Roll-Forming Machine Having Changeover Mechanism
A roll-forming machine for manufacturing purlins from strip material comprises a setup changeover mechanism for converting between a setup that produces purlins having a C-shaped cross-sectional configuration and a setup that produces purlins having a Z-shaped cross-sectional configuration. The changeover mechanism includes an inboard linear actuator connected by an inboard linkage to a plurality of turrets associated with inboard sides of respective roll-forming stations, and an outboard linear actuator connected by an outboard linkage to a plurality of turrets associated with outboard sides of respective roll-forming stations, whereby the turrets are pivotally indexed by operation of the linear actuators to change position of forming rollers carried by the turrets. At least one of the linear actuators is connected to turrets both upstream and downstream from the linear actuator in a feed direction of the roll-forming machine. The linear actuators are driven by a shared control system whereby changeover of both the inboard and outboard sides of the roll-forming machine may be carried out simultaneously by inputting a single changeover command.
The present invention relates generally to roll-forming machines through which a flat strip of stock material is fed to progressively bend the strip to provide the strip with a desired cross-sectional configuration, and more particularly to a changeover mechanism for changing the setup of a roll-forming machine to selectively provide different cross-sectional configurations.
BACKGROUND OF THE INVENTIONRoll-forming machines are commonly used to manufacture metal “purlins” and other elongated members used for roofing and siding in the construction industry. Purlins are typically made to have either a C-shaped cross-sectional configuration as shown in
Roll-forming machines for manufacturing purlins are known to comprise a plurality of roll-forming stations arranged in succession along a material feed direction. The roll-forming stations include drive rollers powered by a motor for frictionally conveying a strip of material in the feed direction, and forming rollers positioned for engaging the strip as it passes through the roll-forming station to bend the strip. The roll-forming stations are said to have an “inboard” side on which the drive motor is located, and an opposite “outboard” side laterally spaced from the inboard side, such that the strip of material passes between the inboard and outboard sides as it travels in the feed direction through the roll-forming machine.
In order to change the setup of a roll-forming machine from a C-configuration setup to a Z-configuration setup, or vice versa, the positions and/or axes of rotation of the forming rollers must be changed. As may be understood by reference to
Changing over the setup of a roll-forming machine to produce a different cross-sectional configuration in a workpiece traditionally involved manually changing the forming rollers and/or their positions on the roll-forming stations, an operation that in many cases required several hours to complete. Various approaches to reducing changeover time have been proposed, as evidenced by U.S. Pat. Nos. 4,724,695; 4,787,232; 4,974,435; 5,829,294; 6,000,266; 6,148,654; and 6,216,514.
Among these, U.S. Pat. No. 4,974,435 discloses the use of a turret pivotally mounted on a support stand of a roll-forming station and carrying a plurality of forming rolls, whereby the turret may be manually pivoted and locked by an insertable pin in a selected rotational position to locate a selected forming roll in a functional position for engaging a strip of material to be formed. U.S. Pat. Nos. 4,787,232 and 6,216,514 describe the use of a pivotable turret having a single forming roll thereon which is repositioned from one functional position to another functional position by pivoting the turret. In the former patent (the '232 patent), the turret is pivoted manually and locked in place by an insertable pin. In the latter patent (the '514 patent), the turret is pivoted by a linear actuator mounted vertically on the stand with a distal end of the actuator plunger being coupled to the turret at a location spaced from the pivot axis of the turret, whereby full extension of the plunger corresponds to one position of the forming roll and full retraction of the plunger corresponds to another position of the forming roll.
U.S. Pat. No. 5,829,294 discloses a split-level roll-forming machine having a vertically movable support wherein changeover is effected by operating vertically extendable linear actuators to move the support up or down relative to an opposite support.
U.S. Pat. No. 6,148,654 teaches the use of a single forming roller eccentrically mounted on a rotatable knuckle support, wherein the knuckle support is connected to a worm gear driven by a worm shaft that also drives other worm gears connected to other knuckle supports of other roll-forming stations.
SUMMARY OF THE INVENTIONThe present invention is directed to a roll-forming machine having a mechanism by which setup may be changed over between a C-configuration setup for manufacturing purlins having a generally C-shaped cross-sectional configuration and a Z-configuration setup for manufacturing purlins having a generally Z-shaped cross-sectional configuration. In accordance with an embodiment of the present invention, a roll-forming machine for bending a strip of material as the strip travels in a feed direction through the roll-forming machine generally comprises a plurality of roll-forming stations arranged in succession along the feed direction. At least one of the roll-forming stations includes a turret carrying a C-configuration forming roller and a Z-configuration forming roller, wherein the turret is pivotable about a turret axis to selectively locate either the C-configuration forming roller or the Z-configuration forming roller for engagement with a strip of material passing through the roll-forming station. A linear actuator is operatively connected to the turret by a linkage, whereby the linear actuator is operable for pivoting the turret to selectively locate the C-configuration roller or the Z-configuration roller for engagement with a passing strip of material.
In accordance with another aspect of the present invention, at least one of the roll-forming stations (an upstream station) includes an upstream-station turret having a C-configuration forming roller and a Z-configuration forming roller, at least one other subsequent roll-forming station (a downstream station) includes a downstream-station turret also having a C-configuration forming roller and a Z-configuration forming roller, and both turrets are connected by a linkage to the same linear actuator whereby the turrets may be pivoted simultaneously to selectively locate both of the C-configuration rollers or both of the Z-configuration rollers for engagement with a passing strip of material.
In accordance with another aspect of the present invention, the roll-forming machine may have a pair of linear actuators, one on an inboard side of the machine and one on an outboard side of the machine, each linear actuator being connected by an associated linkage to a plurality of inboard turrets or a plurality of outboard turrets, as the case may be. The inboard and outboard linear actuators may be connected to a single control system, whereby turrets on both sides of the roll-forming machine may be pivoted to changeover the setup.
The invention extends to a changeover method generally comprising the steps of operating an inboard linear actuator linked to a plurality of inboard turrets to pivot the plurality of inboard turrets from a first index setting to a second index setting; and operating an outboard linear actuator linked to a plurality of outboard turrets to pivot the plurality of outboard turrets from a first index setting to a second index setting.
The nature and mode of operation of the present invention will now be more fully described in the following detailed description of the invention taken with the accompanying drawing figures, in which:
A roll-forming machine formed in accordance with an embodiment of the present invention is shown in top plan view in
Continuing in the feed direction, a fifth roll-forming station 22 includes an inboard side 22A and an outboard side 22B; a sixth roll-forming station 24 includes an inboard side 24A and an outboard side 24B; a seventh roll-forming station 26 includes an inboard side 26A and an outboard side 26B; and an eighth roll-forming station 28 includes an inboard side 28A and an outboard side 28B. At the fifth roll-forming station 22 (“pass five”), formation of the leg bends begins. Further progression and completion of the leg bends occurs as strip 8 travels through the sixth through thirteenth roll-forming stations. By way of illustration, pass seven is shown in
Inboard-outboard side pair 30A, 30B forms a ninth roll-forming station 30; pair 32A, 32B forms a tenth roll-forming station 32; pair 34A, 34B forms an eleventh roll-forming station 34; pair 36A, 36B forms a twelfth roll-forming station 36, and pair 38A, 38B forms a thirteenth roll-forming station 38. Numerals 39 and 40 identify non-forming stations of machine 10. Station 39 provides a straightening pass to remove twist, bow, camber, and/or flaring developed over the length of strip 8 during forming. Finally, station 40 is a drive-out or discharge station that forces strip 8 out of roll-forming machine 10, typically onto a material conveyor positioned adjacent thereto. Other non-forming stations (not numbered) may be interspersed between forming stations to provide drive passes to force strip 8 through the machine.
The inboard sides 14A, 16A, 18A, and 20A of the first through fourth roll-forming stations (which form the lip bends) are mounted on an upstream inboard raft 11A, and their outboard counterparts 14B, 16B, 18B, and 20B are mounted on an upstream outboard raft 11B. Likewise, the inboard sides 22A, 24A, 26A, 28A, 30A, 32A, 34A, 36A, and 38A of the fifth through thirteenth roll-forming stations (which form the leg bends) are mounted on a downstream inboard raft 11C, and their outboard counterparts 22B, 24B, 26B, 28B, 30B, 32B, 34B, 36B, and 38B are mounted on a downstream outboard raft 11D. In order to adjust the web width and accommodate different strip widths, the lateral spacing between upstream rafts 11A and 11B is settable independently of the lateral spacing between downstream rafts 11C and 11D, as is known in the art of roll-forming machines.
As used herein, the terms “upstream” and “downstream” relate to the feed direction, and a first element is said to be upstream relative to a second element if the first element comes before the second element along the feed direction. Conversely, a first element is said to be downstream from a second element if the first element comes after the second element along the feed direction.
Reference is now made to
The second roll-forming station includes inboard and outboard upstanding supports 70A and 70B respectively mounted on rafts 11A and 11B. A forming roller 71 is mounted on inboard support 70A to rotate about a roller axis. In the illustrated embodiment, forming roller 71 is a cylindrical forming roller having a roller axis that extends at an inclined angle relative to horizontal in a plane normal to the feed direction. A turret 74 associated with outboard support 70B is rotatable about a laterally extending turret axis. Turret 74 of the second roll-forming station includes a C-configuration roller 76 and a Z-configuration roller 78 at angularly spaced indices about the turret axis of turret 74. When turret 74 is pivoted to locate its C-configuration index at a functioning position with respect to strip 8, as shown in
The third roll-forming station, like the first two stations, has a pair of upstanding supports 90A and 90B arranged opposite one another on rafts 11A and 11B. However, the third roll-forming station differs in that both the inboard side 18A and the outboard side 18B have a turret associated therewith. As may be seen in
The fourth roll-forming station includes a pair of upstanding supports 110A and 110B arranged opposite one another on rafts 11A and 11B. An inboard turret 113 adjacent support 110A carries a C-configuration roller 115 and an empty or blank space at its Z-configuration index. Likewise, an outboard turret 114 adjacent support 110B carries a C-configuration roller 116 and an empty or blank space at its Z-configuration index. As may be recalled, the lip bends in a C-shaped purlin (
The outboard sides of the fifth through eighth roll-forming stations include respective turrets each carrying a C-configuration roller and a Z-configuration roller. Specifically, fifth station outboard side 22B includes a turret 134 adjacent an upstanding support 130B for carrying a C-configuration roller 136 and a Z-configuration roller 138; sixth station outboard side 24B includes a turret 154 adjacent an upstanding support 150B for carrying a C-configuration roller 156 and a Z-configuration roller 158; seventh station outboard side 26B includes a turret 174 adjacent an upstanding support 170B for carrying a C-configuration roller 176 and a Z-configuration roller 178; and eighth station outboard side 28B includes a turret 194 adjacent an upstanding support 190B for carrying a C-configuration roller 196 and a Z-configuration roller 198. In the embodiment shown, the outboard forming rollers of the fifth through seventh stations are tapered rollers having respective roller axes that extend in a lateral direction perpendicular to the material feed direction and parallel to their associated turret axis, wherein the taper angles are increased with each successive station. The outboard forming rollers 196 and 198 of the eighth station may be cylindrical rollers.
In similar fashion, the outboard sides 30B, 32B, 34B, 36B, and 38B of the ninth through thirteenth roll-forming stations include associated turrets each carrying a C-configuration roller and a Z-configuration roller. For example, the ninth roll-forming station shown in
In accordance with the present invention, the setup of roll-forming machine 10 can be changed from C-configuration setting to a Z-configuration setting, and vice versa, by operation of a changeover system that functions to pivot the turrets of the various roll-forming stations. The changeover system generally comprises an inboard linear actuator 41A for pivoting the inboard turrets and an outboard linear actuator 41B for pivoting the outboard turrets. As shown schematically in
Linear actuators 41A and 41B are each connected by respective linkages to associated turrets. Inboard linear actuator 41A is connected to inboard turrets 93 and 113, and outboard linear actuator 41B is connected to outboard turrets 54, 74, 94, 114, 134, 154, 174, 194, 214, 234, 254, 274, and 294. The inboard linkage is depicted as including a primary link 43A having a proximal end joined to a distal end of linear actuator 41A, and a distal end joined to an attachment block 44. The inboard linkage further includes an upstream connection link 45A fixed to attachment block 44 and connected to turrets 93 and 113 located upstream from linear actuator 41A on the third and fourth roll-forming stations. In the present embodiment, connection link 45A includes a plurality of link pins 46 pivotally joining connection link 45A with each turret to which the connection link is connected. As may be understood, when linear actuator 41A is extended as shown in
Reference is now made to
Reference is now made to
As mentioned above, the lateral spacing between upstream rafts 11A and 11B may be set independently of the lateral spacing between downstream rafts 11C and 11D. Accordingly, coupler 48 may be configured to permit laterally directed adjustment of upstream connection link 45B and downstream connection link 47 relative to one another. As may be seen in
It is noted that linear actuators 41A and 41B may be positioned between the fourth and fifth roll-forming stations where the roll-forming operations transition from formation of the lip bends to formation of the leg bends. On the outboard side of roll-forming machine 10, this is also the location at which upstream connection link 45B meets downstream connection link 47 at coupler 48. In the embodiment shown, actuators 41A and 41B each have a stroke axis parallel to the feed direction but the actuators extend in opposite directions, with inboard linear actuator 41A extending opposite the feed direction and outboard linear actuator 41B extending in the feed direction. However, one skilled in the art will recognize that the stroke direction and location of actuators 41A and 41B may be changed without straying from the present invention. Other positions for actuators 41A and 41B are possible, and it is not necessary that both actuators be at the same position along the feed direction. By way of non-limiting example, outboard linear actuator 41B could be arranged to extend opposite the feed direction and outboard primary link 43B could be attached to the upstream link 45B instead of downstream link 47. By way of further non-limiting example, linear actuator 41A could be located upstream of third roll-forming station 18 to extend in the feed direction. Any suitable linear actuator may be used, including without limitation a mechanical linear actuator, an electromechanical linear actuator, a hydraulic linear actuator, or a pneumatic linear actuator.
As used herein, the term “linkage” is intended to broadly encompass any arrangement of structurally connected elements and links capable of transmitting linear displacement provided by a linear actuator from the actuator to at least one turret of a roll-forming station. A suitable linkage is shown and described in detail, however other linkages differing from that shown may be used.
While the invention has been described in connection with an example embodiment, the detailed description is not intended to limit the scope of the invention to the particular embodiment set forth, but, on the contrary, it is intended to cover such alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.
Claims
1. A roll-forming machine for bending a strip of material as the strip travels in a feed direction through the roll-forming machine, the roll-forming machine comprising:
- a plurality of roll-forming stations arranged in succession along the feed direction;
- the plurality of roll-forming stations including an upstream roll-forming station and a downstream roll-forming station after the upstream roll-forming station in the feed direction;
- wherein the upstream roll-forming station includes an upstream-station turret having a C-configuration roller and a Z-configuration roller, the upstream-station turret being pivotable about a turret axis to selectively locate either the C-configuration roller or the Z-configuration roller for engagement with a strip of material passing through the upstream roll-forming station, wherein the C-configuration roller and the Z-configuration roller respectively function to bend a portion of the strip in opposite angular directions relative to a remaining portion of the strip;
- wherein the downstream roll-forming station includes a downstream-station turret having a C-configuration roller and a Z-configuration roller, the downstream-station turret being pivotable about a turret axis to selectively locate either the C-configuration roller or the Z-configuration roller thereof for engagement with a strip of material passing through the downstream roll-forming station, wherein the C-configuration roller and the Z-configuration roller of the downstream-station turret respectively function to bend a portion of the strip in opposite angular directions relative to a remaining portion of the strip;
- a linear actuator; and
- a linkage connecting the linear actuator to the upstream-station turret and the downstream-station turret;
- wherein the linear actuator is operable for simultaneously pivoting the upstream-station turret and the downstream station turret to selectively locate both of the C-configuration rollers or both of the Z-configuration rollers for engagement with a strip of material.
2. The roll-forming machine according to claim 1, wherein the C-configuration roller of the downstream-station turret further bends the portion of the strip bent by the C-configuration roller of the upstream-station turret relative to the remaining portion of the strip when the C-configuration rollers are selected, and the Z-configuration roller of the downstream-station turret further bends the portion of the strip bent by the Z-configuration roller of the upstream-station turret relative to the remaining portion of the strip when the Z-configuration rollers are selected.
3. The roll-forming machine according to claim 1, wherein the C-configuration roller of the downstream-station turret bends a different portion of the strip than was bent by the C-configuration roller of the upstream-station turret, and the Z-configuration roller of the downstream-station turret bends a different portion of the strip than was bent by the Z-configuration roller of the upstream-station turret.
4. The roll-forming machine according to claim 1, wherein the linear actuator is located after the upstream roll-forming station in the feed direction.
5. The roll-forming machine according to claim 4, wherein the linear actuator is located after the downstream roll-forming station in the feed direction.
6. The roll-forming machine according to claim 4, wherein the linear actuator is located before the downstream roll-forming station in the feed direction.
7. The roll-forming machine according to claim 6, wherein the linkage includes an upstream link for connecting the linear actuator to the upstream-station turret and a downstream link for connecting the linear actuator to the downstream-station turret.
8. The roll-forming machine according to claim 7, wherein the linkage further includes a coupler connecting the upstream link to the downstream link, wherein the coupler enables laterally directed adjustment of the upstream and downstream links relative to one another.
9. The roll-forming machine according to claim 1, wherein the C-configuration roller and the Z-configuration roller of the upstream-station turret are each a cylindrical roller having a respective rotational axis non-parallel to the turret axis of the upstream-station turret.
10. The roll-forming machine according to claim 9, wherein the C-configuration roller and the Z-configuration roller of the downstream-station turret are each a tapered roller having a respective rotational axis parallel to the turret axis of the downstream-station turret.
11. A roll-forming machine for bending a strip of material as the strip travels in a feed direction through the roll-forming machine, the roll-forming machine comprising:
- a plurality of roll-forming stations arranged in succession along the feed direction;
- at least one of the plurality of roll-forming stations including an inboard side and an outboard side opposite the inboard side, an inboard turret on the inboard side and an outboard turret on the outboard side;
- wherein each of the inboard and outboard turrets has a C-configuration tool index and a Z-configuration tool index and is pivotal about a respective turret axis to selectively locate either the C-configuration index or the Z-configuration index thereof in a functioning position with respect to a strip of material as the strip passes through the at least one roll-forming station;
- an inboard linear actuator;
- an inboard linkage connecting the inboard linear actuator to the inboard turret;
- an outboard linear actuator;
- an outboard linkage connecting the outboard linear actuator to the outboard turret; and
- a control system operating the inboard and outboard linear actuators for pivoting the inboard turret and the outboard turret to selectively locate both of the C-configuration indices or both of the Z-configuration indices in their respective functioning positions.
12. The roll-forming machine according to claim 11, wherein the inboard turret includes a C-configuration roller at the C-configuration index thereof and a Z-configuration roller at the Z-configuration index thereof, and the outboard turret includes a C-configuration roller at the C-configuration index thereof and a Z-configuration roller at the Z-configuration index thereof.
13. The roll-forming machine according to claim 12, wherein the C-configuration rollers have respective rotational axes that are mirror images of one another as viewed along the feed direction.
14. The roll-forming machine according to claim 12, wherein the Z-configuration rollers have respective rotational axes that are parallel to one another as viewed along the feed direction.
15. The roll-forming machine according to claim 11, wherein the inboard linear actuator and the outboard linear actuator are arranged to extend in opposite directions relative to one another.
16. A roll-forming machine for bending a strip of material as the strip travels in a feed direction through the roll-forming machine, the roll-forming machine comprising:
- a plurality of roll-forming stations arranged in succession along the feed direction;
- at least one of the plurality of roll-forming stations including a turret having a C-configuration angular index and a Z-configuration angular index, the turret being pivotable about a turret axis to selectively locate either the C-configuration index or the Z-configuration index in a functioning position with respect to a strip of material as the strip passes through the at least one roll-forming station;
- a linear actuator; and
- a linkage connecting the linear actuator to the turret;
- wherein the linear actuator is operable for pivoting the turret to selectively locate either the C-configuration index or the Z-configuration index in the functioning position.
17. The roll-forming machine according to claim 16, wherein the linear actuator has a stroke axis parallel to the feed direction.
18. The roll-forming machine according to claim 16, wherein the linear actuator is selected from a group consisting of a mechanical linear actuator, an electromechanical linear actuator, a hydraulic linear actuator, and a pneumatic linear actuator.
19. The roll-forming machine according to claim 16, wherein the turret includes a Z-configuration roller at the Z-configuration index, and the Z-configuration index has offset means for allowing the Z-configuration roller to be mounted on the turret at a chosen offset position.
20. The roll-forming machine according to claim 16, wherein the turret includes a C-configuration roller at the C-configuration index and a Z-configuration roller at the Z-configuration index.
21. The roll-forming machine according to claim 16, wherein the turret includes a C-configuration roller at the C-configuration index and the Z-configuration index is without tooling.
22. A method of changing over a roll-forming machine from a C-configuration setup to a Z-configuration setup, the roll-forming machine having a plurality of roll-forming stations arranged in succession along a feed direction for progressively bending a strip of material passing through the roll-forming machine in the feed direction to impart either a C-shaped cross-sectional configuration or a Z-shaped cross-sectional configuration to the strip, the method comprising the steps of:
- operating an inboard linear actuator linked to a plurality of inboard turrets to pivot the plurality of inboard turrets from a C-configuration index setting to a Z-configuration index setting; and
- operating an outboard linear actuator linked to a plurality of outboard turrets to pivot the plurality of outboard turrets from a C-configuration index setting to a Z-configuration index setting.
23. The method according to claim 22, wherein the step of operating an inboard linear actuator and the step of operating an outboard linear actuator are performed by way of a control system connected to the inboard and outboard linear actuators.
24. A method of changing over a roll-forming machine from a Z-configuration setup to a C-configuration setup, the roll-forming machine having a plurality of roll-forming stations arranged in succession along a feed direction for progressively bending a strip of material passing through the roll-forming machine in the feed direction to impart either a C-shaped cross-sectional configuration or a Z-shaped cross-sectional configuration to the strip, the method comprising the steps of:
- operating an inboard linear actuator linked to a plurality of inboard turrets to pivot the plurality of inboard turrets from a Z-configuration index setting to a C-configuration index setting; and
- operating an outboard linear actuator linked to a plurality of outboard turrets to pivot the plurality of outboard turrets from a Z-configuration index setting to a C-configuration index setting.
25. The method according to claim 24, wherein the step of operating an inboard linear actuator and the step of operating an outboard linear actuator are performed by way of a control system connected to the inboard and outboard linear actuators.
Type: Application
Filed: Mar 9, 2007
Publication Date: Sep 11, 2008
Inventors: Calin N FUDULU (Toronto), Jozsef Gaspar (Scarborough)
Application Number: 11/684,119
International Classification: B21D 5/08 (20060101);