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: Methods and an apparatus for monitoring and conditioning strip material are disclosed. A disclosed example apparatus includes a plurality of sensors positioned across a width of a strip material, each of the plurality of sensors corresponding to a different one of a plurality of longitudinal zones along the width of the strip material. The example apparatus also includes a material condition monitor to determine a plurality of wave heights of the strip material based on information received from the plurality of sensors. Each of the wave heights corresponds to a respective one of the plurality of longitudinal zones. The material condition monitor is also to determine whether a measured portion of the strip material is substantially flat based on a comparison of each of the wave heights to a threshold value.

Abstract: Methods and apparatus of forming stiffening structures in a material are disclosed. In an example method, a first bend line is formed in the material and a portion of the material is drawn toward the first bend line to form an intermediate stiffening structure. A second bend line is then formed adjacent and parallel to the first bend line so that the intermediate stiffening structure is located between the first and second bend lines. A plurality of stiffening structures is then formed in the intermediate stiffening structure without substantially stretching the material.

Abstract: Methods and apparatus for controlling flare in roll-forming processes are disclosed. An example system includes a component position detector configured to detect a component. The example system also includes a comparator configured to compare a flare tolerance value and a flare measurement value of the component and a storage interface configured to retrieve a roller position value from a memory based on the comparison. In addition, the example system includes a flange roller adjuster communicatively coupled to the storage interface and the component position detector and configured to obtain the roller position value from the storage interface and change a position of a roller based on the roller position value to condition the component.

Abstract: Methods and an apparatus for monitoring and conditioning strip material are disclosed. The disclosed methods and apparatus receive encoder signals and sensor data to monitor a condition of a strip material. The system obtains a plurality of sensor readings associated with the condition of the strip material, converts the readings into a dimensional profile, and outputs a visual display of the dimensional profile. If an undesired material condition is detected, a material conditioner is adjusted to achieve a desired material condition. Each time the strip material passes a sensor, data associated with the strip material is recorded. The dimensional profile is additionally shown to an operator to facilitate the input of commands by the operator used to urge the material toward a desired profile.

Abstract: Methods and systems are disclosed to optimize punching instructions. An example method disclosed herein obtains a tool bed layout, the tool bed including a description of a plurality of tool punch parts, each tool punch part further including tool definition information; obtains a component layout, the component including a description of a component having at least one feature requiring a punching operation; validates the component layout; advances the component to a position of optimum depth; determines a hit score at the position of optimum depth; and repeats the component advancing and the hit score determination until all of the at least one feature of the component is assigned to a tool punch part.

Abstract: Methods and an apparatus for monitoring and conditioning strip material are disclosed. The disclosed methods and apparatus receive encoder signals and sensor data to monitor a condition of a strip material. If an undesired material condition is detected, a material conditioner is adjusted to achieve a desired material condition. Each time a sheet is cut, flatness data associated with that sheet is recorded. Each time a bundle is finished, certification data associated with that bundle is printed.

Abstract: Methods and apparatus for controlling flare in roll-forming processes are disclosed. An example system includes a component position detector configured to detect a component. The example system also includes a comparator configured to compare a flare tolerance value and a flare measurement value of the component and a storage interface configured to retrieve a roller position value from a memory based on the comparison. In addition, the example system includes a flange roller adjuster communicatively coupled to the storage interface and the component position detector and configured to obtain the roller position value from the storage interface and change a position of a roller based on the roller position value to condition the component.

Abstract: Methods and apparatus for controlling flare in roll-forming processes are disclosed. An example method of controlling flare involes moving a material through a roll-forming process and measuring the material to obtain a flare characteristic associated with a zone of the material. A position of a roller is then automatically varied to change the flare characteristic associated with a zone of the material as the material moves through the roll-forming process.

Abstract: A roll-forming apparatus is provided with a plurality of roll-forming stations adapted to facilitate the formation of either a C-shaped component or a Z-shaped component from a sheet of material. The roll-forming stations have forming rolls that make contact with the sheet of material and a pair of telescoping arbor assemblies that support the forming rolls so that the lateral distance between the forming rolls may be adjusted. The roll-forming apparatus has a number of movable forming rolls and a number of fixed forming rolls having two different forming surfaces to facilitate the formation of both C-shaped and Z-shaped components.

Abstract: A roll-forming apparatus is provided with a plurality of roll-forming stations adapted to facilitate the formation of either a C-shaped component or a Z-shaped component from a sheet of material. The roll-forming stations have forming rolls that make contact with the sheet of material and a pair of telescoping arbor assemblies that support the forming rolls so that the lateral distance between the forming rolls may be adjusted. The roll-forming apparatus has a number of movable forming rolls and a number of fixed forming rolls having two different forming surfaces to facilitate the formation of both C-shaped and Z-shaped components.

Abstract: A roll-forming apparatus is provided with a plurality of roll-forming stations adapted to facilitate the formation of either a C-shaped component or a Z-shaped component from a sheet of material. The roll-forming stations have forming rolls that make contact with the sheet of material and a pair of telescoping arbor assemblies that support the forming rolls so that the lateral distance between the forming rolls may be adjusted. The roll-forming apparatus has a number of movable forming rolls and a number of fixed forming rolls having two different forming surfaces to facilitate the formation of both C-shaped and Z-shaped components.

Abstract: A roll-forming machine is provided with a base structure, a plurality of first roll-forming stations that form a first component having a Z-shaped cross section, and a plurality of second roll-forming stations that form a second component having a C-shaped cross section. At least one of the roll-forming stations has a pair of rotatable arbors adapted to support a plurality of forming rolls and a pair of support structures adapted to support a plurality of bearing assemblies. The roll-forming station also includes a pair of adjustment mechanisms that allow the position of some of the bearing assemblies to be adjusted and a pair of compression assemblies that exert a force upon some of the bearing assemblies when the bearing assemblies are moved away from an initial position.

Abstract: A device for justifying an end of a section released from a drop stacking machine. A capture member for engaging an end of the section is slidably mounted to a frame and is shiftable between an extended capture position wherein the capture member is position to engage the end of the section to be dropped from the stacking machine and a retracted position. An end stop having a justifying surface is mounted to the frame. An actuator connected to the capture member shifts the capture member between the extended capture position and the retracted position, and in the process brings the section end into contact with the justifying surface. A control system having a sensor is provided for detecting the presence of a section waiting to be dropped from the stacker and in response thereto activating the actuator. Accordingly, when a section is dropped from the stacking machine the section end is captured by the capture member.

Abstract: A roll-forming apparatus of the type used to transform a flat web or sheet of metal into a component having various cross-sectional shapes is provided with a first elongate base portion with an axis extending in a longitudinal direction, a second elongate base portion with an axis disposed generally parallel to the longitudinal direction of the axis of the first base portion, and a drive mechanism associated with the first and second base portions, the drive mechanism having a coupler associated with the first base portion, a raft plate supported by the first base portion, and a plurality of roll-forming stations supported by the raft plate.

Abstract: A roll-forming apparatus of the type used to form components, such as purlins, having C-shaped and/or Z-shaped cross-sections from sheets of planar material is provided with a plurality of roll-forming stations adapted to form first and second components each of which has a C-shaped cross section with a center portion and a pair of legs connected to the center portion, where the legs of the first component have a first length and the legs of the second component have a second length different than the first length. The roll-forming stations include a first roll-forming station having a plurality of forming rolls and a second roll-forming station for forming the legs of the first and second components.

Abstract: A roll-forming apparatus of the type used to form components, such as purlins, having C-shaped and/or Z-shaped cross-sections from sheets of planar material is provided with a plurality of roll-forming stations adapted to form first and second components each of which has a C-shaped cross section with a center portion and a pair of legs connected to the center portion, where the legs of the first component have a first length and the legs of the second component have a second length different than the first length. The roll-forming stations include a first roll-forming station having a plurality of forming rolls and a second roll-forming station for forming the legs of the first and second components.

Abstract: A roll former line for forming different shapes including a first roll stand attached to a bed which provides vertical adjustable movement. The roll stand includes three spindles in vertical alignment with each other, the forming rolls on the top and bottom spindles working against opposite sides of the middle forming roll, so as to provide reverse shapes between the top and middle forming roll and the middle and bottom forming roll. Linear actuators are connected to the bed of the first roll stand for moving the first roll stand vertically on the bed. Opposite the first roll stand on the line is a second roll stand attached to a second bed including two spindles in vertical alignment and corresponding forming rolls thereon. The first roll stand can be raised or lowered by the linear actuators so as to use reverse forming rolls on the first roll stand in conjunction with the forming rolls on the second roll stand to form a reverse shape on one edge of the sheet being formed.

Abstract: The invention is a method of and apparatus for removing camber from MULT strips by passing the MULT strip through a rolling mill having rolls with contacting surfaces vertically adjustable and positioned to reduce the thickness of the MULT strip from its short edge in reduced amounts thereacross to the opposite edge, so as to eliminate or reduce camber in the MULT strip prior to passing the strip through a roll-forming and punching line.

Abstract: A raft assembly in the roll forming art having a plurality of forming roll stands including a combined horizontal raft plate and first vertical stand formed together in an L-shaped single cast. The first vertical stand supports multiple station pairs of spindles at one end thereof and a plurality of second vertical stands each of which supports the opposite ends of a said pair of spindles on a single roll stand and bolts for attaching the second vertical stands to the raft plate oppositely positioned from said first vertical stand.