Abstract: An operator's console is used to produce, and control the storage of, bend data including: bend number, linear position, rotational position, bend angle and final bend number. The bend data is inserted either manually via a keyboard or by a reader reading a suitable data source (e.g., an optical reader reading punched cards). After all of the bend data is produced, checked and stored, the operator's console displays the first set of bend data. The operator then manually moves the tube, both linearly and rotationally, until the tube is suitably positioned. Encoders mounted so as to detect the rotational and linear position of the tube create related linear and rotational position displays during manual positioning. When the tube reaches the appropriate linear and rotational positions, linear and rotational brakes are actuated and lock the tube in position. When the tube is appropriately positioned (brakes locked), the encoder (actual tube position) displays correspond to the related memory displays.

Abstract: Pinch and pyramid roll forming machines for contouring elongate, tapered structural members are disclosed. Each of the rolls of the pinch and pyramid roll forming machines is segmented and selected segments are mounted such that they are transversely position adjustable with respect to their axis of rotation. The positions of the position controllable segments are controlled by power operated, transversely movable cages that surround a portion of these segments. In pinch roll forming machines, other, corresponding, selected segments of the pinch rolls are semi-floating and follow the movement of the position controllable segments. In both types of machines, the segmented roll arrangement results in the ability to control the roll profiles so that they match the cross-section of a tapered part as it is being contoured.

Abstract: A pinch and forming roll assembly for a numerically controlled contour forming machine wherein a piece of material (part) having a preformed cross-sectional configuration is moved through pinch rolls located in between right and left hand forming rolls is disclosed. Each forming roll is position adjustable both laterally and separationwise with respect to the pinch roll along two longitudinal axes. In addition, each forming roll is position adjustable along two rotational axes. Adjustment is provided by rotatably mounting each forming roll in a position adjustable yoke. The yokes are adapted to swivel about an axis running orthogonally through the centerline defined by the rotational axis of the relative forming roll. In addition, each yoke has a semi-spherical outer surface that is position adjustable. Further, each yoke is supported by a mechanism that allows it to be position adjusted along two orthogonal longitudinal axes.

Abstract: As a part to be contour formed passes through the rolls of a pyramid roll forming machine, the vertical position of the upper roll is continuously controlled. Specifically, upper roll position feedback signals are summed with position command signals and the resultant position error signals used to control hydraulic actuators. The hydraulic actuators, in turn, control the position of the upper roll. In an elongate pyramid roll forming machine (e.g. one designed to contour panels or plates) both ends of the upper roll are controlled such that the axis of the upper roll may be skewed with respect to the axes of the lower set of pyramid rolls, or lie parallel to the axes of the lower rolls. In such a machine the positions of the ends of the upper roll are continuously controllable as a part is being contour formed. In a narrow pyramid roll forming machine (e.g.

Abstract: A plurality of forming stations, each individually numerically controlled to sequentially roll form a blank into a tapered structural member, is disclosed. Each forming station includes upper and lower assemblies of forming rolls mounted on a pair of adjacent shafts so as to generally define an orifice through which the blank passes as it is roll formed. One of the shafts is continuously position adjustable, as are selected forming rolls of the forming roll assemblies. Thus, both the size and shape of the orifice are continuously adjustable. Position sensors continuously sense the positions of the position controllable shaft and forming rolls of each station and generate feedback signals related thereto. The feedback signals are continuously compared with numerical control signals received by a controller. The results of the comparisons produce error signals that are used to continuously control the position of the position controllable shafts and forming rolls.

Abstract: A sensing structure and control system therefor suitable for use in a numerically controlled roll forming machine are disclosed. The sensing structure includes a support arrangement for mounting a sensor in a position such that a work part exiting from contour forming rollers passes through the structure. The support arrangement is formed such that the sensor is free to move as exiting part contours change. As exiting part contours change, the change in position of the sensor varies the position of a rotary variable-differential transformer (RVDTs). The output from the RVDT is compared with signals related to the desired curvature of the part and the result of the comparison is used to modify the control signals applied to the numerically controlled contour forming machine to provide compensation for part springback. Further, a manual signal modifying mechanism is provided for inserting modifying signals also adapted to modify the control signals to compensate for part springback.