Note: Descriptions are shown in the official language in which they were submitted.
21 548 16
FIELD OF THE INVENTION
The invention relates to roll forming machinery, of the type used for
continuously working and/or forming, a continuous strip or web of sheet
material, and
in particular, to such roll forming machinery in which the spacing between the
rolls can
be adjusted for variations in the thickness of the web, or the width of the
web.
BACKGROUND OF THE INVENTION
Roll forming machinery is well known, for forming web
strip materials of a variety of different types and compositions. Typical
applications
include the roll forming of metal web material. The roll forming machine has a
plurality of sets of rolls, usually arranged in upper and lower pairs, and
usually spaced
apart along the length of the machine on what are known as roller stands.
Typically, the
roller dies at one stand will produce a continuous formation in the web, and
the roller
dies of the next stand will for example increase the angle of the formation
which has
already been started at the previous stand and so on. Several different
formations can be
formed, in sequence, in most machines.
A wide variety of commercial and other products are made on such roll forming
machines, such as roof decking, siding, and a large number of components for
consumer equipment. The shapes may simply be webs with edge formations formed
along one edge or both, or may be C sections or U sections, but in many cases
consist
of relatively complex formations with longitudinal formations being formed
along the
length of the web, side by side. Such formed web is finally cut off after the
formations
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21 548 16
are complete, into predetermined lengths, and the lengths are then stacked and
shipped
out to a purchaser.
Generally speaking at each stand of rolls there are two lower dies and two
upper
dies arranged in pairs, to form folds, indentations, bends, and the like in
the web on
either side of a central web axis, simultaneously. The lower dies engage the
underside
of the web and the upper dies engage the upper side of the web. The dies are
formed as
annular or circular shapes, and are mounted on rotatable axles so that as the
web passes
between them the dies can rotate at the same speed as the sheet metal.
A gear drive mechanism is coupled to the dies so as to drive them at the speed
of the sheet metal.
Each set of such roller dies must be designed to provide a particular
formation
in the web. In addition, each pair of dies must have a clearance between them
which is
dete, mined by the thickness of the web.
Thus where it is desired to discontinue working on a web of one thickness, and
to then run a web of another thickness through the dies on the roller die
stands, each
pair of roller dies must be readjusted to a new clearance, to accommodate the
new
thickness of the new web. This involves costly down time, and skilled
machinists are
required in order to perform the fine adjustments.
It is not necessary to change the dies themselves, where the formations to be
prmi aced in the webs are the same shape as before. However if there is a
different
thickness of web, which is formed on the same dies, the clearance of the dies
must be
moved further apart or closer together, to accommodate the new thickness of
the web.
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21 548 16
All of this is very well known in the art and is accepted as the normal
operating
procedure.
It is however well known that a further problem exists in roll forming. The
web
of sheet material which provides the basic feed stock for the roller machine
should
preferably maintain its thickness within very narrow limits, along the entire
length of
the web. If there is any significant variation in thickness, then the dies,
being fixed as
to clearance, will produce varying effects on the web as the web passes along
the roller
stands, or the web may jam causing stoppage of the line.
In practice, it is well known that some web material varies in thickness to a
greater extent than is permissible. This results in unusual effects being
produced in the
final formed web, which may warp or bend or twist, or even jam.
Generally speaking, it is not possible to adjust the clearances of the roller
dies,
during the actual operation of the machine, and the best that can be done is
that in the
initial set up, the machinist will set the die clearances to a predetermined
average web
thickness. The results obtained in this way however are not always entirely
satisfactory.
It would in theory be desirable to provide for automatic self adjustment of
the
spacings or clearances between the pairs of dies in each stand. However, due
to the
shaping of the dies there are difficulties in such adjustments. Usually the
dies will have
two surfaces, one of the surfaces being more or less horizontal, or at least
parallel to
the plane of the web itself, and the other of the surfaces being at a web
forming angle.
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21 548 16
Any attempt to take into account the clearances between both of these die
surraces on both dies in a pair, simultaneously, on a continuous automatic
basis,
presents serious problems.
Another set of problems arises if it is desired to use the same roller dies,
to
form a web having a width which is greater, or narrower.
In the past this was possible, with some down time. Each of the stands would
have to be moved further apart, or closer together, to take into account the
width of the
new web to be processed.
However, the re-adjustment of the spacing of the pairs of stands was time
corr~uming. Desirably spacer rolls will be provided between dies on opposite
stands, to
support the web between the pairs of dies. The use of spacer rolls between the
die sets
on opposite sides of the web was a common practice. However, it was time
consuming
to dismantle the arrangement of dies for one web width, and then reassemble
the dies
with spacer rolls between them for a new web width. In addition, this was
awkward
anti time consuming work.
It is therefore desirable to provide for roller die stands arranged in pairs,
in
which at least one of each of the stands in each of the pairs, and preferably
both, shall
be transversely moveable relative to the other. The dies on one stand are
driven by gear
drives and some form of transmission mechanism is provided between the two
stands,
so that the dies carried on each of the two stands of each pair, are all
positively driven.
Given both die clearance adjustment, and stand width adjustment, it would be
possible, using one set of roller die stands and dies, to provide for the
processing of
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21 5 4~8 1 6
webs both of different thicknesses, and also of different widths. This enables
a
manufacturer to produce a standard rolled form section such as a C section in
a variety
of widths, and in a variety of gauges, from a single machine. This would
reduce the
capital investment in machinery. In addition this would reduce the down time
required
for change over from one web to another and also reduce the need for skilled
labour.
Additional savings would be achieved if the spacer rolls could be introduced
between the pairs of dies by some form of powered mechanism, so that the
stands could
simply be moved to part the spacer rolls placed in position and then the
stands moved
together again, with the spacer rolls in position. This would further reduce
the down
time, and enable manufacturers to maintain the quality of the roll forming
operations.
A further problem arises with roll forming certain sections, particularly
sections
which have the shape of a letter C with in turned flanges, or a partially
closed-in box
section.
In this type of section, the two edges or flanges of the C, or partially
closed-in
box, are turned inwardly. This is usually done by roll forming the edge
flanges first,
and then roll forming the C bends lader downstream. Special dies are required
to form
the last bends, and it is desirable to provides for adjustment of these dies.
Adjustment
of such dies in this location however, to accommodate variations in web
thickness and
to form different sizes of C-section. presents further problems.
BRIEF SUMMARY OF THE INVENTION
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21 5 48 16
The invention provides a roller die apparatus supporting a plurality of pairs
of
roll: r dies in predetermined clearances, and for varying said clearances
between said
roller dies to accommodate variations in the thickness of a web workpiece
passing there
between, said apparatus having first and second roller dies rotatably mounted
on
respective roller die bearings, said apparatus comprising, means for moving
one of
said first and second roller dies along a generally diagonal axis , diagonal
to its axis of
rotation, thereby achieving simultaneous adjusting of the die clearance in two
planes.
Preferably one of the dies is fixed, and the other of said dies incorporates
both
axial adjustment movement means and also transverse adjustment movement means,
so
as to keep all of the adjustment movement means in a common location where it
is
readily accessible for servicing and adjustment.
In another form of the invention means
may be provided for moving said lower roller die axially, and further means
for
moving said upper roller die transversely, thereby adjusting each said die
separately
from the other.
In the latter case the lower die would be movably mounted in fixed support
means, and would be movable axially, along its axis of rotation, and there
would be
lower bearing member movement means for moving said lower bearing member, and
the upper die is movable transversely and has means for moving the upper die
including
an upper bearing member rotatably carried in support means, and defining an
axis of
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21 548 16
rotation, and means for moving the upper bearing member transversely relative
to its
axis of rotation, towards and away from the lower bearing member.
A further feature of the invention provides movement transmission means
coupling all of said movable bearing members together for movement in
unisonant
power operated means for operating each of said movement transmission means.
A further feature of the invention provides a thickness sensor for sensing the
thickness of said web material workpiece, and generating a thickness signal in
response
thereto, and signal responsive means for generating movement signals for
moving said
movement transmission means, whereby to procure simultaneous movement of said
moveable bearing means in response to said thickness signal.
A further form of the invention provides for an edge forming roller die
assembly
for ~ olling the edge formations and means for moving said at least some of
said roller
dies relative to one another, to vary the clearance between them.
A further aspect of the invention provides for a straightening assembly,
comprising straightening rolls adapted to engage the workpiece after exiting
from the
roller dies to prevent warping.
Another aspect of the invention provides for width adjustment of the die
stands,
and means for inserting or removing spacer rolls between the dies.
This form of the invention includes a movable support table movable upwardly
and downwardly between the die stands, with the spacer rolls stored on the
table.
The invention also includes a method of forming a web workpiece.
21 5 48 16
'The various features of novelty which characterize the invention are pointed
out with
more particularity in the claims annexed to and forming a part of this
disclosure. For a
better understanding of the invention, its operating advantages and specific
objects
attained by its use, reference should be had to the accompanying drawings and
descriptive matter in which there are illustrated and described preferred
embodiments of
the invention.
IN THE DRAWINGS
Figure 1 is a side elevation of a roller die apparatus for working a web of
sheet
material partially cut away, and illustrating a plurality of roller die stands
at spaced
apart intervals along the path of the sheet material and controls shown
schematically;
Figure 2 is a top plan of part of Figure 1 in cross section;
Figure 3 is an enlarged s ide elevation of the roller apparatus of Figure 1,
partially cut away to illustrate the movable raise table and spacer rolls;
Figure 4 is a top plan schematic view of the two side plates holding the
roller
stands, and the transverse movement mechanism;
Figure 5 is a cross section of the roller die apparatus of Figure 1 at the
line 5-5,
in a first position;
Figure 6 is a cross section, corresponding to Figure 5, showing parts in a
second position;
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21 5 4a 1 fi
Figure 7 is a cross section corresponding to Figure 5 showing parts in a third
position;
Figure 8 is a section of one roller stand, sectioned along the line 8-8 of
Figure
2, and showing details of the upper die movement means;
Figure 9 is a section corresponding to a portion of Figure 8 along line 9-9 of
Figure 8;
Figure 10 is section along the line 9-9 of Figure 7 and showing movement;
Figure 11 is a section along the line 11-11 of Figure 10, showing upward and
downward movement of the upper die;
Figure 12 is a top plan view partially cut away showing the axial movement
mechanism for the upper die;
Figure 13 is a section, corresponding to Figure 11, but showing axial movement
of ~he upper die relative to the lower die;
Figure 14 is a perspective illustration of the upper die bearing housings, and
the
upward and downward movement mechanism, and the axial movement mechanism;
Figure 15 is a side elevational view of an alternate embodiment of roll
forming
machine using certain of the features of the embodiment of Figures 1 through
14;
Figure 16 is a top plan view of the embodiment of Figure 15;
Figure 17 is a greatly enlarged top plan view showing the area marked 17 on
fig~.ire 16;
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21 5 4g 16
Figure 18 is a top plan view greatly enlarged of the area marked 18 in Figure
16;
Figure 19 is a side elevation of area marked 18 in figure (6)
Figure 20 is a section along the line 20-20 of Figure 19;
Figure 21 is a section along the line 21-21 of Figure 19;
Figure 22 is a section along the line 22-22 of Figure 19;
Figure 23 is a section along the line 23-23 of Figure 19;
Figure 24 is a section along the line 24-24 of Figure 19, and,
Figure 25 is a section along the line 25-25 of Figure 17.
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21 5 48 1 fi
DESCRIPTION OF A SPECIFIC EMBODIMENT
Referring first of all to Figure 1 and 2, it will be seen that this
illustrates a roll
forming apparatus, for use in conjunction with web sheet metal processing
lines.
Additional equipment may comprise an uncoiled, a flattener, a cut off die or
shear, and
a stacker or conveyor, all of which components are essentially well known in
the art
anti form no part of the present invention and are therefore omitted from this
description for the sake of clarity.
The roll forming apparatus comprises a base indicated generally as B, defining
an upstream end U, and a downstream end D, and the web sheet metal W passes
from
the end U, to the other end D, continuously, while being progressively roll
formed.
The roll forming of the web W, is performed progressively at a series of pairs
of roller die stands indicated generally as 10, 12, 14, 16, 18, 20, 22, 24,
26, 28, 30,
32, 34, 36. The stands are secured to the base B, at spaced apart intervals,
along the
path of the web W. As shown in Figure 2, each pair of stands is designated as
l0a and
lOb, 12a and 12b, and so on. The stands are moveable relative to one another,
so as to
accommodate webs W of different widths. The stands l0a and lOb etc. are
supported
by continuous upright plates 38 and 40,(Figures 1 and 3) the lower end of
which are
securcd to the base B.
Each of the stands 10a, l2a,etc. (Figure 5) consist of upper and lower
transverse
bearing shafts 42 and 44. Upper and lower dies 46 and 48 are adapted to be
mounted on
the r espective shafts 42 and 44. Complementary bearing sleeves 50 and 52 are
supported by stands lOb, 12b, etc and support upper and lower dies 54 and 56.
As is
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2~ 5 4a 16
well known in the art, the respective upper and lower roller dies are shaped
in such a
way that they co-operate together to form the web in a continuous fold or
bend, and
each set of dies on each stand successively downstream along the roller die
apparatus
will progressively increase the formation either as to angle or as to depth,
or otherwise
or may produce different formations, depending upon the design of the dies,
and the
desired configuration to be formed in the web.
The apparatus may also incorporate means for moving the sides plates 38 and 40
transversely relative to one another where this additional flexibility is
desired. This
comprises a longitudinal side shaft 58, driven by a suitable motor, and
connected in
suitable manner to transverse movement means shafts 59 at each end of plates
38 and
40 for moving all of the stands relative to each other, so as to accommodate
strips or
webs of different widths (described below).
In accordance with the present invention, as explained above, there is
provided
means for adjusting at least one of the upper and the lower dies relative to
the other, so
as to adjust the clearance between the dies, to match the thickness or gauge
of the web
material as closely as possible. Such adjustments in accordance with the
invention can
be made while the web is actually running through the dies, thus compensating
for
variations in the thickness of the web along its length, all of which will be
described
below. The adjustment facility may be provided in all of the dies in a roll
forming line.
However in many cases it will be found that the adjustment feature may be
requred only
in one or two groups of dies in the line. Generally it may be said that the
adjustment
feature is most often required where the forming angle of the web is greater,
than say
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21 548 16
45 or 50 degrees, or more . At lesser bending angles the thickness adjustment
requirement is not so great, and in some case can simply be ommitted. For the
purpouses of this explanation all of the roller stands are described as
incorporating the
thickness adjustment facility, but it will be understood that , as explained
above the
adjustment facility may be provided only on a few of the roller stands.
Usually these
will be at the downstream end of the machine where the bend angles of the web
are at
their greatest. In some machines such as those used for forming C sections
however
whey a two bends are formed along either side of the web, then the adjustment
facility
may also be incorporated in a group of roller stands mid way along the machine
where
the first of these bends is reaching its greatest angle, and a further group
at the
downstream end where the second of the bends is reaching its greatest angle.u
Referring to Figure 1 it will be seen that a web thickness sensing unit 60 is
provided at the upstream end U of the roll forming apparatus. The thickness
sensing
unit may typically comprise a pair of rolls 62, and a signal generator (not
shown)
coo r~ected to a computer control centre 64.
In a manner to be described below, the sensing unit 60 senses the thickness or
gauge of the web as it passes through the sensing unit, and before it enters
the roller die
stands. The signal generator sends a gauge signal to the computer 64, and by
mechanism to be described below. The clearances between the dies is adjusted
either
closer or further apart depending upon the actual thickness or gauge sensed by
the
sensing unit.
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21 5 48 1 fi
In each of the roller die stands 10a, 12a, 14a the lower shafts 44, in well-
known
manner, are driven by a suitable drive train (not shown), and a suitable drive
motor and
transmission of a type well-known in the art (not shown) will thus drive the
lower roll
shafts .
The lower roll shafts have drive gears 70 secured thereon, and upper roll
shafts
42 have gears 72 secured thereon meshing with gears 70. Thus as lower roll
shafts 44
are all driven in the same rotational direction, all of the upper roll shafts
are driven in
the reverse rotational direction. The shafts connect telescopically with
respective
sleeWes 50 and 52 and drive them.
This, therefore, causes the dies 46 and 48 and 54, 56 to rotate in opposite
directions on opposite sides of the workpiece W, in well-known manner.
The respective lower and upper dies are illustrated only in phantom, since
roller
diPS axe well-known in the art, and their manner of attachment is also well-
known,
typically being attached by means of a single groove and spline.
Each of the lower shafts 44 are rotatably mounted in bearings in openings 74
in
plate 38.
The upper shafts 42 are carried in bearing housings 76. Each bearing housing
76 is supported in a suitable opening in plate 38. As explained above this
adjustment
feature is described as being part of each of the stands, simply for sake of
clarity, it
being understood that these features may be confined to one or two groups of
stands, in
many cases.
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2~ 548 16
Bearing housing 76 is able to rotate in a manner to be described below, and
thus
cause movement of upper die 46 transverse to their axes. This then enables the
clearance between the upper and lower dies to be adjusted by adjusting the
upper die in
a plane transverse to its axis in a manner described below.
Lower bearing sleeves 52 are mounted in suitable openings in side plate 40.
Upper bearing sleeves 50 are mounted in upper bearing housings 80 and are
rotatable in
the same way as housings 76. Roller bearings are mounted within the bearing
housings
76 and 80.
The side plates 38 and 40 are between 5 and 6 inches in thickness, in this
case,
and provide strong support for the shafts, sleeves and dies of the roller
stands.
The axial adjustment movement of the upper dies 42 and 54 is achieved by
means to be described below thus providing adjustment movement in both the
transverse plane, and in the axial direction, the resultant direction of
adjusting
movement being generally diagonal.
As explained above, the plates 38 and 40, incorporating the die stands 10a,
lOb,
etc. , are movable away from and towards one another, by means of the two
transverse
movement transmission shafts 59. The upper and lower shafts 42 and 44 are
dimensioned and designed so as to make a telescopic sliding fit within the
sleeves 50
and ~2. In this way the drive from the die stands 10a, 12a, etc., is
transmitted to the
die stands lOb, 12b, etc. , as described above.
However, referring to Figure 5, 6 and 7, it will be seen that the transverse
movement means can be operated to withdraw the shafts 42 and 44 entirely from
the
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21 548 16
slee;~es, thereby leaving the vacant space between the free ends of the shaft
and the
sleeves.
This feature enables easy changeover of the dies if the dies must be changed.
More importantly however, this feature permits the insertion of spacer rolls
84,
between the free ends of the shafts and the sleeves. This could be achieved
manually.
However, in accordance with a feature of the invention, the sets of spacer
rolls for each
of the pairs of die stands are supported on a length wise support table 86.
The support
table 86 is of rectangular tubular construction (Figure 5) and along its upper
surface it
is provided with a plurality of spacer rolls support brackets 88 spaced apart
from one
another and defining generally downwardly directed three-sided recesses. Along
the
length of the brackets 88, there are provided retention springs 90 at spaced
intervals.
Each set of spacer rolls 84 is provided with a central axial opening, which is
designed to fit on the shaft 44 of the stands 10a, 12a, etc.
As shown in Figure 3 a table raising movement means is indicated generally as
94, located beneath the table 86. Figure 3 shows only the one table movement
means.
However there are two such movement means, one at each end of the table, so as
to
ensure that when the movement means are operated, the table is maintained
level while
it is raised or lowered.
Movement means comprises a raise shaft 96, and guide shaft 98. Both shafts
run through a drive housing 100. A motor 102 drives a drive shaft 104, and a
shaft
extension 106 connects the drive from the motor 102 to the other of the table
raise
mov;.ment means (see Figure 1).
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A
21 5 48 1 fi
Referring again to Figure 5, it will also be appreciated that the table 86 is
movable transversely as well as up and down in a vertical plane. The
transverse
movement is permitted by means of the transverse carriage 108 (Figure 5), in
response
to movement of side plate 40.
Comparison of Figures 5, 6, and 7 will show that the entire table and raise
mechanism has moved substantially to the right to accommodate the simultaneous
closing movement of the two side plates 38 and 40, and the roller die stands.
Note that
in Figure 7 the transverse carriage 108 is extending substantially to the
right in a
rectangular portion of the base B.
As has already been explained all of the stands 10a, l Ob, 12a, 12b, etc. ,
are all
formed integrally with one another, as part of respective single continuous
side plates
38 and 40 (Figures 1 and 4). At each end of each side plate that is to say at
the
upst~ eam end and at the downstream end, there is provided a cross bearing
tube of
substantial diameter indicated as 112. The side plates 38 and 40, for each of
the stands
10a, 12a, etc. , and l Ob, 12b, etc. , are provided with bearing sleeves 114,
adapted to
ride on the tubes 112.
This provides a means for permitting movement of the entire set of stands 10a,
etc. an the one side, and l Ob, etc. , on the other side, for moving
transversely towards
and away from one another in unison. The space between the tube 112 at one end
and
tube 112 at the other end, is free open space, and permits the raising and
lowering of
table 86.
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y'
,: :''~,
21 548 16
It will of course be appreciated that while the illustrations of Figures 5, 6,
and 7
illustrate the lower shaft 44 picking up all of the spacer rolls 84, it is
perfectly possible
that a particular application will not require all of the spacer rolls.
Accordingly, all
that is required in this case is simply to insert the shaft 44, (see Figures 6
and 7) part
wz;~ into the stack of spacer rolls 84. The table 86 would then be lowered,
leaving
some of the spacer rolls on the shaft 44, and removing downwardly the rest of
the
spacer rolls, resting on table 86.
The die stands will then be closed up as in Figure 7 and in fact the die
stands
would be closer together than they are shown in Figure 7, since there would be
fewer
spacer rolls between the dies.
These operations can be controlled by the computer 64 so that the changeover
from; one width of web to another width of web would simply require a few
instructions
to be programmed into the computer, after which the die stands would be moved
apart,
and then moved partially or fully together, depending upon whether they were
picking
up all of the spacer rolls or only a selection of them.
Removal of the spacer rolls, or changing their number can be effected in the
same way.
In this case the table 86 is raised until it is in contact with the spacer
rolls 84.
At this point, the side ii~ames are then moved fully open, withdrawing the
shaft 44 from
the spacer rolls 84. This will then leave the spacer rolls 84 sitting freely
on the racks
88 on the table 86. The table 86 will then be lowered, and the die stands can
simply be
closed up again.
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ADJUSTMENT OF DIE CLEARANCE
21 5 48 1 6
As generally described above, the adjustment of the die clearances is achieved
by moving, in this embodiment, the upper die relative to the lower die. The
lower die
remains unadjusted. Again it is to be understood that while this description
shows that
all of the roller stands are provided with the clearance adjustment feature,
described
below, in many cases it will be sufficient if the adjustment feature is
provided in one,
or two groups of stands, where the bend angle being formed in the web is most
extr cme. Where the bend angle is only slight it may be that no adjustment is
required at
all, or it may be that the adjustment can be confined to a simple up down
adjustment.
The adjustment of the upper die takes place along a generally diagonal
axis,diagonal to its axis of rotation .To achieve this in this embodiment the
die is
moved along the axial direction of the shaft 42, in the axial direction, and
secondly, the
die is moved on an axis transverse to the axial direction of shaft 42, ie. up
and down.
By providing adjustments in both planes,the resultant direction of adjusting
movement is generally diagonal and it is possible to adjust for variations in
web
thickness even while the web is running through the roller dies. The
transverse
adjustment is best understood with reference to figures 8, 9, 10, 11 and 14.
As explained, the lower die 48 remains unadjusted. It simply rotates on its
shaft
44, which runs in bearings mounted directly in opening in plate 38.
The same is also true of die 56, mounted on its sleeve in plate 40.
The two upper dies 46, in stand l0A and 54 in stand lOB however are mounted
respectively on shaft 42, in stand 10A, and in sleeve 50 in stand lOB. Both
shaft 42
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21 548 16
and sleeve 50 are in turn carried in bearing sleeves indicated respectively as
76 and 80.
The bearing sleeves in turn are received in making openings formed in their
respective
plates 38 and 40, so that they can simply rotate.
In order however to provide for adjustment, by means of rotation of the
bearing
sleeves, the bearing sleeve 76 is provided with an offset shaft recess 120,
containing
both bearings, and the shaft 42. The axis of the shaft recess 120 is offset
from the
central axis of the sleeve 76 (see figure 10). Thus when the sleeve 76
rotates, the axis
of the shaft 42 must move relative to the axis of the bearing sleeve 76.
Provided that bearing sleeve 76 is suitably located, so that its thinnest
point and
its widest point lie on a more or less horizontal axis (figure 10) then
rotation of bearing
sleeve 76 in one direction will cause shaft 42 to move upwardly and the
rotation of the
sleeve 76 in the other direction will cause shaft 42 to move downwardly.
Turning to stand IOB, it will be seen that shaft sleeve 50 which is mounted in
the hearing sleeve 80, also has the same characteristics. That is to say the
recess 122 in
bearing sleeve 80 is offset with respect to the central axis of bearing sleeve
80 so that
the central axis of the sleeve 50 is offset with respect to the central axis
of the bearing
housing 80.
Thus if the bearing housing 80 is rotated in one direction the shaft sleeve 50
will
move upwardly, and if the bearing housing 80 is rotated in the opposite
direction the
shafC sleeve 50 will move downwardly.
In order to provide for rotational movement of the bearing housing 76 and 80
in
unison, each bearing housing is provided with an annular rack semi gear
portion 124,
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21 5 48 1 6
which is welded at a suitable position to the edge of the respective bearing
housing 76
and 80.
Two racks 126 are provided in stands l0A and lOB engaging the gear segment
12a (figures 9 and 10). Each of the racks is mounted on to a respective push
pull rod
128. The two push pull rods 128 are mounted so as to extend to the upper
regions of
respective stands 10A, 12A, etc. and IOB, 12B etc. The push pull rods 128 are
threaded along their length, for convenience.
Each of the racks 126 is secured to its respective push pull rod by means by
locknuts 130. The push pull rods 128 are both operated simultaneously, by
means of a
transverse drive coupling shaft 132 (figure 2) and a drive motor 134.
Thus, by the operation of motor 134, all of the respective racks 126 can be
operated so as to move their respective semi annular gear segments 124, thus
moving
simultaneously all the bearing housings 76 and 80 in the stands 10A, lOB, etc.
Thus all of the upper dies will move simultaneously either upwardly or
downwardly by the same increment.
As mentioned above, adjustment also takes place axially along the axis of the
shaft, and shaft sleeves. This axial movement is best understood with
reference to
figures 8, 12, 13 and 14.
Again, the lower die 48, 56, remains unadjusted, in this embodiment.
The upper dies 46 and 54 are the dies that are adjusted. This is achieved by
the
same means in both stands l0A and lOB.
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21 548 16
The bearing housing 76 and 80 are both rotatable in their openings in their
plates 38 and 40, and they are both axially slidable, to a limited extent, to
their plates
38 and 40. This axial movement is achieved by means of an annular groove 133,
formed in each of bearing housings 76 and 80. A self lubricating anti wear
block 135
rides in the groove 133. The block 135 has a central recess (not shown).
A spur gear 138, is secured in a cross member 140 fastened to the top of the
respective plates 38 and 40. The spur gear is engaged by a respective rack
140. The
plurality of racks 140 are secured to respective push pull rods 142, by means
such as
locknuts 144.
The spur gears 138 have a downward axial extension 146. At the free end of
ex~~nsion 146, there is located an offset stub 148. Stub 148 is received in
the recess in
wear blocks 135.
It will thus be seen that by the operation of the racks 140, in response to
the
movement of the push pull rods 142, the spur gears 138 will rotate one way or
the
other. This will cause an orbital movement of the offset stub 148, the axis of
which is
offset relative to the central axis of the extension 146 and gear 136.
This orbital movement will thus force the respective bearing housings 76 and
80, to move axially one way or the other relative to their respective plates
38 and 40.
It will be appreciated that as a result of this movement there is a slight
lateral
displacement of the annular gear segments 124, relative to their respective
racks 126.
However, since the degree of movement is relatively slight, this will not
cause any
problem in operation.
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21 5 48 1 6
The push pull rods 142 are again operated by a cross shaft 150, and motor 152
(figure 5), so that the push pull rods on all of stands 10A, 12A, and IOB, 12B
etc.
operate simultaneously.
It will thus be seen that during operation of the roll forming line, if the
sensor
60 detects a change in the thickness of the web, it will send a signal to
computer 64.
Computer 64 will thereupon signal motors 134 and 152 to adjust the die
clearances, in
two planes simultaneously, to accommodate the different web thickness. This
adjustment which will in effect be along a generally diagonal axis, will of
course be
relatively minor, but will have the effect of maintaining the highest quality
of the roll
forming action on the web, which would otherwise not occur if the die
clearances were
not adjusted.
It will of course be appreciated that in the event of a changeover in the
operation
of the roll forming apparatus from one web to another, the web may have a
thickness
which is increased or decreased somewhat more, as compared with the previous
web
that was being processed.
These adjustments pan in the great majority of cases can be taken into account
simply by programming the computer, so that it instructs the motors 134 and
152 to
adjust the die clearance to suit the new web thickness.
In the event of an extreme change in web it may of course be necessary to
readjust the position of the racks on the push pull rods. This can readily be
done
simply by loosening off the locknut, resetting the positions of the racks and
locking up
the ~ocknuts to hold the racks in the new position.
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a: :;
..~, ~t
21 548 16
In accordance with a further embodiment of the invention, illustrated in
general
in Figures 15 and 16, provision may be made for a somewhat different form of
operation than in the Figure 1 through 14 embodiment.
In the Figure 1 through 14 embodiment, the C-section is formed by bending the
two outer flanges of the C by the main dies, at the leading end of the
machine, and then
progressively forming the intermediate bends of the C-section, in downstream
sets of
rolls.
This however placed certain restrictions on the size and the shape of the C-
section that could readily be formed in this way.
In accordance with the embodiment of Figures 15 and 16, the inner bends of the
C-section are formed first by the main sets of rolls, and the final in turned
flanges of
the C-section are formed last, downstream from the main rolls. This has
certain
advantages. It enables a greater range of flange sizes, and web depths, to be
formed on
a single machine.
It also provides for easier adjustment. The embodiments of Figure 15 and
16 also provide a finished C-section straightener, all to be described below,
which can
in fact be used with the embodiment of Figures 1 through 14 or 15 and 16.
Many of the features of Figures 1 through 14 and Figures 15 and 16 are
common to both, and will therefore be described in somewhat less detail, since
they
have already been described in connection with Figures 1 through 14.
Referring now to Figure 15 it will be seen that this embodiment of the
invention
comprises a roll forming apparatus indicated generally as 200, and having an
upstream
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21 548 16
end 202 and a downstream end 204. A web of material passes from the upstream
end
to the downstream end during the process of being formed from a flat web into
a C-
section.
The apparatus 200 will also have an upstream web thickness measurement
device similar to that shown in Figure 1, and a computer control similar to
that shown
in Figure l, for providing for continuous adjustment.
The entire apparatus, as before, is supported on a base made up of a frame
work
of rectangular beams 206, connected to rectangular cross members 208.
As before, there are a plurality of roller die stands indicated as 210, 212,
214,
216, 218, 220, 222, and 224. As shown in Figure 16, in each case each of the
stands
comprise respective right and left hand die stands indicated by the suffix a-
b.
Also as in the previous embodiment, each of the die stands comprises pairs of
upper and lower dies, which mesh with one another to provide the formations
desired.
As before, selected ones or groups of the upper dies are moveable relative to
the
lower dies by means of push pull rods 226 and 228, the two rods being
respectively
referenced a and b (see Figure 16) on opposite sides of the apparatus.
The operation of the push pull rods to procure the upward and downward
movement, and lateral movement, of the upper die is as already described, and
consequently the apparatus is not described in detail again for the sake of
simplicity.
S imilarly, as in the Figure 1 through 14 embodiment the die stands 210A and
210B, etc. are moveable away from one another and together, to provide for
varying
spacings between the stands and also, to permit varying numbers of spacer
rolls to be
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_w. 21 5 4 8 1 6
introduced there between. The spacer rolls indicated as 230 are carried on a
spacer roll
table 232 operated by means of the raise mechanism 234 (see Figure 15). The
spacer
robs, table and raise mechanism all operate in the same way, as is already
described in
the embodiment of Figures 1 through 14.
As before the roller die stands are all driven by a common drive motor 236
driving through transmissions 238.
The push pull rods 226 are operated by means of motor 240, and the push pull
rods 228 are operated by means of the motor 242.
As mentioned above, this embodiment of the invention provides for the
formation of the edge flanges of the C-section downstream from the main roller
die
stands. The edge flange forming die stands are indicated generally in Figures
15 and
16 as 250 and 252. Each of the edge forming die stands 250 and 252 consists of
in this
case five pairs of outer and inner edge forming dies on each side indicated as
254 and
256.
As will be seen from Figures 17 through 24, each pair of edge forming dies 254
and 256 consist of outer dies 254 and inner dies 256, the outer dies being of
much
larger diameter than the inner dies for reasons to be described below.
It will also be seen that each pair of dies is mounted for rotation on spaced
apart
vertical axes, so that the dies rotate in horizontal planes, again for reasons
to be
described below.
Each set of dies outer 254, is mounted on respective common mounting frames
258 and each set of inner dies 256 is mounted on sub-frames 260. Sub-frames
260 are
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2154816_
rnnunted on mounting frames 258 and are moveable relative thereto as described
below.
All of the dies 254, and 256 can be moved as a group towards and away from the
other
set, to accommodate workpieces of different widths, or to form C-sections of
different
dimensions by movement of the two mounting frames 258-258.
Thus the two mounting frames 258-258 carrying the two groups of dies 254 and
256 can be moved towards and away from one another by transverse movement
means
(nol shown) similar to figures 1-14, and moving all of the dies transversely,
siriultaneously.
The apparatus also provides for upward and downward adjusting movement of
the mounting frames 258-258 holding the two groups of dies 254 and 256. These
upward and downward adjustment movements are procured by means of motor 262
operating through shaft 264 and gear drives 266, the lower ends of which are
connected
directly to the mounting frames 258 and 258 respectively. Guide posts 268
guide such
vertical movement.
In this way, the positioning of the two groups of horizontal dies can be
adjusted
up and down, so as to accommodate the manufacture of C-sections of different
shapes,
ie., having deeper web sections or shallower sections.
Figure 20 shows that each inner die 254, is mounted on a drive shaft 270,
having a driven gear 272, connected by idler gears 272a. One of gears 272
meshes with
an elongated drive gear 274. The reason for the elongated drive gear 274 is to
permit
the upward and downward movement already described, performed by moving the
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2154816
framework 258 upwardly or downwardly, to move all of the pairs of dies in
unison.
Gear 274 is mounted on shaft 276 connected to the main drive train 278.
The outer dies 254 are not in themselves adjustable, other than as already
exr~lained, when the entire assembly of dies is moved by movement of the
mounting
frame 258.
The apparatus also provides means for adjusting the clearance between the
inner
and outer dies in respective pairs, in much the same way as the adjustment of
the upper
dies relative to the lower dies, in the main part of the apparatus, similar to
the
embodiment of Figures 1 through 14.
The purpose of the adjustment of the clearance of the horizontal edge forming
dies is to solve the same problem, namely to accommodate the variations in the
thickness of the workpiece, as it moves along the line.
The adjustment of the outer dies relative to the inner dies, in the pairs of
the
horizontal dies, is best understood with reference to Figures 21, 22, and 23.
Adjustment of the clearance between the outer dies 254 and the inner dies 256
is
achieved by providing for adjusting movement of the outer dies as a group, in
a vertical
plane, and also in a transverse plane. Sub Frames 260 are mounted on mounting
fraxraes 258 in such a way that they can be moved both vertically in such a
way that they
can be moved both vertically and transversely.
Vertical adjustment for the inner dies comprise shafts 280 on which the sub-
frame 260 is mounted at each end. The shafts 280 are provided within sleeves
282.
Jack screws 284, engage threaded members 286. Shafts 280 are operated by means
of
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2154816
the push pull rods 226a and 226b, engaging elongated gears 288 on the upper
ends of
shafts 280. Members 2865 are secured to captive plates 290 secured within
either end
of sub-frame 260 (Figure 21 and 22). Rotation of shafts 280 will thus raise,
or lower,
sub-frames 260 relative to frames 258.
The transverse adjustment of the inner die relative to the outer dies for
clearance
adjustment, is also achieved by means of movement of sub-frames 260 relative
to
frames 258, transversely.
Shafts 292 have gears 294 which engage push pull rods 228a and 228b. Shafts
292 are connected to eccentric shafts 296 which extend down through sub-frames
260,
and into side frames 38. Shafts 296 at their lower ends have bosses 296,
coaxial with
shafts 292. Thus rotation of shafts 292 will cause eccentric orbital movement
of shafts
296 causing sub-frames 260 to move transversely relative to frames 258.
It will thus be seen that it is possible to move the entire assembly of inner
and
outer dies, on each side of the apparatus, both upwardly and downwardly, as an
assembly and also inwardly and outwardly as an assembly.
It will also be seen that it is possible to adjust the inner dies both
upwardly and
downwardly and also inwardly and outwardly relative to the outer dies, to
accomodate
variations in the thickness of the web.
The apparatus of Figure 15 and 16 further provides an end finishing operation,
by means of two pairs of end finishing roll assemblies 300a and 300b, on
opposite sides
of the apparatus. The end finishing roll assemblies have lower dies 302 and
upper dies
304 and intermediate side dies 306. In this way, it is possible for the three
dies to
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2154816
engage all three outer surfaces of the C-section, and provide the final
finishing and
squaring step.
Inward and outward movement of the two die assemblies is provided by the
main transverse movement mechanism already described above (see Figure 1-14).
The lower die 302 in each of the finishing die assemblies 300 will remain
fixed
as to height, and is not adjustable. The side dies 306 are simply likewise
fixed, relative
to uhe lower dies 302, so that they simply adjust inwardly and outwardly, with
the
in°~~~ard or outward movement of the entire finishing die assemblies.
The upper dies 304 of each finishing die assembly are moveable upwardly and
downwardly, to take into account different dimensions of different C-sections
being
formed. This is achieved by means of the jack screws 308 operated through
suitable
transmissions by motors 310. The lower ends of the jack screws are secured by
the
bearing housing 312 carrying shaft 314 for the upper dies 304.
Operation of the jack screw will thus cause the entire bearing housing 312 to
eitr~er move upwardly or downwardly.
In the finishing dies, there is no separate adjustment for die clearance to
accomodate different thicknesses of web material, since the upper and lower
and side
dies are simply working to finish the exterior of the C-section (Figure 24).
Finally, in this embodiment, provision is made for straightening the C-section
as
it exits from the finish rolls.
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2154816
It is well known that when forming C-sections, they may have a tendency to
warp, which implies either that the section will bend upwardly or downwardly,
or
sideways.
In order to overcome this tendency, there are provided straightening
assemblies
320a and b, which are located just downstream, at the exit end of the
apparatus. This is
best understood with reference to Figure 19 and 25. The straightening assembly
comprises a fixed lower roll 322, which is located along the pass line of the
lowermost
web of the C-section. Two, leading and trailing, straightening rolls 324 and
326 are
mounted above the lower roll, and spaced apart with respect thereto upstream
and
downstream.
In addition, a side roll 328 is provided for engaging the side portions of the
C-
section.
As in the case of all of the rest of the rolls, the straightening rolls are
mounted
as lift and right hand sets of rolls on opposite sides of the apparatus, and
will move
towards and away from one another in conjunction with and in unison with the
mo ~ ernent towards and away from one another and all of the rest of the dies
in the
manner described above.
The lower roll 322 is fixed. The two upper rolls are mounted on a generally
inverted U-shaped yoke 330, which is pivotally mounted on the axle 332 (Figure
19).
The yoke can thus tilt about the axle, bringing one of rolls downwardly and
the
oth;,. roll upwardly and vice versa.
-31-
2154816
Connected to one end of the yoke 330, is a jack screw 334, which is operated
by
motor 336 (Figure 25).
Operation of the motor will thus cause the one end of the yoke to either tilt
upwardly or downwardly.
Thus if the C-section is tending to warp up, the jack screw 334 will be raised
thereby causing the trailing die 326 to move downwardly, and thus correcting
the
upward warp of the C-section.
If the C-section is warping downwardly, then the jack screw 334 is operated in
the apposite way to depress the leading die 324.
The side rolls are also operable from side to side in order to correct any
sideways warping. This is achieved by means of the jack screws 338, operated
by
motors 340. Operation of the jack screw 338 in one direction will cause the
side roll
328 to move in one direction, and operation of the jack screw in reverse will
move the
roll in the other direction.
Thus by operation of the motors 340-340 on opposite sides, it is possible to
mo ~ a the two side rolls 328, one on each side of the C-section, either to
the left or to
the right, thus straightening any sideways warping.
Warp sensors, such as optical sensors 342 (Figure 19) and 344 (Figure 25) are
connected to computer 64 and would cause appropriate signals to be sent to
motors 336
and 340.
The invention also includes the method of forming a web work piece as
described
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2154816
The foregoing is a description of a preferred embodiment of the invention
which
is given here by way of example only. The invention is not to be taken as
limited to
any of the specific features as described, but comprehends all such variations
thereof as
come within the scope of the appended claims.
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