Web forming machine
A web forming machine, and a method of forming a web is described and which includes a first rotatable assembly; a second rotatable assembly positioned in spaced relation relative to the first rotatable assembly, and wherein a gap is defined between the first rotatable assembly, and the second rotatable assembly; and wherein a web of material to be formed is received in the gap; and means for reciprocally moving the first rotatable assembly into contact with the web, and into mating relation relative to the second rotatable assembly.
The present invention relates to a web forming machine, and more specifically to an apparatus having cooperating first and second rotatable assemblies, and wherein one of the rotatable assemblies is reciprocally movable relative to the other. The invention finds usefulness for rapid, continuous, punching, forming or shearing of web like material such as sheet metal, and the like.
BACKGROUND OF THE INVENTIONThe prior art is replete with numerous examples of sheet metal cutting and forming devices which have been fabricated for various purposes including specific operations such as cutting, perforating, embossing, crimping, and forming to name but a few. As a general matter, conventional sheet metal cutting and forming devices are typically fabricated utilizing numerous reciprocating presses. In this regard, material to be worked is placed within a press; positioned in a stationary location over a die; and thereafter the press, which is usually mechanically operated, is closed thereby forcing a second die into contact with the material being worked. Upon completion of the perforation or other forming step, the press is opened and the material being worked or other work piece is removed and a new work piece is later inserted; or the material being worked is indexed to a new position such that the process can be repeated.
Various solutions have been suggested for increasing the speed of operation of such devices. For example, in U.S. Pat. No. 4,732,028 the teachings of which are incorporated herein, one prior art solution included the use of a so-called flying shear or die which is used with a strip which is moving continuously. In this system, the die is accelerated to the speed of the strip, and the press closes while the die and strip are moving in unison. The die then opens and returns to its starting position. Typically the punching, forming and shearing of continuous material utilizing a device such as this is limited to a line speed of about 250 feet per minute.
The prior art further discloses various rotary machines which are useful in shearing or forming web-like material. However, in the use of such devices it is well known that flat dies used in conventional reciprocating presses do not operate in such devices. Still further, considerable problems are encountered in the use of curved dies. In this regard, many prior art references teach and acknowledge that curved dies, while they will work on various materials, will often cause deformation and distortion of a work piece.
In addition to the foregoing difficulties, many products that are fabricated from web-like material such as sheet metal, and the like, often require that different sized apertures be formed in various locations in the web in order to form a resulting work piece. Examples of such work pieces such as metal structural members, are illustrated in
Therefore, a new and improved web forming machine which addresses these and other shortcomings attendant with the prior art practices and apparatuses utilized heretofore is the subject matter of the present invention.
SUMMARY OF THE INVENTIONOne aspect of the present invention relates to a web forming machine which includes a first rotatable assembly; a second rotatable assembly positioned in spaced relation relative to the first rotatable assembly, and wherein a gap is defined between the first rotatable assembly, and the second rotatable assembly, and wherein a web of material to be formed is received in the gap; and means for reciprocally moving the first rotatable assembly into contact with the web, and into mating relation relative to the second rotatable assembly.
Still another aspect of the present invention relates to a web forming machine and which includes a work station; a selectively rotatable and moveable punch assembly positioned above, and in spaced relation relative to, the work station; a selectively rotatable die assembly positioned below the work station and which is operable to matingly cooperate with the punch assembly; a web of material selectively positioned in the work station, and wherein the punch assembly is moveable along a path of travel and into penetrating contact with the web and into mating relation relative to the rotatable die assembly; a computer memory which stores at least one pattern of apertures which are to be formed in the web; and a controller electrically coupled with the computer memory, and further controllably coupled with each of the rotatable punch and die assemblies, and further controllably positioning the web in the work station, and wherein the controller selectively causes the rotational movement of the rotatable punch and die assemblies and the selective positioning of the web, and further causes the rotatable punch assembly to move along the path of travel and into penetrating contact with the web to form the at least one pattern of apertures which are stored in the memory.
A further aspect of the present invention relates to a method of forming a web which includes providing a web of material having a top and bottom surface; defining a work station and selectively positioning the web of material in the work station; providing a selectively moveable and rotatable punch assembly and positioning the moveable and rotatable punch assembly in spaced relation relative to the top surface of the web; providing a selectively rotatable die assembly and positioning the selectively rotatable die assembly in an adjacent position relative to the bottom surface of the web; and forming at least one aperture in the web of material by moving the rotatable punch assembly into penetrating contact with the top surface of the web and into mating engagement with the rotatable die assembly.
These and other aspects of the present invention will be discussed in greater detail hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGSPreferred embodiments of the invention are described below with reference to the following accompanying drawings.
This disclosure of the invention is submitted in furtherance of the constitutional purposes of the U.S. Patent Laws “to promote the progress of science and useful arts” (Article 1, Section 8).
The web forming machine or apparatus of the present invention is generally indicated by the numeral 10 in
Referring now to
The web forming machine of the present invention 10 is operable to form various work products as seen in
Referring now to
As seen in the longitudinal, substantially vertical sectional view of
The second work station 72 further includes a frame 100 which is mounted on the top surface 75 of the base frame 74. The frame 100 mounts a fluid powered ram assembly 101 on the top surface thereof. The fluid powered ram assembly includes a ram portion 102 which is reciprocally moveable along a path of travel for the purposes which will be described below. The second work station 72 further includes a rotatable punch assembly which is generally indicated by the numeral 103. The rotatable punch assembly is selectively rotated by means of an indexing motor 104 (as seen in
Referring still to
A first selectively rotatable and reciprocally moveable punch assembly 140 is mounted in the third work station 73, and on the respective pair of frame members 121, as discussed above. The first rotatable punch assembly 140 has a cylindrically shaped main body 141 which has a first end 142, and an opposite second end 143. As should be understood, the main body may assume other shapes. As seen in
Referring now to
As illustrated in
A punch movement assembly is generally indicated by the numeral 190 in
Referring now to
As seen in
As will be appreciated from a study of
Referring now to
Referring now to
The operation of the described embodiment of present invention is believed to be readily apparent and is briefly summarized at this point.
A web forming machine of the present invention is shown in
In operation, the individual punches 153 are operable to mate with the individual dies 234. To effect this, the controller 282 selectively actuates the respective first and second motors 134 and 243 to rotate the rotatable punch assembly 140 and rotatable die assembly 210 so as to substantially coaxially align mating punches 153 and dies 234. In the arrangement as shown, the movement of the first rotatable punch assembly into contact with the second rotatable die assembly 210 is along a linear path of travel 240 (
Another aspect of the web forming machine 10 of the present invention includes at least one work station 72 or 73, and a selectively rotatable and moveable punch assembly 140 positioned above, and in spaced relation relative to, the work station 72. Still further, the web forming machine 10 includes a selectively rotatable die assembly 210 positioned below the work station 73 and which is operable to matingly cooperate with the punch assembly 140. Still further, a web of material 24 is selectively positioned in the work station 73. The selectively rotatable punch assembly 140 is moveable along a path of travel 240 and into penetrating contact with the web 24 and into mating relation relative to the rotatable die assembly 210. A computer memory 281 stores at least one pattern of apertures 52 and 53, and which are to be formed in the web 24, and as seen in
The present invention further includes a method of forming a web 24 into a work product 40, and which includes a step of providing a web of material 24 having top and bottom surfaces; and further defining a work station 73, and selectively positioning the web of material 24 in the work station. Still further, the method includes the step of providing a selectively moveable and rotatable punch assembly 140, and positioning the moveable and rotatable punch assembly in spaced relation relative to the top surface of the web. The method also further includes the step of providing a selectively rotatable die assembly 210 and positioning the selectively rotatable die assembly in an adjacent position relative to the bottom surface of the web. The method includes the step of forming at least one aperture 52 or 53 in the web of material 24 by moving the rotatable punch assembly into penetrating contact with the top surface of the web and into mating engagement with the underlying rotatable die assembly. After the step of providing the rotatable die assembly 210, and before the step of moving the rotatable punch assembly into penetrating contact with the web of material 24, the method includes the step of indexing the respective rotatable punch and die assemblies 140 and 210 relative to the top and bottom surfaces 50 and 51 of the web material 24. The method of the present invention further includes the step of providing a computer memory stored in a computer 281 and which stores at least one pattern of apertures to be formed in the web 24, and providing a controller 282 which is electrically coupled to the memory and which is further operably coupled to the rotatable punch and die assemblies 140 and 210, respectively. In the present method, the controller 282 indexes the respective rotatable punch and die assemblies 140 and 210, and then further selectively positions the web of material 24 in the work station 73. After the step of indexing, the controller is operable to move the rotatable punch assembly 140 into penetrating contact with the top surface of the web and into mating relation relative to the rotatable die assembly 210.
Therefore it will be seen that the present invention provides a convenient means of forming products 40 from a continuous web 24 in a fashion not possible heretofore. Still further, the apparatus of the present invention 10 is compact and has a reduced factory footprint in relative comparison to the prior art devices and other assemblies utilized to form products of this type. Still further, the present apparatus provides a convenient means whereby patterns of apertures can be stored in a computer memory and thereafter formed in a continuous web of material in a fashion not possible heretofore.
In compliance with the statute, the invention has been described in language more or less specific as to structural and methodical features. It is to be understood, however, that the invention is not limited to the specific features shown and described, since the means herein disclosed comprise preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted in accordance with the doctrine of equivalents.
Claims
1. A web forming machine, comprising:
- a first rotatable assembly;
- a second rotatable assembly positioned in spaced relation relative to the first rotatable assembly, and wherein a gap is defined between the first rotatable assembly, and the second rotatable assembly, and wherein a web of material to be formed is received in the gap; and
- means for reciprocally moving the first rotatable assembly into contact with the web, and into mating relation relative to the second rotatable assembly.
2. A web forming machine as claimed in claim 1, and wherein a punch is borne by the first rotatable assembly, and wherein the reciprocal movement of first rotatable assembly causes the punch to penetrate the web to form an aperture.
3. A web forming machine as claimed in claim 1, and wherein a severing tool is borne by the first rotatable assembly, and wherein the reciprocal movement of the first rotatable assembly causes the severing tool to cut the web of material.
4. A web forming machine as claimed in claim 1, and wherein the web of material may be permanently deformed, and wherein a deforming tool is borne on the first rotatable assembly, and wherein the reciprocal movement of the first rotatable assembly causes the deforming tool to deform the web of material.
5. A web forming machine as claimed in claim 1, and wherein a severing tool, deforming tool, and a punch are borne on the first rotatable assembly, and wherein the first rotatable member may be selectively indexed into given orientations relative to the second rotatable member so as to permit each of the severing tool, deforming tool and punch to be reciprocally moved into contact with the web of material.
6. A web forming machine as claimed in claim 1, and wherein the first rotatable assembly comprises as rotatable punch assembly which has an axis of rotation, and an exterior facing surface, and wherein a plurality of punches are borne by the rotatable punch assembly.
7. A web forming machine as claimed in claim 1, and wherein the first rotatable assembly comprises as rotatable punch assembly, and the second rotatable assembly comprises a rotatable die assembly, and wherein the web forming machine further comprises:
- a first, selectively actuatable motor disposed in force transmitting relation relative to the rotatable punch assembly and which causes the rotatable punch assembly to rotate to a predetermined orientation relative to the rotatable die assembly;
- a second, selectively actuatable motor disposed in force transmitting relation relative to the rotatable die assembly and which causes the rotatable die assembly to rotate to a predetermined orientation relative to the rotatable punch assembly; and
- a controller controllably coupled to the first and second selectively acutatable motors, and the means for reciprocally moving the rotatable punch into penetrating contact with the web and into mating relation relative to the rotatable die assembly, and wherein the controller first causes the rotatable punch and die assemblies to each be positioned in the respective predetermined orientations, and then secondly causes the rotatable punch assembly to reciprocally move into penetrating contact with the web.
8. A web forming machine as claimed in claim 7, and wherein the rotatable punch assembly and the rotatable die assembly each have an axis of rotation, and an exterior facing surface, and wherein the rotatable punch assembly has a plurality of punches positioned at various locations about the exterior surface thereof, and the rotatable die assembly has a plurality of dies positioned at various locations about the exterior surface thereof, and wherein individual punches are operable to mate with individual dies, and wherein the controller selectively actuates the respective first and second motors to rotate the respective rotatable punch assembly and rotatable die assembly so as to substantially coaxially align mating punches and dies.
9. A web forming machine as claimed in claim 1, and wherein the means for reciprocally moving the first rotatable assembly comprises a hydraulic cylinder and moveable ram, and wherein the moveable ram is affixed in force transmitting relation relative to the first rotatable assembly, and is operable to reciprocally move the first rotatable assembly along a substantially linear path of travel into contact relative to the web, and into mating relation relative to the second rotatable assembly to penetrate, sever and/or permanently deform the web of material.
10. A web forming machine as claimed in claim 1, and wherein the first rotatable assembly comprises a rotatable punch assembly which has an axis of rotation, and an exterior facing surface, and wherein at least one punch is moveably borne on the rotatable punch assembly, and is operable to travel along a path of travel from a first position, wherein the at least one punch extends outwardly relative to the exterior facing surface, to a second position, wherein the at least one punch is received substantially internally of the rotatable punch assembly.
11. A web forming machine as claimed in claim 10, and further comprising:
- a punch orientation assembly borne by the rotatable punch assembly and which is operable in a first mode of operation to position the at least one punch in the first position, and in a second mode of operation permits the at least one punch to move from the first to the second position.
12. A web forming machine as claimed in claim 11, and further comprising:
- a means for placing the punch orientation assembly in the first and second modes of operation.
13. A web forming machine as claimed in claim 10, and wherein the second rotatable assembly comprises a rotatable die assembly, and wherein the web forming machine further comprises:
- a punch movement assembly borne by the rotatable punch assembly, and which is operable to move at least one punch along a course of travel which is substantially parallel to the axis of rotation of the rotatable punch assembly to change the relative position of the punch with respect to the exterior facing surface;
- a die movement assembly borne by the rotatable die assembly, and wherein the rotatable die assembly has an exterior facing surface, and an axis or rotation, and wherein the die movement assembly is operable to selectively move at least one die along a course of travel which is substantially parallel to the axis of rotation of the rotatable die assembly; and
- a drive assembly borne on each of the rotatable punch and die assemblies, and which is operably coupled to the respective punch and die movement assemblies, and which moves the respective at least one punch and die to a predetermined position relative to the exterior facing surfaces of the respective rotatable punch and die assemblies.
14. A web forming machine comprising:
- a work station;
- a selectively rotatable and moveable punch assembly positioned above, and in spaced relation relative to, the work station;
- a selectively rotatable die assembly positioned below the work station and which is operable to matingly cooperate with the punch assembly;
- a web of material selectively positioned in the work station, and wherein the punch assembly is moveable along a path of travel and into penetrating contact with the web and into mating relation relative to the rotatable die assembly;
- a computer memory which stores at least one pattern of apertures which are to be formed in the web; and
- a controller electrically coupled with the computer memory, and further controllably coupled with each of the rotatable punch and die assemblies, and further controllably positioning the web in the work station, and wherein the controller selectively causes the rotational movement of the rotatable punch and die assemblies and the selective positioning of the web, and further causes the rotatable punch assembly to move along the path of travel and into penetrating contact with the web to form the at least one pattern of apertures which are stored in the memory.
15. A web forming machine as claimed in claim 14, and further comprising:
- a severing tool borne by the selectively rotatable and moveable punch assembly, and wherein the controller selectively positions each of the punch and die assemblies in a manner so as move the severing tool into severing contact with the web of material.
16. A web forming machine as claimed in claim 14, and further comprising:
- a deforming tool borne by the selectively rotatable and moveable punch assembly, and wherein the controller selectively positions each of the moveable punch and die assemblies so as to move the deforming tool into deforming contact with the web of material.
17. A web forming machine as claimed in claim 14, and wherein the web of material is selectively moveable along a substantially linear path of travel in the work station.
18. A web forming machine as claimed in claim 14, and wherein the path of travel of the selectively rotatable and moveable punch assembly is substantially perpendicular relative to the web of material when it is positioned in the work station.
19. A web forming machine as claimed in claim 14, and wherein the selectively rotatable punch and die assemblies do not rotate when the rotatable punch assembly moves along the path of travel and into penetrating contact with the web.
20. A web forming machine as claimed in claim 14, and wherein the rotatable punch assembly has an exterior facing surface, and wherein a plurality of punches extend outwardly relative to the exterior facing surface thereof, and wherein the rotatable die assembly has an exterior facing surface, and wherein a plurality of dies are positioned on the exterior facing surface of the rotatable die assembly, and wherein individual punches are operable to operably mate with individual dies, and wherein the controller selectively rotates the rotatable punch and die assembly so as to substantially coaxially align mating punches and dies so as to facilitate the formation of the at least one pattern of apertures in the web.
21. A web forming machine as claimed in claim 20, and further comprising:
- a punch orientation assembly borne by the rotatable punch assembly and which is operable in a first mode of operation to position at least one of the plurality of punches in a first position, and wherein the punch extends outwardly relative to the exterior facing surface of the rotatable punch assembly; and wherein the at least one punch orientation assembly has a second mode of operation and wherein the at least one punch is moveable along a path of travel from the first position, to a second position where the at least one punch is positioned at or below the exterior facing surface of the punch assembly;
- means for placing the punch orientation assembly in the first and second modes of operation, and wherein the controller is operably coupled to the means for placing the punch orientation assembly.
22. A web forming machine as claimed in 21, and further comprising:
- a punch movement assembly borne by the rotatable punch assembly, and wherein the rotatable punch assembly has an axis of rotation, and wherein the punch movement assembly is operable to move at least one of the plurality of punches along a course of travel which is substantially parallel to the axis of rotation of the rotatable punch assembly to change the relative position of the at least one punch with respect to the rotatable punch assembly; and
- a die movement assembly borne by the rotatable die assembly, and wherein the rotatable die assembly has an axis of rotation which is substantially parallel to the axis of rotation of the rotatable punch assembly, and wherein the die movement assembly is operable to selectively move at least one die along a course of travel which is substantially parallel to the axis of rotation of the rotatable die assembly; and wherein the controller is operably coupled in controlling relation relative to the punch and die movement assemblies to selectively position the at least one punch and die in an appropriate orientation relative to the respective rotatable punch and die assemblies to facilitate the formation of the at least on pattern of apertures which is stored in the memory.
23. A method of forming a web, comprising:
- providing a web of material having a top and bottom surface;
- defining a work station and selectively positioning the web of material in the work station;
- providing a selectively moveable and rotatable punch assembly and positioning the moveable and rotatable punch assembly in spaced relation relative to the top surface of the web;
- providing a selectively rotatable die assembly and positioning the selectively rotatable die assembly in an adjacent position relative to the bottom surface of the web; and
- forming at least one aperture in the web of material by moving the rotatable punch assembly into penetrating contact with the top surface of the web and into mating engagement with the rotatable die assembly.
24. A method for forming a web as claimed in claim 23, and wherein the step of selectively positioning the web of material in the work station further comprises:
- moving the web of material into the work station along a substantially linear path of travel.
25. A method for forming a web as claimed in claim 23, and further comprising:
- after the step of providing the selectively moveable and rotatable punch assembly, and before the step of moving the rotatable punch assembly into penetrating contact with the web of material, indexing the selectively moveable and rotatable punch assembly relative to the top surface of the web material.
26. A method for forming a web as claimed in claim 25, and further comprising:
- after the step of providing the rotatable die assembly, and before the step of moving the rotatable punch assembly into penetrating contact with the web of material, indexing the rotatable die assembly relative to the bottom surface of the web of material.
27. A method for forming a web as claimed in claim 26, and further comprising:
- providing a computer memory which stores at least one pattern of apertures to be formed in the web of material; and
- providing a controller which is electrically coupled to the memory and operably coupled to the rotatable punch and die assemblies, and wherein the controller indexes the respective rotatable punch and die assemblies, and further selectively positions the web of material in the work station, and wherein after the step of indexing, the controller is operable to move the rotatable punch assembly into penetrating contact with the top surface of the web of material and into mating relation relative to the rotatable die assembly.
28. A method of forming a web as claimed in claim 27, and wherein the step of providing the selectively moveable and rotatable punch assembly further comprises providing a plurality of punches which extend outwardly therefrom, and wherein the step of providing a rotatable die assembly further comprises providing a plurality of individual dies on the rotatable die assembly, and wherein the method further comprises:
- providing a punch movement assembly which is borne on the rotatable punch assembly, and which selectively positions at least one of the plurality of punches in different locations relative to rotatable punch assembly; and
- providing a die movement assembly which is borne on the rotatable die assembly, and which selectively positions at least one of the dies in different location relative to the rotatable die assembly; and wherein the controller is controllably coupled to the punch and die movement assemblies.
29. A method of forming a web as claimed in claim 28, and further comprising:
- providing a punch orientation assembly which is operable in a first mode of operation to position at least one of the plurality of punches in a first position where the at least one punch extends outwardly relative to the rotatable punch assembly, and is further operable in a second mode of operation to facilitate the movement of the at least one punch from the first position, to a second position where a preponderance of the at least one punch is received within the rotatable punch assembly; and wherein the controller is controllably coupled to the punch orientation assembly.
Type: Application
Filed: Mar 10, 2004
Publication Date: Sep 15, 2005
Inventor: L. Jensen (Liberty Lake, WA)
Application Number: 10/798,103