MACHINE AND PROCESS FOR PRODUCTION OF THREE-DIMENSIONAL STIRRUPS

Abstract

Machines and processes for production of three-dimensional stirrups (1a) with two converging legs (4,5), from rods, wire or other material of any cross-section. A planar stirrup (9) with parallel legs is either produced with the aid of a bending head (19) by making two bending operations, or is furnished in prepared, precut form and is restrained, for example by a grip or jaw (26). Afterwards, utilizing a stirrup-leg adjustment mechanism (25) located immediately following this bending head (19), which mechanism (25) includes an arm (16) that may move in reciprocation with the aid of a suitable mechanism (18) and has a hook (17) at its end, the free leg (5) of the planar stirrup (9) is trapped by the hook (17). This trapped free leg (5) is moved towards the opposite leg (4) as arm (16) reciprocates, covering an appropriate distance. Finally, the third dimension is generated by bending simultaneously at locations (12, 13) with a suitable bending mechanism (22) that is located after the stirrup-leg adjustment mechanism (25).

Description

This application claims foreign priority under 35 U.S.C. 119 to prior Greek (GR) National Application No. 20060100262 filed on May 4, 2006, the entire contents of which are hereby incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention refers to a machine and process for production of three-dimensional stirrups 1a from rods, wire, or other material of any cross-section. Such three-dimensional stirrups may, for example, be employed for joining construction elements of reinforced concrete that are either fabricated on-site at construction sites, or are prefabricated.

2. Description of Related Art

With reference to FIGS. 9-10 labeled as prior art, three-dimensional stirrups 1a of the type depicted in FIGS. 9-10 were typically produced according to the following techniques:

(a) Manual formation with the aid of hand-operated or semiautomatic tools. In this regard, it may be understood that U.S. Pat. No. 919,206 to Newlin discloses a manually-operated rod bending tool applicable in bending rods employed for reinforcing concrete. U.S. Pat. No. 1,425,261 to Kardong also discloses a manually-operated rod bending tool applicable in bending rods used for reinforcing concrete. A more recent publication, U.S. Pat. No. 6,997,030 to Williams, also discloses a manually-operated rod bending tool applicable in bending rods used for reinforcing concrete. U.S. Pat. No. 3,908,425 to Ware discloses a manually-operated power tool suitable for bending rods used for reinforcing concrete.

(b) With the aid of automated stirrup machines having a first bending mechanism, bending on only one plane, where is first produced a planar stirrup 3a with converging side legs 4,5. This first bending mechanism thus makes at least four bendings. Afterwards the planar stirrup 3a is manually positioned on another suitable mechanism, usually hand-operated or semiautomatic, where for the generation of the third dimension, bends are made of the two angles out-of-the plane at locations 12,13 simultaneously.

(c) With the help of automatic stirrup machines, which include an arrangement of two bending mechanisms, wherein a first bending mechanism generates the planar stirrup 3a, with converging legs 4,5. This first phase requires at least four bendings. Then the second bending mechanism, which includes an arrangement of two parallel arms, one fixed and a second which moves cyclically about the fixed one, bends two angles simultaneously at locations 12,13 so that the third dimension of the stirrup product is formed.

These existing machines, processes, and techniques present numerous problems which it would be desirable to alleviate. Again having reference to FIGS. 9-10 labeled prior art, first, it may be noted that such three-dimensional stirrups 1a are typically placed in metallic cases with shape U or double-U, which are then covered with a suitably shaped cover of metal, synthetic materials, cardboard, or other suitable material. In this regard, it is required that their legs 4,5 which are located on one plane converge at suitable angle, that their opposing sides 6, 7 that are located on the other plane be mutually parallel. Thus, in order that the three-dimensional stirrups 1a be produced with these characteristics, it is necessary that at least five bendings must occur. First, stirrups taking a planar shape 3a are formed by effecting four bendings on one plane. Subsequently there are formed the two angles that establish the third dimension. These usually are bent simultaneously in the fifth bending with a suitable mechanism.

The first technique (a) discussed above has a high cost of production since it requires the manual involvement of laborers, it is time-consuming, and productivity is low. Furthermore, the quality of the resulting three-dimensional stirrups 1a is not always that required for their further use. Since the shape of the in-question product does not have absolute precision as to its geometric characteristics this creates difficulties in its placement in the metallic cases.

In the second technique (b) discussed above, there again must occur at least five bendings of the material.

In the third technique (c) discussed above, there again must also occur at least five bends of the material. Here the disadvantage is that the bends in the third dimension must fall precisely on the two opposing locations 12,13 of the planar shape 3a, something which is not feasible with precision, because of the torsions that the material has and the qualitative alterations that are present within the same spool from which it originates. The result is that the thus-produced product creates difficulty in its further application.

It may be noted from the aforegoing discussion that all of the techniques according to the state of the art have a common characteristic that the converging legs 4,5 are produced first in the planar stirrup 3a by effecting at least four bending operations. The third dimension of the shaped stirrup is generated subsequently.

SUMMARY OF THE INVENTION

It is an object of this invention to present versions of innovative machines and processes concerning the automated production of three-dimensional stirrups 1a, 1b, 1c, 1d, 1e from rods, wires, or other suitable materials of any cross-section, wherein first a planar stirrup 9 with parallel legs 4,5 is produced by making two bends. Then the free leg 5 is moved towards the opposite leg 4 which is restrained from moving. Finally, a third product dimension is created by bending the stirrup out of the plane simultaneously at suitable locations 12,13. In this fashion the creation of the planar stirrup 9, which leads to the final three-dimensional stirrup 1a, may require only two bending operations.

In relation to the enumerated problems with the previous existing techniques discussed in the aforegoing description, and in contrast thereto, we note several exemplary specific advantages that may be afforded by versions of the invention:

• • The time for production of the stirrups is shortened.
  • The cost of production is reduced.
  • As a result of the high quality of the product and the greater precision of its shape, the further placement of stirrups in the special cases is easy and in parallel time is economized here also.
  • As a result of the requirement of two less bendings for the generation, we have a fair amount of economization of energy during the production of each three-dimensional stirrup 1a. This may be considered as something significant if we contemplate that these products are produced at many thousands.

More details about the machines and processes according to the present invention will be better comprehended in the immediately following detailed description of exemplary particular implementations of versions of the invention. The machines and processes are described in the attached figures, in the sense of non-restrictive examples and without limitation in the range of the applications of the machines and processes. These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings, where:

BRIEF DESCRIPTION OF THE DRAWINGS

The machines and processes according to the present invention will be better understood with reference to the exemplary attached drawing figures, where:

FIG. 1 depicts a first form of three-dimensional stirrups that may be produced in accordance with the present invention.

FIG. 2 depicts a second form of three-dimensional stirrups that may be produced in accordance with the present invention.

FIG. 3 depicts a third form of three-dimensional stirrups that may be produced in accordance with the present invention.

FIG. 4 depicts a fourth form of three-dimensional stirrups that may be produced in accordance with the present invention.

FIG. 5 depicts a fifth form of three-dimensional stirrups that may be produced in accordance with the present invention.

FIG. 6 helps depict in idealization the process of production and its kinematic requirements, according to the present invention and shows a planar stirrup.

FIGS. 7-8 likewise help depict in idealization a process of production and its kinematic requirements, according to the present invention.

FIGS. 9-10 depict idealized a process of production of the three-dimensional stirrups according to the prior art.

FIG. 11 schematically depicts a version of the machines able to effect the processes of production of three-dimensional stirrups according to the present invention.

FIG. 12 schematically depicts another version of the machines able to effect the processes of production of three-dimensional stirrups according to the present invention.

DETAILED DESCRIPTION

Definitions: For simplicity and ease of reference thereto, the terms “wire,” “wire rods,” “rods,” “rod material,” and “material of any cross-section,” are used interchangeably and equivalently throughout the remainder of the detailed description and appended claims. Thus, artisans in the art will readily understand that the term “wire” within the appended claims encompasses and includes the aforesaid “rods,” “wire rods,” “rod material,” and generally “material of any cross-section” without differentiation unless such differentiation is explicitly set forth. Thus, all these known, utilizable materials of prismatic cross-section may be conveniently and clearly referred to in non-limiting brief form by the terms “wire,” or “rod” within the text of the description which immediately follows and within the appended claims.

With reference to FIGS. 1-8 and 11, the processes concern the automated production of three-dimensional stirrups 1a, 1b, 1c, 1d, 1e from rods, wire or other suitable materials of any cross-section. There is produced first a planar stirrup 9 with parallel legs 4,5 by making two bends, or alternatively there may be received a prepared and precut planar stirrup 9. Afterwards the free leg 5 is biased at a suitable location 11 towards the opposite leg 4, which is held unmoved. Finally, simultaneously bending at suitable locations 12,13 bends the stirrup out of the plane, so as to create a third dimension. In this fashion only two bending operations may be needed for the creation of the planar stirrup 9 leading to the final three-dimensional stirrup 1a.

This process effects the production of three-dimensional stirrups 1a from rod, wire, or other suitable material of any cross-section. Such three-dimensional stirrups 1a typically have the two legs 4,5 on which are found the two ends of the stirrup 1a, being on the same plane and converging at a particular angle, though some of the other sides, that are located on a different plane, may converge under a different angle or may be parallel. In the present process preferably there is produced first the planar stirrup 9 from suitable layout; afterwards, with a suitable mechanism the leg 5 having a free end is trapped at a suitable location 11 and is pulled towards the opposite leg 4, so that the two legs' 4,5 two sides converge under a suitable desired angle. Finally, with another suitable bending mechanism 22 there are created simultaneously at least two sides 6, 7 under a suitable angle, outside of the plane, so that there is formed the third dimension of the product. A cutting may follow. The result is that the two free legs 4,5 converge under the desired angle even though the opposite sides 6, 7 in the other plane maintain their geometry as it was prior to the creation of the third dimension. In another version of the method as described above within the present paragraph, there may be produced simultaneously more than one three-dimensional stirrup 1a, applying the process to corresponding plural locations.

In a version of the process according to the immediately aforegoing paragraph, as further understandable with regard to FIG. 12, the two-dimensional stirrups 9 may first be prepared and shaped in the suitable dimensions and then be supplied to suitable mechanisms 25, 22 so as to undergo the further processing for the shaping of the end-product product 1a, 1b, 1c, 1d, 1e.

In a further version, in the processes according to the immediately preceding two paragraphs there may be received from the suitable layout more than one (i.e. plural) two-dimensional stirrups 9 simultaneously in plural corresponding locations of receipt by suitable mechanisms so that they undergo further processing for the shaping of the final product.

It must be explained also, with particular reference to FIGS. 2-5, that with the present process it is possible to produce three-dimensional stirrups, which in the third dimension can have any form, such as for example non-perpendicular angles, uneven leg sides with oblique slanted axial bend 1b, with curved configuration 1c, with triangular configuration 1d, with polygonal configuration 1e and others.

In one aspect, and with reference to FIG. 11 of the appended drawings, the process may be implemented by an intermediate stirrup-leg adjustment mechanism 25 which is preferably disposed in stirrup machines having the following characteristics: they have an arrangement of an advancement mechanism 21 for the rod, wire or other suitable material, that may come from a spool or from straightened pieces; they have a bending head 19 that bends the material in one place, creating planar stirrups; they have a cutter 20 for cutting the material after the creation of the three-dimensional stirrup 1a by a second bending mechanism 22. This second bending mechanism comprises a stationary arm 23 and a second arm 24 that can move cyclically around the stationary arm 23 thereby bending the two legs 4,5 of the planar stirrup simultaneously. In such an arrangement, the stirrup-leg adjustment mechanism 25 is placed between the first bending mechanism 19 and the second bending mechanism 22 and comprises one arm 16 that can move in an alternating, reciprocating manner with the aid of a suitable mechanism 18 and at a suitable angle as to the legs 4,5 of the planar stirrup 9 trapping with the aid of a suitable hook 17 the free leg 5 which it moves towards leg 4. Traversing a suitable distance, it holds the leg 5 until the second bending head 22 bends the two legs 4,5 at suitable locations 12,13 creating the third dimension. Afterwards the cutting of the material of leg 4 at a suitable cutting location is made by cutter 20.

The machines of the present invention are further described with reference to FIGS. 11-12 and FIGS. 1-8 of the appended drawings.

An intermediate stirrup-leg adjustment mechanism 25 for the production of three-dimensional stirrups 1a, 1b, 1c, 1d, 1e, with converging free legs 4,5, from rod, wire, or other suitable material of any cross-section, is placed in stirrup machines. Such stirrup machines may include an arrangement of an advancement mechanism 21 for the rod, wire or other suitable material that may be supplied from a spool or from straightened pieces. In this case they may include a first bending mechanism 19 that bends the material in one plane to generate planar stirrups 9. Also in this case they may also include a cutter 20 for the cutting of the material after the generation of the three-dimensional stirrup 1a, 1b, 1c, 1d, 1e by a second bending mechanism 22. This second bending mechanism 22 comprises a fixed arm 23 and a second arm 24 that can move cyclically around the fixed arm 23 bending thus the two legs 4,5 of the planar stirrup simultaneously.

Alternatively, such stirrup machines may receive prepared and precut planar stirrups 9 trapping one free leg 4 with the aid of a grip or jaw 26. This is schematically depicted in FIG. 12. In this case, the arrangement includes the grip or jaw 26 that can receive the planar stirrup restraining it via leg 4. Thus, stirrup-leg adjustment mechanism 25 may be used also in stirrup machines that work planar prepared or preformed, precut planar stirrups 9, and that have an arrangement including only the second bending head 22 which creates the third dimension. It will be readily understood from the aforegoing description that in this second case the first bending mechanism 19 is not necessary and may be absent.

Assuming the first case, above, for illustration, the intermediate stirrup-leg adjustment mechanism 25 is placed between the first bender 19 and the second bender 22, under the plane of the under-production product. It comprises an arm 16 that can move with the aid of suitable mechanism 18 that produces a controlled, alternating, reciprocating motion. This may, for example, be a motor or drive mechanism 18. The arm 16 moves at a suitable selected angle relative to legs 4,5 of the planar stirrup 9, trapping with the aid of a suitable hook 17 the free leg 5, 11, and adjusting it towards the other leg 4. The arm 16 traverses a suitable distance, holding it until the second bending head 22 bends the two legs 4,5 at the suitable locations 12,13 creating the third dimension.

As a further alternative, the stirrup-leg adjustment mechanism 25 may be placed above the plane of the subjected-to-generation product. Thus it will be readily understood that the stirrup-leg adjustment mechanism 25 may be located either under the plane of the under-production part or above it.

As a further alternative, the stirrup-leg adjustment mechanism 25, according to the aforegoing description may trap the free leg 5 of the planar stirrup 9 with the aid of grip. Thus it will be understood that the free leg 5 may be trapped also with the aid of a suitable grip in place of the hook 17.

Finally, in a further version, a stirrup machine with a stirrup-leg adjustment mechanism 25 according to the aforegoing description, may include a suitable electronic computer for the maintenance, coordination, and control of all the functions of the process of production of the three-dimensional stirrup 1a. To this suitable electronic computer are entered the necessary product characteristics for the production of the three-dimensional product 1a. Thus, the coordination and control of all the functions of the process of production of the three-dimensional stirrup 1a may preferably be effected by a suitable electronic computer, in which are entered all necessary data, such as product characteristics for the production of the product.

In the implementation of the invention the materials that are used as well as the dimensions of the individual elements can be in accordance with the requirements of the particular construction.

Various exemplary devices and methods have been illustrated in the accompanying drawings and described in the foregoing detailed description but it will be understood that the claims to the methods and devices shown and described are not limited to the particular embodiments described herein, as these may be capable of numerous rearrangements, modifications, and substitutions, and may be implemented in many forms and dimensions without departing from the scope and spirit of the claims set forth below. Consistent with legal precedent, the spirit and scope of the appended claims should not be limited to the description of the preferred versions contained herein. Accordingly, the techniques and structures described and illustrated herein should be understood to be illustrative only and not limiting upon the scope of the present invention. The scope of the present invention is defined by the appended claims, including known equivalents and unforeseeable equivalents at the time of filing of this application.

Claims

1. A machine for producing stirrups, comprising:

a wire advancement mechanism;

a first bending mechanism configured to receive wire from said advancement mechanism and form planar stirrups therefrom;

a stirrup-leg adjustment mechanism configured to move at least one stirrup leg towards another; and,

a second bending mechanism configured to bend a third dimension into planar stirrups received by said stirrup-leg adjustment mechanism.

2. A machine for producing stirrups as claimed in claim 1, further comprising:

an arm in said stirrup-leg adjustment mechanism.

3. A machine for producing stirrups as claimed in claim 2, further comprising:

a drive configured to controllably reciprocate said arm.

4. A machine for producing stirrups as claimed in claim 2, further comprising:

trapping means functioning to trap a free stirrup leg, said trapping means located on said arm.

5. The machine for producing stirrups as claimed in claim 2, wherein:

said arm is located above the plane of receipt of stirrups.

6. The machine for producing stirrups as claimed in claim 2, wherein:

said arm is located below the plane of receipt of stirrups.

7. A machine for producing stirrups as claimed in claim 1, further comprising:

a first arm in said second bending mechanism; and,

a second arm configured to move cyclically around said first arm.

8. A machine for producing stirrups, comprising:

a grip configured to restrain preformed, precut planar stirrups;

a stirrup-leg adjustment mechanism configured to move at least one stirrup leg towards another; and,

a second bending mechanism configured to bend a third dimension into planar stirrups received by said stirrup-leg adjustment mechanism.

9. A machine for producing stirrups as claimed in claim 8, further comprising:

an arm in said stirrup-leg adjustment mechanism.

10. A machine for producing stirrups as claimed in claim 9, further comprising:

a drive configured to controllably reciprocate said arm.

11. A machine for producing stirrups as claimed in claim 9, further comprising:

trapping means functioning to trap a free stirrup leg, said trapping means located on said arm.

12. The machine for producing stirrups as claimed in claim 9, wherein:

said arm is located above the plane of receipt of stirrups.

13. The machine for producing stirrups as claimed in claim 9, wherein:

said arm is located below the plane of receipt of stirrups.

14. A machine for producing stirrups as claimed in claim 8, further comprising:

a first arm in said second bending mechanism; and,

a second arm configured to move cyclically around said first arm.

15. A process for producing stirrups, comprising:

restraining a first leg of the stirrup,

trapping a free leg of the stirrup with a stirrup-leg adjustment mechanism;

moving the free stirrup leg towards the first stirrup leg with said stirrup-leg adjustment mechanism; and,

bending a third dimension in said planar stirrup when the free stirrup leg has been advanced towards the first stirrup leg a selected distance by said stirrup-leg adjustment mechanism.

16. A process for producing stirrups as claimed in claim 15, further comprising:

controllably reciprocating an arm of said stirrup-leg adjustment mechanism.

17. A process for producing stirrups as claimed in claim 16, further comprising:

trapping the free stirrup leg to move it with reciprocation of said arm.

18. A process for producing stirrups as claimed in claim 15, further comprising:

restraining the first leg of the stirrup with a grip.

19. A process for producing stirrups as claimed in claim 15, further comprising:

rotating a second arm around a first arm to bend the third dimension.

20. A process for producing stirrups as claimed in claim 19, further comprising:

forming the stirrup from wire with a first bending mechanism.