Abstract: Methods and Apparatus to increase the efficiency of roll-forming and leveling systems are described herein. An example strip material processing apparatus includes a first drive system to drive an exit workroll at an exit of the strip material processing apparatus, and a second drive system to drive an entry workroll at an entry of the strip material processing apparatus, where the strip material is to travel through the strip material processing apparatus from the entry to the exit. The example strip material processing apparatus also includes a controller to provide a first command reference to the first drive system to drive the exit workroll at the first command reference.

Abstract: A packaging line to pack profiles and a rotor are described herein. An example method includes transferring a first profile to a movable head carrying a rotor, coupling the first profile to the rotor, along a first side wall of the first profile, with a concave section of the first profile facing upwards, rotating, via the rotor, the first profile such that the concave section of the first profile is facing downwards, transferring a second profile to the movable head with a concave section of the second profile facing upwards, and releasing the first profile over the second profile to insert a side wall of the first profile into the concave section of the second profile and a side wall of the second profile into the concave section of the first profile.

Abstract: Methods to drive material conditioning machines are described. An example method includes determining a first torque of a first roller of a material conditioning machine through which the strip material moves, calculating a second torque of a second roller of the material conditioning machine based on a relationship between the second torque and the first torque, and maintaining the relationship between the second torque and the first torque by adjusting the second torque after a change in the first torque.

Abstract: Methods and apparatus to monitor conditioning machines are disclosed herein. An example system includes a plurality of work rolls to process a continuous strip material positioned between an entry and an exit of an apparatus. A sensor determines a measured distance between an upper surface of the strip material and a reference location, where the sensor is downstream from the exit of the apparatus. A controller determines a difference value between the measured distance and a predetermined distance to detect material curvature in the strip material.

Abstract: Methods and apparatus to monitor conditioning machines are disclosed herein. An example system includes a plurality of work rolls to process a continuous strip of material positioned between an entry and an exit of an apparatus. A sensor is positioned downstream from the exit of the apparatus. The sensor measures a first distance between an upper surface of the strip material and a predetermined reference. The sensor measures a second distance between the upper surface of the strip material and the predetermined reference. The first and second distances is measured at at least one of two different locations or two different instances in time as the strip material exits the apparatus. A controller compares the first distance and the second distance to detect material curvature or longbow in the strip material.

Abstract: Methods and Apparatus to increase the efficiency of roll-forming and leveling systems are described herein. An example strip material processing apparatus includes a first drive system to drive an exit workroll at an exit of the strip material processing apparatus, and a second drive system to drive an entry workroll at an entry of the strip material processing apparatus, where the strip material is to travel through the strip material processing apparatus from the entry to the exit. The example strip material processing apparatus also includes a controller to provide a first command reference to the first drive system to drive the exit workroll at the first command reference.

Abstract: Methods and apparatus for controlling a hem profile in roll-forming processes are described. An example roll-forming apparatus includes a first plurality of work rolls to form a first hem on a material and a second plurality of work rolls. One of the second plurality of work rolls is adjustable relative to an opposing work roll and to the first plurality of work rolls to adjustably control a profile of the first hem.

Abstract: An automated packaging line for C- or U-shaped profiles are related methods are disclosed. An example method includes transferring a first profile and a second profile to a first location, each of the first and second profiles having a u-shaped or c-shaped cross-section defining an external convex side and an internal concave side. The example method also includes rotating a first blade and a second blade about a horizontal central axis, where the first blade and the second blade are coupled to opposite ends of a pair of rotor arms including a first rotor arm and a second rotor arm. The first and second rotor arms rotate about axes that are parallel to and offset from each other. The example method also includes inserting the first profile into the first blade with the internal concave side of the first profile facing upwards as the first blade moves upward through its rotation.

Abstract: An example packaging line to pack profiles having a U-shaped or a C-shaped cross-section includes a first conveyor and a second conveyor to transfer profiles. The first conveyor and the second conveyor are spaced from and parallel to each other. The example includes a head block to move upward and downward. The first conveyor and the second conveyor transfer profiles to an area beneath the head block. The example includes a rotor, carried by the head block, to couple to a first profile transferred by the first and second conveyors with a concave side of the first profile facing upwards. The rotor rotates the first profile such that the concave side of the first profile is facing downwards over a second profile, where a concave side of the second profile is facing upward, and the rotor releases the first profile to insert the first profile into the second profile.

Abstract: Methods and apparatus to determine a plunge depth position of material conditioning machines are disclosed. An example method for setting a plunge depth of a leveler includes incrementally adjusting, via an actuator, a first work roll relative to a second work roll between a plurality of incremental plunge depth positions; measuring a pressure value in the actuator at the respective incremental plunge depth positions; associating the measured pressure values with the corresponding incremental plunge depth positions; detecting a smallest one of the measured pressure values; and identifying a first one of the incremental plunge depth positions corresponding to the smallest one of the measured pressure values.

Abstract: An automated packaging line for C- or U-shaped profiles is described. The example packaging line includes a first blade and a second blade that are rotatable around a horizontal axis in a first vertical plane and a third blade and a fourth blade that rotatable about the horizontal axis in a second vertical plane that is parallel to and offset from the first vertical plane. The first blade and the third blade are synchronously rotatable around the horizontal axis and the second blade and the fourth blade are synchronously rotatable about the horizontal axis.

Abstract: Methods and apparatus for monitoring and conditioning strip material are disclosed. A disclosed example method includes coupling a feedback unit to a first material conditioner. The first material conditioner includes a first sensor and a second sensor, where the first and second sensors are located along a width of a first material moving through the first material conditioner, a first adjustable backup bearing and a second adjustable backup bearing. The disclosed example method also includes mapping the first sensor to the first adjustable backup bearing, where the first sensor corresponds to a first longitudinal zone located along a width of the first moving material.

Abstract: Methods and apparatus for controlling flare in roll-forming processes are disclosed. An example method involves predefining a plurality of position values to adjust a tilt angle of a flange roller and adjusting the tilt angle of the flange roller based on one of the pre-defined position values to change an amount of flare in a zone of a component. The one of the pre-defined position values is associated with the zone of the component.

Abstract: Methods and Apparatus to increase the efficiency of roll-forming and leveling systems are described herein. An example strip material processing apparatus are described herein includes a first drive system to drive a first plurality of workrolls and a second drive system to drive a second plurality of workrolls. A controller provides a first command reference to the first drive system. The controller measures a first output parameter of the first drive system when the first drive system operates at the first command reference. The controller determines a second command reference based on the first output parameter and the controller drives the second drive system based on the second command reference.

Abstract: Methods and apparatus to monitor conditioning machines are disclosed herein. An example system includes a plurality of work rolls to process a strip material. A first sensor detects a first distance between an upper surface of the strip material and a first reference location and a second sensor detects a second distance between an upper surface of the strip material and a second reference location. A controller determines a difference value between the first distance and the second distance to detect material curvature of the strip material.

Abstract: Methods and apparatus for monitoring and conditioning strip material are disclosed. A disclosed example apparatus includes a plurality of sensors located along a width of a moving material. Each of the plurality of sensors corresponds to a respective one of a plurality of longitudinal zones located along a width of the moving material. The apparatus also includes a material condition monitor configured to determine the condition of the moving material, and a feedback unit coupled to the material condition monitor and configured to be coupled to a plurality of different types of material conditioners. The feedback unit is configured to map each of the plurality of sensors to at least a respective one of a plurality of adjustable backup bearings based on being coupled to any one of the material conditioners.

Abstract: Apparatus and methods to drive material conditioning machines are described. An example apparatus includes a first plurality of work rolls to process a strip material and a second plurality of work rolls to process the strip material. The example apparatus also includes a motor to drive the second plurality of work rolls. The motor is to apply a first rolling torque to the second plurality of work rolls that is different than a second rolling torque applied to the first plurality of work rolls.

Abstract: Methods and systems to drive rotary presses are described. In one described example, a rotary press system includes a first rotary press and a second rotary press adjacent to the first rotary press. The first and the second rotary presses are to receive a strip of material. A drive member is operatively coupled to the first and the second rotary presses and a motor coupled to the drive member rotates the drive member to cause the first and second rotary presses to process the strip material.

Abstract: Methods and apparatus for controlling a hem profile in roll-forming processes are described. An example roll-forming apparatus includes a first plurality of work rolls to form a first hem on a material and a second plurality of work rolls. One of the second plurality of work rolls is adjustable relative to an opposing work roll and to the first plurality of work rolls to adjustably control a profile of the first hem.

Abstract: Methods and apparatus for controlling flare in roll-forming processes are disclosed. An example method involves predefining a plurality of position values to adjust a tilt angle of a flange roller and adjusting the tilt angle of the flange roller based on one of the pre-defined position values to change an amount of flare in a zone of a component. The one of the pre-defined position values is associated with the zone of the component.