a unitary one-piece rail frame assembly 32
that rigidly and rotatably supports the roller 20. The unitar~
rail frame assembly 32 includes an elongated generally channel-
shaped rail frame 34 which is sometimes referred to as a "rail"
or "track." In the preferred embodiment, the rail 34 generally
has the configuration of an inverted U and is made of resilient
steel or other resilient metal. Structurally, the rail 34 has
a pair of generally parallel upright side walls 36 and 38 and
a generally planar intermediate section 40 extending generally
horizontally between and integrally connecting the side walls
36 and 38. In the preferred form, intermediate section 40 is
positioned above the lateral axis 30 and provides the top of
the rail 34.
Intermediate section 40 has a plurality of roller
xeceiving openings 42 which are longitudinally spaced apart
from each other. Each roller-receiving opening 42 receives one
of the rollers. Preferably, each roller-receiving opening 42
is generally rectangular in shape and has a longitudinal dim-
ension perpendicular to the lateral axis 30 less than the maximum
diameter of the outer cylindrical surface 22 and a size less than
; the maximum size of the roller 20 received in the opening 42
taken along an imaginary horizontal plane cut through the lateral
axis 30 of that roller 20 as viewed in top plan view, but has
a width greater than the roller 20, so that only the outer
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surface 22 and a portion of that roller 20 projects upwardly
out of the roller-receiving opening 42 above the top 40 of the
rail 34~ This construction and arrangement permits the packayes
to roll upon the rollers 20 generally without rubbing against
the rail 34.
Side walls 36 and 38 each have a U-shaped lower end
or edge 44 with an upwardlv turned flange or lip 46 that extends
generally vertically towards the top 40 to provide additional
reinforcement for the frame assembly 32. The upwardly turned
flanges 46 of the side walls 36 and 38 are in general parallel
relationship to each other and are of the same height.
In order to further reinforce the unitary frame assem-
bly 32 and provide a gripping and engaging surface for a support
frame or rack 16 or 18, each slde wall 36 and 38 has a longi-
tudinal reinforcing and stiffening rib 48 that is located closely
adjacent to the lower end 44 of the rail 34, beneath the lateral
axis 30. In the preferred form, the reinforcing ribs 48 of the
side walls 36 and 38 are positioned in general horizontal align-
ment and parallel relationship to each other and extend later-
ally inwardly to form a longitudinal upright inner rib wall 50generally about the vertical center line of the U-shaped lower
end 44 and a longitudinal generally planar and upright grasping
- surface or outer rib wall 52 generally vertically aligned with
the upright inner side wall surfaces 54.
In order to rotatably and securely support the rollers
20 in a manner which is relatively simple, inexpensive and easy
to manufacture, assemble and install, the unitary rail frame
assembly 32 includes pairs of arcuate shaft sections or pintles
56 and 58 that are spaced longitudinally along the rail 34.
Each pair of arcuate shaft sections 56 and 58 extend integrally
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and laterally inwardly from the side walls 36 and 38, respec-
tively/ into a socket 28 of one of the rollers 20. Desirably,
each pair of arcuate sha~t sections 56 and 58 are positioned in
general horizontal alignment and are axially spaced from each
other to define an axial opening 60 therebetween.
Prefera~ly, arcuate shaft sections 56 and 58 are
tapered or slanted laterally inwardly in a downward direction
from the lateral axis 30 towards an opposite side wall for ease
of assembly. In the illustrative embodiment the unattached ends
of the shaft sections 56 and 58 are tapered downwardly 1/2
degree from the lateral axis 30. It is believed that the down-
ward taper also makes the shaft sections 56 and 58 easier to
fabricate and provide high spots with minimum fric~ional sur-
face area for quicker and smoother rotation of the roller 20.
Desirably, the innermost edge of the unattached ends
of the shaft section 56 and 58 are curved or chamfered down-
wardly sc as not to engage and interfere with rotation of the
roller 20.
As shown in Figures 4 and 5, each shaft section 56 and
58 is preferably arcuately shaped or semi-tubular with a cross-
sectional configuration of an inverted U or upstanding arch as
viewed laterally, and has an outer surface 62 that faces upwardly
to provide an upper bearing frame surface upon which the roller
20 can rotate. It is preferred that the shaft sections 56 and
58 each extend arcuately at a generally equal radi~s more than
180 degrees about the longitudinal axis 64 of its associated
side wall 36 and 38 to provide adequate support for the roller
20. ln the illustrative embodiment, the lower edges of each
arcua~e shaf. sect~iorl 56 and 58 extend about 30 degrees, respec-
tively~ beiow the longitudinal axis 64 so that each arcuate
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upper bearing surface 62 extends about 240 degrees.
For economy of material and manufacture, the shaft
sections 56 and 58 are formed from material b~anked and bent out
of the side walls 36 and 38. To this end, each side wall 36 and
38 has a series of specially configured side wall openings or
apertures 66 which are longitudinally spaced apart from each
other. Each opening 66 has a generally U-shaped lower portion
68 (Figure 2) and an upper portion 70 that is generally "omega'
or horseshoe-shaped.
The upper wall portion 72 (Figure 3) ir~mediately
above and adjacent the arcuate shaft section 56 and 58 of each
side wall 36 and 38 is in vertical alignment with the lower side
wall portion 74 extending immediately beneath and adjacent the
side wall openings 66. Preferably, upper and lower wall por-
tions 72 and 74 are substantially planar or flat and are posi-
tioned in general coplanar relationship to each other. ~`
In order to rigidly and firmly support the longitud-
inal ends of the rail 34 and roller assembly 14, an improved
support frame 16 or 18 (Figures 2, 3 and 6-9) having front
shelf or shelving members 75 or 76 (Figures 6 and 8) and rear
shelf or shelving members 77 or 78 (Figures 7 and 9) is provided.
The front shelf member 75 in Figures 2 and 6 includes
` an upright support section 79 with a base or horizontal ledge
portions 80 ~hat engage and support the lower edges 44 of the
; rail 34 so as to~firmly support the front end 34f of roller
assembly 14. Upright support section 79 has generally upright
T-shaped end members 81 extending upwardly fxom the base or
horizontal 3adge portjons 80. Each T-shaped member 81 has a
pair of late~ally spaced side portions 82 that are generally
L-shaped and symmetrical and complementary to each other.
62
Each side portion 82 has an upright edge 84 and a laterally
extending gripping and rib-engaging foot 85. The adjacent
upright edges 84 and feet 85 of adjacent T~shaped members 81
are positioned closely adjacent the outer side wall p~rtions 44e
of the lower edges 44 of the rail 34 and engage the grasping sur-
faces 52 of the longitudinal ribs 48, respectively, and are con-
nected by and cooperate with a base or ledge portions 80 to
define a pair of inverted T-shaped rail-receiving openings 83 for
snugly receiving and engaging the side walls 36 and 38 of the
rail 34. Feet 85 also serve to stabilize the positioning of the
rail 34. In some circumstances it may be desirable that the up-
right edges 84 extend above the feet 85.
At the lateral ends of the support section 79 (Figure
6) there are inverted L-shaped upright end members 81a. Each
end member 81a has only one laterally extending foot 85a. Foot
85a faces laterally inward.
A generally horizontal bottom 86 (Figure 6) is inte-
grally connected to the upright support section 79. An in-
clined or sloped side 87 extends upwardly and rearwardly from
the bottom 86. A generally upright head plate or abutment plate
88 depends downwardIy from the upper edge portion or top of
the inclined side 87 and is spaced forwardly of the upright sup-
port section 79. Abutment plate 88 serves as a stop or abut-
ment surface for the rail 34 as well as the packages. Pre-
~erably, the corners formed at the junctions of the abutment
plate 88, inclined side 87, bottom 86 and upright support sec-
tion 79, respectively, are rounded to minimize concentration of
stresses on the fron~ shelf member 75.
The rear shelf member 77 in Figure 7 is similar to the
front shelf member 75, except that its side 187 is generally
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upright rather than inclined and is of a lesser overall height
than the inclined s.ide 87 (Figure 6) of the front shelf member 75.
The rear shelf member 77 is also squared off to have a generally
flat or planar top 174, and the downwardly extending abutment
plate or head plate 188 is spaced rearwardly of the upright sup-
; port section 179 to engage the rearward end of the rail 34.
The upright support section 179 (Figure 7) of ~herear shelf member 77 is generally similar to the upright sup-
port section 79 (Figure 6) of the front shelf member 75 and
10 for ease of understanding and clarity, similar parts have been ~.
given similar numbers, but increased by 100, such as base 180,
foot 185, etc. When installed, the upright support section 179
` and head plate 188 of the rear shelf member 77 generally face
the upright support section 79 (Figure 6) and head plate 88,
respectively, of the front shelf member 75.
The front shelf member 76 in Figure 3 has an elongated
generally horizontal base, bottom or base portion 89 which sup-
portingly engages the lower edges 44 of the rail 34 to support
the roller assembly 14. An inclined or sloped side 90 extends
upwardly and rearwardly from the base 89. A generally upright
head plate or abutment plate 91 depends downwardly from the
upper edge portion or top of the inclined side 90. Abutment
plate 91 serves as a stop or abutment surface for the packages.
Longitudinal feet or shelf surfaces 92 extend generally hori-
zontally and in a longitudinal direction from the lower portion
or bottom of the abutment pla~e 91. Each foot 92 has a pair o~
laterally opposed longitudinal sides or upright edges 93.
The unattached rearward edge of the longitudinal feet 92 are
positioned forwa~dly of ~'ne rearward edge of the base 89.
The adjacent upright edges 93 of adjacent feet 92 are connected
by one of a plurality of lateral abutment portions 97 and engage
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~he upright grasping surfaces 52 of the longitudinal ribs 48.
Lateral abutment portions 97 are spaced rearwardly of the abut-
ment plate 91 and serve as a stop or abutment surface for the
front end 34f of the rail 34. Feet 92 also serve to stabilize
the positionin~ of the shelf member 76.
The rear shelf member 78 in Figure 9 is similar to
the front shelf member 76 ~Figure 8) except that the side 190 J
is generally upright rather ~han inclined and has a height less
than the overall height of the inclined side 90 (Figure 8) of ~ _
the front shelf member 76. The rear shelf member 78 i5 also
squared of to provide a generally horizontal top 179 from which de-
pends a downwardly extending abutment plate or head plate 191. The
longitudinal feet 192 are substantially similar to the longitudinal
feet 92 (Figure 83 of the front shelf member 76 and the head
plate 191 and fee~ 192 are spaced rearwardly of the front edge
of the base 189. When installed, the head plates 191 and 9i of
.the.~ear and front shelf members 78 and 76 (Figures 9 and 8)
generally face each other.
Preferably, the longitudinal ribs 48 snap fit into
ïnterlocking engagement with the feet 85 and 185 (Figures 2,
6 and 7) and 92 and 192 (Figures 3, B and 9). To this end the
minimum distance between the grasping surfaces 52 of the roller
assembly 14 (before engaging the support frames 16 and 18) should
normally be slightly greater than the minimum distance between
each of the adjacent rib-engaging feet 85, 185, 92 and 192.
In order ~o assemble the roller assembly 14 to the
support ~rames 16 and 18 (Figures ~ and 3), the side walls 36
and 38 of the roller as8embly 14 ~e temporarily compressed
inwardly so that the minimum distance between the grasping sur-~
faces 52 is less than normal minimum distance between the
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uncompressed grasping surfaces 52 and is less than the minimum
lateral distance between engagement feet 85, 185, 92 and 192 of
each shelf member 75-78, respectively. The roller assembly 14
is then inserted and posi~ioned.between the T-shaped end mem-
bers 81 and 181 (Figures 2, 6 and 7) or longitudinal feet 92
and 192 (Figures 3, 8 and 9) so that the longitudinal ribs 48
are aligned with the feet 85 and 185 or 92 and 192, respectively.
Upon releasing ~he side walls 36 and 38, the outer rib walls or
grasping surfaces 52 will expand, snap-fittingly engage and be
biased against the feet 85 and 185, ox 92 and 192. Preferably,
the lower ends or underside 44 of the roller assembly 14 is
positioned upon the base 80, 180, 89 or 189 tFigures 6-9) and
the front end of the rail 34 is positioned in abutting confron-
tation against the front abutment plate 88 ~Figure 6) or abutment
portion 97 (Figure 8) or closely adjacent there~o.
While the roller assembly 14 can be made and manu-
factured by various means, a preferred method and process for
making the roller assembly 14 i5 shown in Figure 1.
In Figure 1, a generally continuous imperforate web
or sheet 94 of metal is provided in a generally planar or flat
condition. Web 94 is sequentially, consecutively and system-
atically fed and advanced, left to right, as shown in Figure 1,
in a generally continuous manner through a series of processing
ox forming stations A-M to form the unitary xail frame assem-
bly 32 and roller assembly 14 (Figures 2 and 3). During the
forming process, the unitary rail frame assembly 32 and roller
assembly 14 is formed and assembled, respectively, in an inver-
ted or upside down state or condition and is subsaquently
installed right side up.
Asjthe web 94 passes station A, web 94 is sequen-
tially blanked or stamped to form longitudinally spaced sets of
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aligned openings, including roller-receiving openings 42 and
laterally opposite pairs of side wall openings 66a and 66b in
lateral alignment with the roller-receiving openings 42.
Desirably, each of the roller-receiving openings 42 are rec-
tangular in shape and have an area less than the maximum area
of the roller 20 to be inserted in said opening 42 taken through
the lateral axis 30 (Figure 3) of the roller 20 as viewed in
top and bottom plan views. In some circumstances it might be
desirable that the roller-receiving openings 42 and the side
wall openings 66a and 66b are blanked or stamped a~ different
stations and times, rather than simultaneously at station A.
In order to provide integral shaft sections 56 and
58 (Figure 3) integral with side walls 36 and 38, the side wall
openings 66a and 66b are stamped or blanked without completely
severing the blanked material 96 from the web 94. Specifically,
U-shaped lower portions 68 of the side wall openings 66a and
66b are blanked and severed, while upper portions 70 remain in
tact and unsevered.
At station B, the unsevered materials 96 blanked from
2n the side wall openings 66a and 66b are arcuately raised or bent
to form the arcuate upper surfaces 62.
At station C, the arcuate surfaces 62 are bent or
turned upwardly to form the arcuate shaft sections 55 and 58.
Preferably, the arcuate ~urfaces 62 are bent at an angle slightly
less than 90 degrees from the side wall defining portions of
the web 94, such as about B9.5 degrees, to form the tapered
axially spaced shaft sections 56 and 58 for ease of assembly
and insertion into axial socket 28.
At station D web 94 i8 indented in an upward direc-
tion at two rib forming locations 98 and 100 to form a pair of
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generall~ p~rallel reinforcing and stiffening ribs 48a and
48b. Because some of the metal is pushed out of ~he plane of
the web to form the ribs 48a and 48b at station D, the overall
width of the web 94 is thereafter reduced.
At station E the outer lateral edges 102 and 104 of
the web 94 are bent upwardly about 90 degrees in the beginning
stages of a generally continuous roll foxming process to form
the end flanges 46 (Figure 3). At station F the flanges 46 axe
completely bent and web 94 is advanced to station G.
At station G the unbent outer lateral edges 106 and
108 of the side wall defining portions of the web 94 are bent
or turned upwardly about 90 degrees to form horiæontal end por-
tions or bights 110 (Figure 3) and the generally U-shaped edges
44 of ',he side walls 36 and 38. At station H the edges 44 of
the side walls 36 and 38 axe completely formed and the web 94
is advanced to station I.
At station I the web 94 is prefoxmed by partially
turning or bending the web 94 to form semi-formed side walls
.
112 at about a 45 degree angle as shown in phantom or dotted ~
line in Figure 3.
At station J an impact-resistant roller 20, which
has been previously molded or otherwise formed, is positioned
and placed upon the web 94 with its axial socket 28 extending
; transversely or laterally in a direction towards the arcuate
- shaft sections 56 and 58. Preferably, the web 94 is being con-
tinuously roll formed at station ~, although in some circum-
stances it may be desirable to stop roll forming at station J
to permit placement of the roller 20 upon the web 94.
As the web 94 passes station K the side walls 36 and
38 are being turned and formed and the arcuate shaft sections
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62
56 and 58 will begin entering the axial socket 28 of the roller
20 to fo~n upper bearing surfaces 62 (Figures 4 and 5).
At station L, the side walls 36 and 38 are completely
bent or turned upwardly, generally at right angles to the hori-
zont~l intermediate section 40 (Figures 2 and 3) of the rail 34O
At station M, the unitary rail assembly 32 is com-
pletely formed with the arcuate shaft sections 56 and 58 com-
pletely inserted into the axial socke-t 28 and engaging the hub
26 ~Figure 2) of the roller 20, with the shaft sections 56 and
58 in general axial alignment with each o~her. Thereafter, the
web 94 can be cut or severed across its width at any desired
length to provide a rail 34 (Figure 2) with the desired number
of rollers 20.
While the various steps required in the formation of
the roller assembly 14 have been described as being carried out
in a preferred oxder at separate stations, it may be desirable
in some situations, to carry out these steps in a different order
or to perform several of the operations simultaneouslyO
The preceding description has been given for ease of
understanding only. No unnecessary limitations are to be under-
stood therefrom as modifications will be obvious to those skilled
in the art.
