Note: Descriptions are shown in the official language in which they were submitted.
CA 02643248 2008-11-05
1120C111
FIELD OF THE INVENTION
The invention relates to apparatus and method for forming strip sheet metal,
and in
particular to such an apparatus and method having a plurality of different
functions
which can be performed, including punching openings, stamping and drawing
flanges,
cutting to length, and roll forming .
These operations can be performed on a strip in sequence one after the other,
or can
be performed selectively, at the wish of the operator.
The apparatus also adjusts for variations in thickness of the strip sheet
material, and
can be adjusted to accept material of different widths.
BACKGROUND OF THE INVENTION
Metal forming of continuous strip sheet metal is usually carried out by Roll
Forming.
This well known process forms strip sheet metal into lengthwise bends and
folds, along
the length of the strip. In many cases such machines will accept one thickness
and one
width of strip, and must be manually changed over to accommodate a strip of
different
gauge or width characteristics.
Metal strip of a given gauge is known to exhibit minor variations in
thickness. These
minor variations can cause serious defects in the end product. Certain roll
forming
apparatus has been developed which can accommodate such variations of strip
thickness, as the strip is passing through the roller stands. These machines
can also
be changed over from a strip having one gauge or one width to another strip
with
different specifications, with a minimum of down time.
Examples are shown in US Patents 6,647,754 - Variable width roll forming
apparatus,
1
CA 02643248 2008-11-05
1120C111
6,644,086 - Retro-fit roll forming mill with jack screw, and 6,282,932 - Axial
and
transverse roller die adjustment apparatus and method.
Roll forming machines do not have the ability of punching holes or forming
flanges
spaced apart along the strip. Rotary punching and stamping machines have been
developed for this purpose. These machines will punch holes, and will form
flanges
around such holes, along a continuously moving strip. Cutting or shearing
strip material
into lengths has been carried out with flying dies. However rotary shearing is
more
flexible. It is also faster, and can be cut at closer intervals.
Examples of such machines are shown in US Letters Patent 6,725,751 Rotary
Punch
Apparatus and 6,205,898 Rotary cutoff device and method.
These machines enable a manufacturer to make a continuos strip with holes
punched
at intervals, and with flanges stamped around such holes, or other formations
formed at
spaced intervals, and such strip can be roll formed to provide longitudinal
bends, in a
roll former, downstream of the rotary punches.
However where such products are to be used for a specific market, for example
for use
as studs or joists in construction, the strip must be cut to length, into
separate work
pieces , for a particular job site, or market. In this case it becomes
necessary to
preselect the locations of the holes and flanges to be formed, at spaced
intervals which
match the requirements of the job site. The two ends of each cut workpiece
must be
free of holes and flanges, in most cases.
Machines are required having the ability to punch or not punch, stamp or not
stamp,
and cutters which can cut at precise lengths, in order to perform these
operations
2
CA 02643248 2008-11-05
1120C111
satisfactorily.
Putting all these complex machines, with their own specific abilities, into a
single
production line, requires a very large investment.
Where production of the work pieces warrants such an investment, then this is
acceptable. However in many cases a manufacturer will not have sufficient
volume of
orders to keep the entire line busy making one product.
The manufacturer will want a line which is capable of making a wide variety of
different
work pieces or products, in order to justify the large investment .
A line having numerous different functions, which can be changed over from
making
one work piece, to making another with a minimum of down time required for
change
over, will also achieve savings in floor space, and in training of skilled
help.
BRIEF SUMMARY OF THE INVENTION
With a view to satisfying the need for such a machine the invention provides a
multi-
function strip sheet metal processing apparatus having the usual strip feed
systems,
and further having at least one rotary punch apparatus for receiving the strip
and
forming spaced apart formations along its length, and having punch control
means for
controlling the timing and location of such forming operations on said strip,
and further
having a shear apparatus and controls for shearing the strip at spaced
intervals, in
spaces between said spaced apart formations and having a plurality of roller
die
assemblies downstream of said shear apparatus, for forming lengthwise bends.
The invention further comprises such an apparatus wherein the punch control
means is
operable to discontinue punching while permitting said strip to pass through
said punch
3
CA 02643248 2008-11-05
1120C111
apparatus, untouched.
The invention further comprises such an apparatus wherein the rotary punch
apparatus
is mounted on transverse movement means, whereby said rotary punch apparatus
can be moved transversely out of alignment with said strip.
The invention further comprises such an apparatus wherein said rotary punch
apparatus incorporates upper and lower rotors each carrying respective dies,
and being
rotatable in a forward direction for forming said strip, and being rotatable
in a reverse
direction, for positioning said dies .
The invention further comprises such an apparatus wherein said rotors are
guided by
cam follower rollers, and guide cams, and incorporating moveable gates on said
guide
cams for controlling said cam follower rollers.
The invention further comprises such an apparatus wherein there are two said
pairs of
rotors and two said pairs of dies, a first pair of said dies punching openings
and flange
at spaced intervals in said strip and a second pair of said dies forming
alternate
openings and flanges;
The invention further comprises such an apparatus wherein said punch control
means
is operable to speed up rotation of said rotors just prior to closing of said
dies on said
strip, and thereafter slowing down said rotation, as said dies close on said
strip, and
thereafter speeding up said rotors as said dies begin to open from said strip.
The invention further comprises such an apparatus wherein said punch control
means
is operable to stop rotation of said rotors and permit said strip to pass
there between
without contacting said dies.
4
CA 02643248 2008-11-05
1120C111
The invention further comprises such an apparatus wherein said shear is
operable to
shear said strip at a predetermined length, and including length sensing meas
sensing
the length of said strip and operable to deliver a shear signal to said shear.
The invention further comprises such an apparatus and further including feed
rolls
positioned between said punch rotors and said shear for providing a positive
feed of
said strip .
The invention further comprises such an apparatus wherein forming rolls are
incorporated with said feed rolls, said forming rolls engaging parts of said
flanges and
forming the same with longitudinal bends.
The invention further comprises such an apparatus wherein said feed rolls and
forming
rolls are mounted together on transverse rails , and adjustment mechanism for
moving
them transversely relative to said strip.
The invention further comprises such an apparatus wherein said roller die
assemblies
consist of lower rolls and upper rolls, and means for adjusting the spacing
between said
lower and upper rolls in response to variations in thickness of the work
pieces.
The invention further comprises such an apparatus wherein there are right and
left
hand sets of lower and upper rolls, and wherein said right and left hand sets
are
moveable transversely away from and towards one another, to accommodate work
pieces of varying width.
The invention further comprises such an apparatus wherein there are two sets
of angle
rolls and including swingable mounting blocks for supporting said angle rolls
and
adjustment means for adjusting the angular position of said mounting blocks.
5
CA 02643248 2008-11-05
1120C111
The invention provides a method of forming work pieces from a strip sheet
metal supply
and in which the strip is processed by repeatedly punching formations at
spaced
intervals, repeatedly bending spaced apart flanges at spaced intervals,
repeatedly
shearing the strip into work pieces, and roll forming continuous flanges along
the work
pieces.
6
CA 02643248 2008-11-05
1120C111
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 made to the accompanying
drawings
and descriptive matter in which there are illustrated and described preferred
embodiments of the invention.
IN THE DRAWINGS
Figure 1 a is a side elevation of a first portion of a multi-function
apparatus illustrating
the invention;
Figure lb is a side elevation of a second portion of the multi-function
apparatus
illustrating the invention;
Figure 2, is a schematic illustration showing the various different stages of
operations
labelled a to g, that can be performed on a sheet metal work piece;
Figure 3 is a perspective illustration of three stations of the apparatus of
Fig I
Figure 4 is a side elevation of the apparatus of Fig 3;
Figure 5 is a perspective illustration of one of the rotary punch portions of
the
apparatus;
Figure 6 is a perspective of the die carrier for the female die of the rotary
punch
portion of Fig 5;
Figure 7 is a is a perspective of the die carrier for the male die of the
rotary punch
portion of Fig 5;
Figure 8 is a perspective of one side of the guide cams for rotary punch
portion of Fig
7
CA 02643248 2008-11-05
1120C111
5;
Figure 9 is a side elevation of one side of the guide cams for the rotary
punch portion
of Fig 5, in a first position;
Figure 10 is a is a side elevation of one side of the guide cams for the
rotary punch
portion of Fig 5, in a second position;
Figure 11 is a perspective illustration of the feed and form portion of the
apparatus;
Figure 12 is an exploded perspective illustration of one side of the feed and
form
portion of the apparatus;
Figure 13 is an exploded perspective illustration of the other side of the
feed and
form portion of the apparatus;
Figure 14 is a perspective illustration of the rotary shear portion of the
apparatus;
Figure 15 is a perspective illustration of one of the shear rotors of the
rotary shear
portion of the apparatus;
Figure 16 is a perspective illustration of the other of the shear rotors of
the rotary
shear portion of the apparatus;
Figure 17 is a perspective illustration of the guide cams of the rotary shear
portion;
Figure 18 is a side elevation of the guide cams of the rotary shear portion;
Figure 19 is a perspective of a lead portion of the roller die assemblies;
Figure 20 is a perspective of the trailing end portion of the roller die
assemblies;
Figure 21 is a cut away perspective of the diagonal flange roll dies;
Figure 22 is an end view in elevation of the diagonal roll dies;
Figure 23 is a side elevation of the lancing rolls for forming slots in one
embodiment of
8
CA 02643248 2008-11-05
1120C111
product; and,
Figure 24 is a section along line 24- 24 of Fig 23.
DESCRIPTION OF A SPECIFIC EMBODIMENT
Referring first of all to figure 1a, it will be seen that this figure
illustrates the first
portion of the apparatus. This first portion begins with the uncoiler (10).
The uncoiler
(10) is merely illustrative of such equipment which is typical in the roll
forming art. The
purpose is to receive a coil of sheet metal strip (12), and to the enable the
sheet metal
strip (12) to be unwound from the coil and fed into the remainder of the
machinery
downstream. As such, the uncoiler (10) is regarded as being well known in the
art and
is not specifically described in detail. Once unwound from the uncoiler (10),
the sheet
metal strip (12) is supported by the extendable support arms (14), which can
be
extended to receive the sheet metal strip (12), as it is unwound from the
coil. The
extendable support arms (14) are supported on the next portion of the line
which
comprises the flattener (16).
The flattener (16) is also a piece of equipment which is generally well known
in
the art and has been in use for many years. It consists of a plurality of
upper and lower
rolls, which engage the upper and lower sides of the sheet metal strip, and
form it into a
flat strip, removing any curling tendency which may have arisen as a result of
the sheet
metal strip being formed into a coil. The details of the flattener are not
described, since
it is regarded as well known in the art.
From the flattener (16), the strip passes to a first rotary punch (18), and
from the
9
CA 02643248 2008-11-05
1120C111
first rotary punch (18) the strip passes to a second rotary punch (20). From
the second
rotary punch (20), the strip passed through a feed/form unit (22), and from
the
feed/form unit (22) the strip passes to the rotary shear (24).
Figure lb illustrates the second portion of the apparatus or roll forming line
(26)
ending in a stacking table (28).
It will be appreciated that this apparatus can perform a variety of different
functions on a sheet metal strip (12), and is also capable of performing some
of these
functions, and omitting others, as may be required for a particular customer
or order or
product.
The various different functions can best be understood by reference to figures
2a to 2g.
Figure 2a illustrates merely a flat piece of sheet metal strip (12), as it
would exit from
the flattener (16).
Figure 2b represents the sheet metal strip after it passes through the first
and second
rotary punches (18) and (20). In this case, openings are blanked out and
flanges are
formed usually at right angles, around the opening formed by the rotary
punches.
Figure 2c illustrates the sheet metal strip as it passes through the feed/form
unit (22). In
this case, the flanges on either side of the openings in the sheet metal strip
are shown
as being bent, usually at right angles.
Figure 2d illustrates the sheet metal strip after it passes through the rotary
shear (24),
and is cut into separate lengths or work pieces (32).
Figure 2e illustrates a work piece (32) as it passes through a first portion
of the roll
forming line (26),
CA 02643248 2008-11-05
1120C111
Fig 2 f illustrates the work pice at an intermediate stage of the roll forming
line, and,.
Figure 2g illustrates the work piece as it passes through a final portion of
the roll
forming line (26).
It will be appreciated as explained above, that these illustrations from
figures 2a to 2f
show various steps or functions that can be carried out, in sequence, on the
sheet
metal strip (12), by use of the apparatus. It is also understood that one or
more of the
operations can simply be omitted if it is not required. Other operations can
be
performed by means of suitable controls any portion of the apparatus can be
maintained inactive and out of contact with the sheet metal strip (12), so
that the sheet
metal strip (12) passes that portion of the apparatus without any work being
performed
on it at that station, or can be activated in other cases.
ROTARY PUNCH AND FORM
The first rotary punch (18) and second rotary punch (20) components of the
apparatus will now be described in more detail.
The first rotary punch (18) and second rotary punch (20) are of essentially
identical construction. The function of both the first rotary punch (18) and
second rotary
punch (20) is to punch openings or holes in the sheet metal strip (12) at
spaced
intervals as the sheet metal strip (12) is moving, and to form portions of the
sheet metal
strip (12), around the holes or the openings formed.
These operations can be performed by each of the punches, alternately.
Each of the first rotary punch (18) and second rotary punch (20) units are
comprised of
upper rotors (34) and lower rotors (36), mounted in upright end plates (38),
and
11
CA 02643248 2008-11-05
1120C111
rotatable in opposite directions. Swingable die carriers (40) are carried, two
on the
upper rotors (34) and two on the lower rotors (36). The swingable die carriers
(40) in
turn support respectively male dies (42) (upper rotor) and female dies (44)
(lower rotor).
The swingable die carriers (40) are swingably mounted on their respective
upper rotors
(34) and lower rotors (36). In order to control the swinging movement of the
swingable
die carriers (40), the swingable die carriers (40) are provided with cam
followers (46).
The cam followers (46) engage respective inner guide cams (48) and outer guide
cams
(50). The inner guide cams (48) and outer guide cams (50) define predetermined
guide
paths, around which the cam followers (46) will run, as the upper rotors (34)
and lower
rotors (36) rotate. Swingable gates (52) are provided for controlling movement
of the
cam followers (46) as they traverse around the inner guide cams (48) and outer
guide
cams (50) . The swingable gates (52) are provided with abutments which permit
the
upper rotors (34) and lower rotors (36) to be rotated either in one direction,
or in a
reverse direction, so that the cam followers (46) traverse around their
respective inner
guide cams (48) and outer guide cams (50) either in one direction or in the
opposite
direction. This feature significantly assists in the operation of the entire
line as will be
described below. Respective drive motors (54) for each of the first rotary
punch (18)
and second rotary punch (20), driving through suitable drive trains, and are
electronically coupled so that they may be driven in timed relation to the
operation of
the entire line. Each of the first rotary punch (18) and second rotary punch
(20) are
supported on mounting cross bars (56) extending transversely across the line.
The
mounting cross bars (56) are in turn slidedly supported on slide rails (58).
In this way
12
CA 02643248 2008-11-05
1120C111
each of the first rotary punch (18) and second rotary punch (20) can be slid
sideways
out of the line, for servicing or for die changes and the like.
While there are described only two rotary punch stations, namely the first
rotary
punch (18) and the second rotary punch (20) it will be understood that there
may be
merely one station, or three or more stations, depending on the requirements
of the
customer.
The stations may perform various respective functions. One or more of the
stations may be left inactive. In this way a wide variety of different work
pieces can be
produced, on the one multi-function line.
FEED AND FORM UNIT
It will be appreciated that in this embodiment the function of the first
rotary punch
(18) and second rotary punch (20) is to form openings through the strip, and
to form
flanges or edge formations around the edges of the openings, or otherwise form
spaced
apart formations in the strip. These edge flanges, in some construction
products such
as studs or joists, may require additional bends or formations, to provide
specific extra
features in the product. In order to provide for this, and in addition, in
order to provide
for a positive control over the feed of the sheet metal strip (12), the
feed/form unit (22)
is provided immediately downstream of the second rotary punch (20).
Referring now to figures 11, 12 and 13, it can be seen that feed/form unit
(22) is
made up of lower bearing blocks (60), providing lower bearings and upper
bearing
blocks (62), providing upper bearings. Between the two lower bearing blocks
(60) there
are in this case three lower die shafts (64), extending from side to side
parallel to each
13
CA 02643248 2008-11-05
1120C111
other. Between the two upper bearing blocks (62) there are in this case three
upper die
shafts (66) extending from side to side. The lower die shafts (64) carry lower
feed rolls
(68) and the upper die shafts (66) carry respective upper feed rolls (70).
Between the
three pairs of lower feed rolls (68) and upper feed rolls (70), there are two
sets of angle
die holders (72). The angle die holders (72) in turn hold moveable angle die
rolls (74).
The angle die rolls (74) engage the flanges formed around the openings, by the
first
and second rotary punches and form these flanges over into additional angled
formations for reasons to be described below, (Fig 2b and 2c). These angled
flanges
are thus formed repeatedly, spaced apart from one another, as the sheet metal
strip
(12) passes through the feed/form unit (22). The feed/form unit also includes
a length
measuring unit (76).
The lower and upper bearing blocks (60) and (62) are coupled by vertical jack
screws (78) and screw drive (80). This enables the blocks to be adjusted
vertically, for
changes in thickness of the strip (12). Transverse jack screw (82) and drive
enable the
blocks to be adjusted apart or together for strips of different widths.
ROTARY SHEAR UNIT
The sheet metal strip (12), after it exits the feed/form unit (22), then
passes to the rotary
shear (24). The rotary shear (24) operates to shear the sheet metal strip (12)
into work
pieces (32) of specific lengths. As outlined above, the length of the work
piece (32) will
usually be a function of the construction site or particular building design
for which it is
intended, assuming the work piece (32) is a piece of construction material.
Work pieces
of this kind such as studs and joists, for example, must have ends which are
free from
14
CA 02643248 2008-11-05
1120C111
openings, so that they are strong. It will thus be appreciated that the rotary
shear (24)
must function to shear the strip in a space between two openings. It will then
become
apparent that the first rotary punch (18) and second rotary punch (20) must be
controlled in such a way that they provide their openings and flanges at
predetermined
locations along the sheet metal strip (12). They must be controlled in such a
way that
they interrupt their operation to provide a predetermined spacing between two
of the
openings, in which the rotary shear (24) can then operate and shear the sheet
metal
strip (12).
The rotary shear (24), in order to provide its selective, intermittent
shearing
function, is provided with a lower shear rotor (84), and a upper shear rotor
(86),
mounted in registration adjacent one another, and rotatable in opposite
directions. Each
of the lower shear rotor (84) and upper shear rotor (86), in this embodiment,
carry a
respective swingable lower cutting die (88) and upper cutting die (90). The
lower cutting
die (88) and upper cutting die (90) are swingably mounted on their respective
lower
shear rotor (84) and upper shear rotor (86) in much the same fashion as the
swingable
die carriers (40) are mounted on there respective upper rotors (86) and lower
rotors
(84).
In order to swing the lower cutting die (88) and upper cutting die (90) into
the correct
position, and operate them for shearing the sheet metal strip (12), each of
the lower
cutting die (88) and upper cutting die (90) are provided with a respective
rotor cam
follower (92). The rotor cam follower (92) of the lower cutting die (88) and
the upper
cutting die (90) follow a respective rotor cam guide (94). The rotor cam
guides (94) are
CA 02643248 2008-11-05
1120C111
mounted on respective side bearing plates (96). The side bearing plates (96)
are
mounted on a base mounting plate (98). The base mounting plate (98) in turn is
adjustably moveable by means of a control screw (100), mounted in an fixed bar
(102).
It should also be noted that lower cutting die (88) and upper cutting die (90)
are
provided with respective corner punches (104) which function to cut corners or
notches
in the ends of the sheet metal strip (12) work piece, when required.
It will be appreciated that the shearing function takes place after a
predetermined length
of the sheet metal strip (12) has passed through the rotary shear (24). The
leading end
of the sheet metal strip (12) will thus enter the roll forming line (26),
before the sheet
metal strip (12) is sheared by the rotary shear (24), in most cases. Once
sheared, each
separate piece of strip (12) becomes a work piece (32).
ROLL FORMING LINE
The work piece (32) will then pass along the roll forming line (26) through
the
various roller die stands. The various roller die stands will form edge
flanges
longitudinally as illustrated generally in figures 2e and 2f. It will be
appreciated that the
forming of the inturned flange illustrated in figure 2f will be performed as a
last function.
This function is performed in a plurality of diagonal roll dies (106) which
engage the
inside of the work piece (32), and hold it so that it can be folded inwardly
over itself as
illustrated in figure 2f.
In order to provide for variations in the gauge or thickness of the sheet
metal strip (12),
the clearance between dies carried on the roller die stands (108) can be
adjusted while
the line is in operation. This is achieved by means of the lower support plate
(110)
16
CA 02643248 2008-11-05
1120C111
supporting the lower dies in each roller die stands (108), and the upper
support plate
(112) supporting the upper dies in each roller die stands (108). The upper
support plate
(112) is adjustable upwardly and downwardly relative to the lower support
plate (110).
Vertical jack screws (114) are provided at spaced intervals, operated by
suitable drive
means. The thickness of the sheet metal strip (12) can be sensed, for example,
by
measuring unit (76) in the feed/form unit (22), or by providing an independent
gauge
sensor (not shown).
In order to provide accommodation for variations in the width of the sheet
metal strip,
the lower support plate (110) and upper support plate (112) of each roller die
stands
(108) can be adjusted transversely by means of transverse adjustment screws
(116)
and suitable drive means.
The diagonal roll dies (106) are adjustable vertically, by means of vertical
jack screw
(118), and are also adjustable transversely by means of transverse adjustment
screws
(120).
Opposite to each of the diagonal roll dies there is a complementary vertical
bearing roll
(122) which bears against the side flange of the workpiece .
The diagonal roll dies (106) and their respective vertical bearing rolls (122)
are thus
offset right and left lengthwise along two of the work piece (32).
Certain products are required to have a series of closely spaced openings .
Such
products typically include stud products for embedment in concrete panels. By
providing such closely spaced openings, in the part of the stud that is
embedded in
concrete, concrete can flow through the openings and thus form a secure bond
with
17
CA 02643248 2008-11-05
1120C111
each stud.
For this purpose, a pair of lancing rolls (124) are provided, located at a
suitable station
along the roll forming line (26).
The lancing rolls (124) consist of a upper lance roll (126) and a lower lance
roll (128),
driven by suitable gears (Fig 23-24).
The lower lance roll (128) has suitable lance formations, and the upper lance
roll (126)
has recesses complementing them. As an edge portion of a work pieces passes
between them a series of openings will be lanced out, closely spaced apart
there
along.
For other products, where such openings are not required, then the upper lance
roll
(126) can be raised up by lance roll screw (130).
OPERATION
The production of a typical series of workpieces on the apparatus will proceed
essentially as follows;
A coil of strip sheet metal (12) is mounted on the uncoiler (10). Such sheet
metal will
pass through the flattener (14), and from there to the first rotary punch (18)
and to the
second rotary punch (20). In the two punch stations the first and second
punches in
most cases will both punch openings through the metal, the openings being
punched by
the first and second punches alternately, so that the openings can be as close
together
as is required for the product. It will be appreciated that if openings are
required which
are further apart that it may be possible to perform all of this using only
one of the two
18
CA 02643248 2008-11-05
1120C111
punch stations.
Each of the rotary punch units is capable of blanking out openings through the
strip,
and also forming edge flanges around the openings when required. In addition
the
rotary punch units are also capable of forming transverse and diagonal ridges
and
grooves across the work piece for additional strength, and forming other
depressions in
the strip depending upon the nature of the product that is being produced. A
typical
cycle of one of the rotary punches will be to rotate both the upper rotors
(34) and the
lower rotors (36) simultaneously in the forward direction, bringing the male
dies (42)
and the female dies (44) around so that they engage and blank out and form the
sheet
metal and then open apart once more. These operations will require the upper
rotors
(34) and lower rotors (36) to start off at a predetermined first rotational
speed, and then
gradually slow down until they are fully engaged with the sheet metal and then
speed
up again as they open. This is achieved both by the cam followers with the
inner guide
cams (48) and outer guide cams (50) respectively and also by the central
processing
controller (30) controlling the speed of the drive motors. In some cases it is
possible for
the upper rotors (34) and the lower rotors (36) to be reversed so that they
rotate in the
opposite direction to the direction of travel of the sheet metal.
After passing through the first rotary punch (18) and second rotary punch
(20), the
sheet metal strip then passes into the feed and form unit (22). In the
feed/form unit (22),
the sheet metal is securely engaged by the feed rollers (68) and (70), mounted
on lower
die shafts and upper die shafts. Between the feed rollers, the angle die rolls
(74),
mounted on angle die holder (72), operate to engage the upstanding flanges
around the
19
CA 02643248 2008-11-05
1120C111
openings on the strip sheet metal. As each flange is engaged, it is bent
outwardly at 90
degrees, so as to lie in a plane substantially spaced from and parallel to the
plane of
the strip itself. These bends form the flanges into generally three sided
channel shapes
for added strength. These channels extend lengthwise anlong the shorter and
longer
linear sides of each main opening. At the same time the length of the strip
passing
through the feed/form unit (22) is sensed and detected by the length measuring
unit
(76). The length measuring unit (76) continuously feeds length signals to the
central
processing controller (30).
The central processing controller (30) will receive such length signals and at
the
appropriate moment deliver a cut signal to the rotary shear (24) unit. This
will cause the
lower shear rotor and the upper shear rotor to rotate in unison forwardly,
bringing the
lower cutting die and upper cutting die into contact with the strip, shearing
it between
two adjacent openings.
As explained above, where the end use of the work pieces is in construction,
for
example, then both ends of each workpiece must be free of openings. For this
purpose,
the central processing controller (30) will have delivered "punch," or "no
punch" signals
to the first rotary punch (18) and second rotary punch (20). The precise
measurement
of the workpiece therefore will control both the operation of the first rotary
punch (18)
and second rotary punch (20), and will withhold them from operation when a
space is
required between two openings to signify the beginning or the end of the
workpiece
(32). The same central processing controller (30) will signal rotary shear
(24) to shear
the workpiece in the extra space allowed between the two openings.
CA 02643248 2008-11-05
1120C111
As the rotary shear cuts the strip, the leading end of the strip has already
entered the
roll forming line and has been gripped by the rolls in that line so that
although it has
been sheared upstream of the roll forming line its progress through the roll
forming line
is controlled.
In the case of the majority of the products, the roll forming line will
progressively form
edge flanges longitudinally along both edges of the workpiece simultaneously,
which
are substantially identical, as shown in the progressive views in Figure 2a to
2g.
However, if the product being produced is required to have an edge flange for
embedment in a concrete panel, then one edge of the work piece is turned out
at an
angle, after that edge has passed through the rotary lance (124). The rotary
lance (124)
will form a series of closely spaced openings in the one edge of the work
piece. That
edge will then be rolled into the angular Z shape required for embedment.
In order to form the edge flanges to close tolerances, the diagonal rolls
engage the
workpiece and deliver accurate inside corners.
Various different work pieces can be formed on the apparatus. Usually, though
not
exclusively they will be some form of metal stud used in construction.
These may be simple C-section, or thermal studs, with openings formed in
various
patterns to reduce thermal conduction.
Another form of stud is used in making composite thin shell concrete panels.
This
form of work piece is for use in forming composite reinforced concrete and
steel panels.
Such concrete and steel reinforced panels are known in the art. A thin shell
of concrete
21
CA 02643248 2008-11-05
1120C111
is reinforced by a framework of metal work pieces, having edge portions
embedded in
the concrete.
In these work pieces, it will be appreciated that in the vast majority of
cases the
work piece will have two ends so that it can be put in place in construction.
For this
purpose, while openings will be formed along the length of each stud , the
ends of the
studs are formed solid - i.e. openings have not been formed at the ends. This
function
is achieved by signals sent from the CPU to the first and second punching
rotors, to
allow a greater length of strip metal to pass between them without being
punched or
formed at all. Such similar signals will be sent by the CPU to the rotary
shear (24) , to
shear the work piece in such a space between openings.
In cases where embedment studs are required to be formed into a framework,
embedment flanges are formed along one, or both edges. However, at each end of
the
work piece the flanges will be notched out. This is achieved by the rotary
shear (24)
and the corner punches (104) incorporated in the rotary shear. In this way it
is possible
for the embedment studs to be formed with the embedment flange turned
outwardly,
and, by providing notches at each end of such embedment flanges the embedment
flanges can be seated in conventional C-section studs, to form a generally
rectangular
reinforcing framework.
It will thus be appreciated that all of these forms of studs, and others not
illustrated, can be made on the apparatus described above, giving the
apparatus great
flexibility in production. In addition, these various products can be made one
after the
other by simply changing various parts of the apparatus described above
without
22
CA 02643248 2008-11-05
1120C111
requirement for major down time, stripping the machine and retooling it
extensively.
Indeed much of the tooling can be left in place, and when for example lancing
of
slotted openings is not required the lance is simply disabled. When main
openings are
not required, one or both of the rotary punches can be disabled.
By operation of the CPU, the timing of the operation of the rotary punches,
and
the rotary shear, can be regulated to produce studs with openings at various
centres,
and work pieces of various lengths, having end portions without openings, for
particular
orders.
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.
23
