ARCHING METALLIC PROFILES IN CONTINOUS IN-LINE PROCESS

Abstract

A method and apparatus for manufacturing an arched metallic profile, in a continuous in-line process. The method comprises forming the metallic profile; and arching the formed metallic profile in a continuous in-line process. The apparatus includes a roll forming station configured to receive flat metallic composition and output a given profile. An arching device is configured to receive the metallic profile and bend the metallic profile having a desired radius of curvature wherein a portion of the arching device is displaced with respect to said roll forming station vertically and/or horizontally.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application No. 61/012,929 filed Dec. 12, 2007 which is herein incorporated by reference in its entirety.

BACKGROUND

1. Field of the Invention

The present invention generally relates to a method and apparatus for roll forming steel. More particularly, the present invention relates to a process and machine for forming arch configurations of metallic profiles from roll-formed steel during a continuous in-line process.

2. Discussion of Related Art

Continuous in-line processing of steel provides an efficient and relatively quick method for transforming flat strip steel into steel profiles to accommodate high volume production with greater uniformity and consistency. This continuous in-line process is well known in the art as disclosed in, for example, U.S. Pat. Nos. 3,122,114 and 3,696,503, both to Krengel et. al.; 3,468,145 to Ostrowski; and 3,667,095 to Ostrowski et. al., the disclosures of which are incorporated herein by reference. In particular, U.S. Pat. No. 3,122,114 disclosed the continuous formation of steel profiles and the galvanized treatment of the external surfaces of the formed profiles. U.S. Pat. No. 3,696,503 disclosed a method for continuously galvanizing strip steel in which a forming roll operation, a galvanizing section and a reforming roll operation were used to produce steel profile having all exposed surface areas of the strip steel galvanized. In U.S. Pat. No. 3,468,145, a method is disclosed for processing steel having a relatively thick cross-section and producing steel having a desired cross-section by moving the stock through a mill multiple times. U.S. Pat. No. 3,667,095 disclosed an apparatus for the continuous forming, galvanizing and application of a protective coating to steel profiles.

Generally, a continuous in-line process first forms strip steel into a desired profile having a cross-section configuration, for example, C-shaped, “U” shaped, etc. The particular steel profile is formed as straight pieces within a continuous in-line machine and cut to a desired length. If the cut steel profiles require a particular radius of curvature, the cut profile sections undergo a separate secondary process to form arched sections using, for example, a standard three roll bending machine. However, several drawbacks are associated with performing the arching process after cutting. First, this additional arching step of the formed and cut profile sections requires additional labor, separate process machines and consumes valuable process time. Secondly, if the steel profiles are produced with a plurality of equally spaced mounting holes along its longitudinal axis, the subsequent arching process may produce undesirable hole elongation along the bend radius area. Thirdly, warping may occur along the bend profile of the steel profile once sections are arched. Moreover, the cross-section at the end of the steel profile may change after the steel is bent. For example, a steel profile having a “U” shaped cross-section essentially comprises a pair of vertically opposed wall members connected by a lower transverse member. At each longitudinal (i.e. lengthwise) end portion of the steel profile, these vertically opposed wall members ideally have a common transverse plane. Once this “U” shaped profile is arched, one of the vertically opposed wall members extends beyond this transverse plane. An additional cutting step is required to ensure that each of the “U” shaped wall members ends on the same transverse plane. This adds labor, time and unwanted material waste to the manufacturing process. Thus, there is a need for a method and apparatus for manufacturing roll formed steel into a particular profile, arching the formed profile and cutting the arched profile all within a continuous in-line process.

SUMMARY OF THE INVENTION

Exemplary embodiments of the present invention are directed to an apparatus and method for manufacturing arched metallic profiles, particularly steel profiles, using a continuous in-line process. The method includes forming the metallic profile; and arching the formed metallic profile in a continuous in-line process. The apparatus includes a roll forming station configured to receive flat metallic composition and output a given profile. An arching device is configured to receive the metallic profile and bend the metallic profile having a desired radius of curvature wherein a portion of the arching device is displaced with respect to the roll forming station vertically and/or horizontally.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a block diagram illustrating the steps included in a continuous in-line process in accordance with the present invention.

FIG. 1B illustrates a diagrammatic view of a continuous in-line arrangement for forming an arch in a steel profile embodying the various steps shown in FIG. 1A;

FIG. 2A is a side view of a process for bending a steel profile in a continuous in-line process in accordance with the present invention;

FIG. 2B is a top plan view of the process for bending a steel profile in a continuous in-line process shown in FIG. 2A in accordance with the present invention;

FIG. 2C is a top plan view of the process for bending a steel profile in a continuous in-line process shown in FIG. 2A in accordance with the present invention;

FIG. 2D illustrates a cross sectional view of a portion of an arching device including an exemplary top insert roller in accordance with the present invention; and,

FIGS. 3A and 3B are perspective views of arched metallic profiles formed as part of a continuous in-line forming process in accordance with the present invention.

DESCRIPTION OF EMBODIMENTS

The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention, however, may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. In the drawings, like numbers refer to like elements throughout.

The present invention is directed to a method and apparatus for manufacturing an arched or curved steel profile as part of a continuous in-line forming process. As such, the method roll forms a steel profile from strip steel and bends this formed steel profile during the continuous movement of the steel through the in-line process in a desired cross-section configuration. Applications of the present continuous in-line process include, for example manufacture of profiles for storage buildings, greenhouses, boat hulls, canopies, awnings, garages, ponds, swimming pool, structural enclosure elements, furniture, etc. FIG. 1A generally illustrates the continuous in-line roll forming process or method in accordance with the present invention. The method includes the functions of roll forming strip steels into a desired profile at step 100, bending the formed steel profile at step 200 and shearing or cutting the arched steel profile into individual units for shipping at step 300. The bending step 200 employs apparatus 200A and forming device 200B. FIG. 1B illustrates a diagrammatic view of a continuous in-line arrangement for forming an arch in a steel profile embodying the various steps shown in FIG. 1A. In particular, step 100 in which strip steel is roll formed into a desired profile may be accomplished through the use of an uncoiler 102, end welder 104, accumulation pit 106, punching station 108 and roll forming station 110. Uncoiler 102 is configured to stream out long sections of steel sheet or strips from coils. The end welder 104 is used to mate the individual steel sheet sections into a continuous steel sheet length. The accumulation pit 106 provides excess length of steel sheet for end welder 104 to work. The punching station 108 is configured to punch holes or other voids into the continuous steel sheet if desired. The formed profile may be an open or closed profile. Typical open profiles include, for example, “C” shape (most common), “U” shape and angled configurations. Typical closed profiles may include such configurations as polygons, e.g., square, rectangle, triangle and the like, or curved configurations such as oval, circle, and the like. The formed profile may be either welded or non-welded. The roll forming station 110 roll forms the continuous steel sheet into a particular steel profile.

The step of bending or arching the steel profile includes utilizing Turkshead 202, Turkshead 204 and cutoff guide 206. The step of shearing or cutting 300 the bent steel profile is accomplished using, for example, a flying cutoff assembly 302. As will be described in more detail below with reference to FIGS. 2A-2C, a Turkshead may remain stationary in an angular or vertically displaced position relative to roll forming station 110 as the steel is feed through the process line to provide a constant radius of curvature to the formed steel profile prior to cutting. Alternatively, the Turksheads 202 and 204 may be synchronized for linear and/or angular displacement with respect to the roll forming station 110 as the steel profile is shaped, providing a variable radius of curvature. As such, variable radii may be formed within a single cut steel profile or different radii may be formed in different cut lengths of steel profile. The bent formed steel profile forms an arch, which may include either a singular arch or multiple arches. Multiple arches may also be formed where the arches are within the same plane having different radii, or arches within different planes of formations, whether the arch has the same radius or different radii than other arches in different planes. In addition, the steel profile may be arched by the bending profile step 200 to form: (i) a consistent arch, (ii) multiple arches within more than two dimensions, (iii) different arches in the same direction, (iv) different arches in different directions, or (v) a spiral configuration. In this manner, various combinations or arch radii, profile forms and section lengths may be implemented using the present invention as described below.

FIG. 2A illustrates an exemplary process line 10 mounted on a base 5 for forming steel profiles from strip steel. In particular, strip steel is supplied by an uncoiler which rotates to feed the continuous flat steel 111 to roll forming station 110. The strip steel may include a plurality of holes, varying in hole location, size, shape, or combinations thereof. Roll forming station 110 defines a steel profile forming device and includes a plurality of roll forming stands 115₁-115_N in which the strip steel is roll formed to a profile. The roll forming stands are positioned along the process line aligned with a central axis (denoted as “A” in FIG. 2B) to produce a straight rolled steel profile. Each roll forming stand includes a plurality of rolls which engage both the upper and lower surfaces of the strip steel 111 and apply pressure thereto to bend the steel. The axis of rotation of each roll is transverse to the direction that the strip steel moves through process line 10. Certain of the plurality of roll forming stands 115₁-115_N may be configured to have either an upper or lower combination of rolls which remain fixed relative to the direction of movement through the process line. The number of roll forming stands 115₁-115_N will depend on the desired shape of the steel profile where each stand works or bends the flat steel progressively until the desired shape or profile is achieved. For example, strip steel 111 is supplied to first roll forming stand 115₁ where it is rolled and output as steel 111₁. The next roll forming stand in the process 115₂ receives the formed steel 111₁ where it is again rolled to output steel 111₂. The next roll forming stand in the process 115₃ receives the formed steel 111₂ where it is again rolled to output steel 111₃. As can be seen in FIG. 2A, the steel outputted by each roll forming stand produces a changed profile which is rolled in progressive increments by the next successive roll forming stand in station 110. This process continues until the desired cross-section of steel profile 111_N is outputted by the last roll forming stand 115_N in the process line 10. By way of example, a simple “U” shaped steel profile or cross-section may require six roll forming stands (115₁-115₆) and a more complex shape such as a “U” shape with channel edges may require twelve to 18 roll forming stands (115₁-115₁₈). In addition to forming the desired profile of the formed steel, the rollers in each stand also act to move or advance the strip steel through the process line 10.

Once the steel has been formed into a desired profile, a pair of Turksheads 202 and 204 are disposed between the last roll forming stand 115_N and the cutoff assembly 302. The Turksheads 202 and 204 define an arch forming device (200B of FIG. 1A). In particular, Turkshead 202 receives the formed steel profile 111_N from roll forming stand 111_N. The Turksheads 202 and 204 impart sufficient force to the steel profile to arch the profile in a desired direction. Each Turkshead 202 and 204 includes individual rollers or roll clusters rigidly held within a rotary housing. Representative Turksheads include, for example without limitation, Turksheads similar to Model Number TH-500-SSU available from Addison Machine Engineering Inc. of Reedsburg, Wis. The formed steel profile 111_N is arched by the Turksheads 202 and 204 to a desired bend radius to form profile 111_T. The arched steel profile 111_T is then cut to desired lengths by cutoff assembly 302 to form cut steel profile section 111_C. In order to perform the bending step 200, either Turkshead 202 and/or Turkshead 204 may be disposed linearly in the vertical Y direction through the use of movable platforms 225 and 228 respectively. In particular, as steel profile 111_T engages Turkshead 204 at the desired location along the profile's longitudinal axis, platform 228 displaces Turkshead 204 vertically with respect to Turkshead 202 which remains stationary. This displacement of Turkshead 204 defines a bend point incident on Turkshead 202 causing an arching of steel profile 111_T along its longitudinal axis to produce profile 111A. Similarly, Turkshead 202 may be disposed on a movable platform 226 such that Turkshead 202 is disposed linearly in the vertical Y direction with respect to roll station 111_N and Turkshead 204. This displacement of Turkshead 202 defines a bend point incident on the last roll stand 111_N. The displacement (linearly or angularly) of either Turkshead 202 and/or 204 with respect to last roll station 111_N causes an arching of steel profile 111_T along its longitudinal axis to produce steel profile 111_A which is supplied to cut-off assembly 302 where it is cut into desired lengths.

Turksheads 202 and 204 may also be configured to be displaced angularly a distance in direction X off the central axis “A” formed by the roll forming stands 115₁ . . . 115_N in process line 10 as described in greater detail with reference to FIGS. 2B and 2C. In this manner, the Turksheads 202 and 204 provide a constant radius of curvature for the steel profile formed by roll forming station 110 prior to cutting by cut-off assembly 302 within the continuous in-line process. Alternatively, the Turksheads 202 and 204 may be synchronized to move as the steel profile is shaped by the roll assembly 110 thereby providing a variable radius of curvature. In addition, cut-off assembly 302 is also movable on platform 301 such that cut-off assembly 302 must be in-line with Turkshead 204 to provide an end cut along a common transverse plane. In other words, cutoff assembly 302 is perpendicular to the steel profile being roll formed by station 110. An exemplary C-shaped steel profile was formed using the above described continuous in-line process with a web width of 70 mm, a leg height of 50 mm, and a return length of 10 mm. Once formed, and as a part of the in-line continuous process, the steel profile was driven through a Turkshead to create an arch with an outer radius of 12.5 meters, and an overall length of 4.2 meters. Once bent, the steel profile was cut to the desired length.

The Turkshead 202 and/or 204 may also include a forming device 200B to provide support and/or restrain the desired profile in critical locations during the arching process. In particular, when the arching process engages the movement of Turkshead 204 while Turkshead 202 remains stationary, the stress on the profile about its bend point may compromise the integrity of the formed profile. Thus, a support guide or guide plate is used to alleviate these bend forces incident on the formed profile. For example, a guide plate or a Turkshead guide roll cut device has the corresponding shape of profile 111_N undergoing the arching process and may be positioned within Turkshead 202. This device is used to support the steel profile during arching while avoiding damage to the given cross-section of the profile as it passes through the process line. In this manner, the forming device (200B) is positioned to best enhance the structural integrity of the steel profile and provides a stabilizing effect while the steel profile is being arched or bent. These forming devices may be provided in specified shapes, or contact along specified locations of the steel profile and are generally used in the formation of bends in open profiles, such as being shaped to fit in, and conform to, a given internal space within the steel profile. This forming device 200B may be separate from or incorporated into the Turkshead(s) to contribute to the forming of the prescribed curve while maintaining the desired profile. Alternatively, the forming device 200B may be part of or in juxtaposition to cutoff assembly 302 to contribute to the forming of the prescribed curve while maintaining the desired profile and to promote the unimpeded operation of the cutoff assembly 302. For example, a forming device may be used in bending a C-shape in conjunction with a Turkshead by providing a resistive force to pull against the inside of the C-shape during bending, e.g., having four rolls providing pressure on a side member of the steel profile to force it in a certain direction while minimizing wrinkles in the steel profile.

FIG. 2B is a top plan view of the process line 10 shown in FIG. 2A having a plurality of roll forming stands 115₁-115_N centrally disposed along axis A to better illustrate the angular displacement feature of bending or arching step 200. Strip steel 111 is supplied to first roll form stand 115₁ and the process of roll forming proceeds as described above to produce a desired steel profile 111_N. Turkshead 202 remains stationary and Turkshead 204 is displaced angularly a distance Δ from the central axis “A” such that a bend radius “R” is formed in the steel profile. The distance may be varied during the forming of the steel profile using roll forming station 110 to form a profile with multiple radius of curvatures. As Turkshead 204 is displaced, a different degree of arch is imparted into the steel profile. This movement is controlled to account for the speed of the process, amount of bend within a steel profile, and repetition of the process to reproduce similar steel profiles consecutively having corresponding degrees of arch therein. Preferably, the process may be used to create dissimilar sets of steel profiles, where each set of profiles are formed as a set, that may be used together, e.g., the left and right rails (mirror sides) of a slide, etc. In this manner, the constituents of a particular steel profile set are manufactured with a high degree of accuracy for use together. Once the profile is arched, the profile is supplied to cut-off assembly 302 which is angularly aligned with Turkshead 204 to cut the arched steel profiles into desired lengths.

FIG. 2C is a top plan view of the process line 10 shown in FIG. 2B where both Turksheads 202 and 204 are displaced angularly with respect to axis “A” to form another arched configuration of steel profile. In particular, Turkshead 202 is displaced angularly a distance Δ₁ from the central axis “A” such that a bend radius is formed in the steel profile with respect to bend station 115_N. Turkshead 204 may also be displaced angularly a distance Δ₂ from the central axis “A”. In this manner, a steel profile having an arching radius of curvature “R” may be tailored to a particular configuration. Cutoff assembly 302 receives the arched steel profile and cuts the profiles into desired lengths. Again, cutoff assembly 302 is aligned with Turkshead 204 to provide an end cut along a common transverse plane of the steel profile. The relationship of the distances Δ₁ and Δ₂ will depend on the desired radius of curvature of the profile to be arched. FIG. 2D illustrates a cross sectional view of a profile through Turkshead 204 and an exemplary top insert roller 250 disposed with Turkshead 204. Insert roller 250 is included in the top section of Turkshead 204 to maintain the shape of the roll formed profile 111_T during the arching step to equalize the longitudinal stress on the profile during arching to prevent kinking/warping thereof. In particular, roll formed profile 111T is disposed between Turkshead side rollers 251A and 251B for bending. Insert roller 250 is configured to engage profile 111T such that as the profile is being arched, end 250A of insert roller 250 cooperates with the profile to maintain shape thereof. Insert roller 250 shown in FIG. 2D is an exemplary shape for profile 111T and may be exchanged within Turkshead 204 to accommodate other profile shapes.

The degree of bend or arch within the steel profile is determined by the vertical and/or angular displacement of Turkshead 202 and/or Turkshead 204. Representative bends include, for example, arch ranges in radius from about 3 meters to about 24 meters. As seen in FIGS. 3A and 3B, the formed arch may include a bend along the sides of the steel profile, such as that shown as a simple arch in FIG. 3A, or a reverse arching structure with varying degrees of arch, shown in FIG. 3B. Representative dimensions of the steel profile may include a web width of from about 1.5 inches to about 6 inches. Representative arch ranges have a radius from about 3 meters to about 24 meters. Although bends within the steel profile may include a variety of configurations, the bent formed steel profile preferably forms an arch. The formed arch preferably has a consistent radius. Consistent radius include those radii having a minimal deviation along a given length of formed steel profiled with representative deviations ranging from about ⅛^th of an inch to about ½ inch. The arch may be in the form of a singular arch or multiple arches, with a singular arch preferred. Representative multiple arches include multiple arches within more than two dimensions, different arches in the same direction and different arches in different directions. The arch may be formed into a full circle structure, which may be formed using guides that offset the feed out of the bending steel profiles outside of the plane of the circle, prior to being cut. Examples of the final steel profiles, include for example without limitation, spirals, circles, slides, S-shapes, and the like.

During the in-line continuous process the arched steel profile is cut or severed by assembly 302 after the steel profile has been arched. This avoids drawbacks associated with prior methods where the steel profiles were first cut to length and then arched or bent to a desired radius of curvature pursuant to a secondary process. Accordingly, the method and apparatus of the present invention forms a bent steel profile product continuous in-line at high production rates. Representative production rates include, for example, from about 50 ft/min to about 500 ft/min, with rates of from about 60 ft/min to about 2040 ft/min preferred, and rates from about 60 ft/min to about 90 ft/min most preferred. Supports at the cutoff assembly may be located on the side rail to move the weight load of the steel profile off of the blade. Additionally, these supports may be used to push at the bottom or top of the steel profile to reduce twist, or increase the arch. Although steel profiles are preferred and referred to herein, other metallic compositions may be used in the formed profiles to be arched. For example, when aluminum profiles are manufactured, formed profiles may result from an extrusion process prior to being bent in the continuous in-line process. Other metals may be used, which are generally designed as specific functional components.

While the present invention has been disclosed with reference to certain embodiments, numerous modifications, alterations and changes to the described embodiments are possible without departing from the sphere and scope of the present invention, as defined in the appended claims. Accordingly, it is intended that the present invention not be limited to the described embodiments, but that it has the full scope defined by the language of the following claims, and equivalents thereof.

Claims

1. A method for manufacturing an arched metallic profile in a continuous in-line process comprising the steps of:

forming the metallic profile; and,

arching the formed metallic profile.

2. The method of claim 1, further comprising the step of stabilizing the steel profile.

3. The method of claim 2, wherein the step of stabilizing the steel profile is preformed in conjunction with a Turkshead.

4. The method of claim 2, wherein the step of stabilizing the steel profile is preformed in conjunction with a cutoff assembly.

5. The method of claim 1, further comprising the step of:

forming holes within the strip steel prior to forming the steel profile.

6. The method of claim 1, wherein the metallic profile is selected from the group of a steel profile, and aluminum profile, and combinations thereof.

7. The method of claim 6, wherein the step of forming the metallic profile includes the step of:

forming a steel profile from a strip steel in a continuous roll forming process.

8. The method of claim 6, wherein the bent formed steel profile forms multiple arches.

9. The method of claim 6, wherein the bent formed steel profile forms multiple arches within two or more distinct planes.

10. The method of claim 9, wherein the bent formed steel profile forms different arches in the same direction.

11. The method of claim 9, wherein the bent formed steel profile forms different arches in different directions.

12. The method of claim 1, further comprising the step of:

cutting the bent steel profile within the in-line continuous process.

13. An apparatus for bending metallic profiles within a continuous in-line process comprising:

a roll forming station configured to receive flat metallic composition and output a given profile; and

an arching device configured to receive said metallic profile and bend the metallic profile having a desired radius of curvature wherein a portion of said arching device is displaced with respect to said roll forming station.

14. The apparatus for bending metallic profiles of claim 13 wherein said roll forming station comprises a plurality of roll stations, each of said roll stations including rollers configured to receive the metallic composition and successively bend the composition into the given profile.

15. The apparatus for bending metallic profiles of claim 13 wherein said arching device comprises at least one Turkshead.

16. The apparatus for bending metallic profiles of claim 13 further comprising a cutting assembly configured to receive said arched profile and cut said profile into particular lengths.

17. The apparatus for bending metallic profiles of claim 15 further comprising a support guide disposed within said Turkshead about which said metallic profile is arched.

18. The apparatus for bending metallic profiles of claim 13 wherein said arching device is displaced linearly with respect to said roll forming station.

19. The apparatus for bending metallic profiles of claim 13 wherein said arching device is displaced angularly with respect to said roll forming station.

20. The apparatus for bending metallic profiles of claim 15 wherein said Turkshead is a first Turkshead, said arching device further comprising a second Turkshead disposed between said first Turkshead and said roll forming station.

21. The apparatus for bending metallic profile of claim 20 wherein said second Turkshead includes an insert roller device corresponding to a shape of said profile, said insert roller device configured to equalize a longitudinal stress incident on the profile during arching.