Sheet metal decoiling device and multi-coil decoiling system
A decoiling device for decoiling a coil of sheet material includes first and second support rollers on which to support a coil of sheet material. The first and second support rollers are oriented such that their rotation axes are parallel to a first direction. The decoiling device also includes a frame supports the first and second support rollers, a rotatable mandrel, and first and second guide members. The first and second guide members are positionable at first and second sides of the frame, respectively, so as to limit movement of the coil of sheet material in the first direction. Multiple such decoiling devices can be configured together with a support member that supports the multiple decoiling devices to provide a mobile multi-coil decoiling system that is transportable from one location to another.
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1. Field of the Invention
The present disclosure relates to metal building construction, and particularly to providing feed material for metal building construction equipment at a job site. The disclosure more particularly relates to a decoiling device for sheet metal and other feed material for metal building construction.
2. Background Information
In the metal building construction process, it is necessary to provide feed material for the crimping, roll-forming, and fastening operations that comprise metal building construction. Typically the feed material, such as sheet metal of varying gauges, is manufactured, shipped, and stored in large diameter coils. The coiled feed material must be decoiled before it is fed into any apparatus that will perform the aforementioned crimping, roll-forming, and fastening operations. A known example of a decoiling device to decoil a large steel coil for feeding the steel into a roll-forming machine or the like, hereinafter referred to as a forming machine, is an expanding mandrel type decoiling device. In the expanding mandrel decoiling device, a coil of feed material slides over a mandrel that expands to contact the inner diameter of the coil. The coil is supported by the mandrel, which includes a rotating shaft that supports the weight of the coil, so that the coil of material is unrolled or decoiled, and then fed into a roll-forming machine. Other devices such as a drum type decoiler are known, wherein the coiled feed material slides on a drum and is then fed into a roll-forming machine.
There are significant safety issues presented by the prior art decoiling devices. The most significant dangers result from the nature of the feed material, specifically sheet metal. When the sheet metal is manufactured and rolled into coils, the resilience of the sheet metal can cause the coils to unroll unless the coils are secured. To prevent undesired unrolling, sheet metal coils are generally wound tightly and secured with circumferential strip-metal bands to hold the coil of sheet material in place. When operating any decoiling device, and particularly a conventional expanding mandrel type decoiler, the operator must physically release the coil of steel by releasing the circumferential band or bands. Once such circumferential bands released, the coil can unravel very rapidly, thus creating a potential hazard for anyone nearby.
Another difficulty in working with coiled sheet metal is commonly called telescoping. Telescoping is the result of inner layers of the coiled material shifting axially slightly off center, so that one end of a layer extends beyond an end of the coil, while the opposite end of that layer recedes inside the coil. The stress produced by a single telescoped layer applies a similar axial displacing force on the adjacent layer, and the effect cascades through the layers producing the telescoping phenomenon. In its most extreme, the steel coil becomes telescoped in a manner such that the axis of the coil is so skewed from the axis of the inner telescoped layers, that the coil is functionally detached from the inner most layers. At this point the skew in the layers of the coil can render the coil unusable. The operator then must manually straighten the coils out before they can be fed into a roll-forming machine.
The difficulty of preventing and/or correcting the skewing or telescoping of coils can be exacerbated by stress conditions that the coiled material can acquire during storage. For example, when coiled steel is stored in a location where it is exposed to the elements, ambient temperature variations create stress in the material through thermal expansion and contraction of the material. Furthermore, oxidation can cause variations the thickness of individual layers of coiled sheet metal, thus creating more stress in the coiled sheet metal. These naturally-occurring stresses are naturally relieved by telescoping. In other words, telescoping is a naturally occurring and expected consequence of coiling sheet metal or other resilient sheet building material.
The present inventors have observed a need for a device that will simultaneously and safely accomplish the tasks of facilitating the safe removal of circumferential bands from coiled feed material and correcting/preventing the problem of coil telescoping, all within the same device as a decoiling mechanism.
SUMMARYIn order to overcome the above-mentioned shortcomings of the related art, it is an object of the present invention to provide a device for decoiling sheet metal or other building construction sheet feed material. It is a further object of the invention to provide a decoiling device for decoiling sheet material that overcomes the safety hazards associated with conventional decoiling. It is another object of the present invention to provide a decoiling device for decoiling sheet material that permits the safe removal of circumferential bands from the coiled material. It is another object of the present invention to provide a sheet material decoiling device that permits the safe correction of telescoped coils of sheet feed material for varying conditions of previously stored coiled material. It is another object of the present invention to provide a decoiling device configured to enhance safety by preventing a coil of sheet material from becoming unintentionally dislodged from the decoiling device. It is another object of the present invention to provide such advantages via the same decoiling device.
According to an exemplary embodiment, a decoiling device for decoiling a coil of sheet material is described. The decoiling device (also called a decoiler herein) comprises first and second support rollers on which to support a coil of sheet material. The first and second support rollers (e.g., comprising stainless steel roller surfaces) are oriented such that their rotation axes are parallel to a first direction. The decoiling device also comprises a frame that supports the first and second support rollers, a rotatable mandrel, and first and second guide members. The first and second guide members are positionable at first and second sides of the frame, respectively, so as to limit movement of the coil of sheet material in the first direction.
In an exemplary aspect, the first and second guide members can comprise first and second guide rollers (e.g., comprising stainless steel roller surfaces), respectively. In addition, each of the first and second guide rollers can be positioned midway between the first and second support rollers, wherein rotation axes of the first and second guide rollers are oriented in a vertical direction relative to a plane intersecting the rotation axes of the first and second support rollers.
In another exemplary aspect, the frame can be configured to allow displacement of the rotatable mandrel in a vertical direction relative to a horizontal plane intersecting the rotation axes of the first and second rollers. Also, the frame can be configured to substantially constrain displacement of the rotatable mandrel in a direction perpendicular to the vertical direction. In another exemplary aspect, the frame can comprise a retaining mechanism to prevent the mandrel from exceeding a maximum displacement in the vertical direction. In another exemplary aspect, the rotatable mandrel can be expandable. In another exemplary aspect, the decoiling device can comprise an adjustment mechanism that permits at least one of the first and second guide members to be moved in the first direction.
According to another exemplary embodiment, multiple decoiling devices can be supported together by a support member to provide a multi-coil decoiling system, which may comprise a mobile platform (e.g., a trailer or a truck) that includes the support member. In such a mobile multi-coil decoiling system, two, three, four, five or more coils could be provided on a single trailer or truck, for example (five coils is advantageous). Of course, any suitable number of decoilers could be used depending upon the weight and size considerations of both the coiled material and the trailer. According to another exemplary aspect, a mobile multi-coil decoiling system can feed sheet material from a given decoiling device into a forming machine, which may be located on a separate but adjacent facility (e.g., an adjacent trailer).
The exemplary decoiling device can remove and further prevent telescoping of the coil of sheet material by virtue of the guide members, which are preferably guide rollers, and which are positionable at sides of the coil. The guide rollers are positioned to limit movement of the coil in the first direction parallel to the rotation axes of the first and second support rollers. In particular, the guide rollers can be positioned so that both guide rollers contact opposing ends of the coil of sheet material to prevent telescoping. The prevention of telescoping not only avoids mechanical difficulty associated with feeding the sheet material to a forming machine or other apparatus, but also enhances safety to an operator. The location of the guide rollers midway between the first and second support rollers accommodates the diminishing radius of the coil of sheet material without the need for adjustment of the guide rollers during decoiling (because the rotation axes of the guide rollers are always oriented toward the rotation axis of the coil of sheet material regardless of how much sheet material has been decoiled). The exemplary decoiling device can be configured to permit the operator to control the positioning of either or both of the guide rollers either manually or with powered assistance. In a manual operation, the operator can simply rotate a hand wheel crank to position the guide rollers at sides of a coil of sheet material. A power-assisted, semiautomatic operation can be implemented by using electrical and/or hydraulic devices (e.g., motors and/or pistons) to position the guide rollers.
During normal operation of the exemplary decoiling device, the two support rollers, rather than the rotatable mandrel, support the weight of the coil of sheet material. The support rollers permit the coil rotate such that sheet material can be fed into a forming machine or other apparatus. The use of two support rollers and a frame configured to allow displacement of the rotatable mandrel in the vertical direction is advantageous because the device can thereby automatically accommodate the diminishing radius of the coil of sheet material as material is removed—as the coil radius becomes smaller, the coil naturally shifts downward in the vertical direction, and the rotatable mandrel shifts downward vertically with the coil.
The use of two support rollers also provides for straightforward loading of the coil into the decoiling device and straightforward operation of the decoiling device, and provides greater safety than if the weight of the coil were supported only by a rotatable mandrel. For example, the exemplary decoiling device can enhance safety in removing circumferential strip bands from coiled sheet material because the weight of the coil can keep the outer surface of sheet material firmly in contact with the support rollers, thereby preventing the coil from unraveling uncontrollably when the circumferential bands are cut. This configuration provides a very safe operation for the operator.
The retaining mechanism of the exemplary decoiling device, which prevents the rotatable mandrel from exceeding a maximum displacement in the vertical direction, in combination with the frame configuration that substantially constrains displacement of the rotatable mandrel in a direction perpendicular to the vertical direction, can enhance safety by preventing the coil from escaping the device should there be a malfunction with a forming machine, a mishap in transporting/positioning the decoiler device, or other type of accident The expandable, rotatable mandrel can expand within the inner diameter of the coil so as to contact firmly the inner surface of the core of the coil. If some occurrence (e.g., stresses within the coil) applies forces that would tend to impel the coil off the decoiling device, or if the coil becomes dislodged from the support rollers, the retaining device can restrain the movement of the rotatable mandrel within certain limits, thereby preventing the coil from becoming dislodged from the decoiling device. This retaining device is designed to handle the weight of the coil.
According to another aspect, the design of the decoiling device permits the operator to control the rotation of the coil of material so that it feeds into a forming machine or other apparatus, which can all be done with one hand from a location separated from the coil itself, for example, using a remote electrical control that controls decoiler drive motors.
The design of the exemplary decoiling device can permit safe and continuous operation even before the operator intervenes to correct any of the above-described problems that can occur with the decoiling device. The exemplary decoiling device can be used with building machines, which are known in the art for roll-forming self-supporting steel buildings. When the decoiling device is used with a building machine, such as a roll-forming machine, the decoiling device can provide both control and safety to a single operator while the coiled material is being fed into the building machine.
BRIEF DESCRIPTION OF THE DRAWINGS
Reference will now be made in detail of exemplary embodiments of the invention, as illustrated in the accompanying drawings. Whenever possible, similar reference numbers will be used throughout the drawings to refer to the same or like parts.
The first and second support rollers 34 and 35 can each comprise solid metal (e.g., stainless steel) shafts supported at each end by appropriate bearings 34A and 35A mounted to the frame 61. Alternatively, the support rollers 35 and 35 can each comprise a metal (e.g., stainless steel) cylinder that rides on a stationary metal shaft (e.g., stainless or hardened steel) via bearings between the support roller and its stationary metal shaft, wherein the stationary metal shaft can be rigidly attached to the frame 61. Moreover, each of the support rollers can comprise multiple, segmented rolling surfaces (e.g., multiple segmented cylinders) arranged end-to-end along the stationary metal shaft. Other variations will be apparent to those of ordinary skill in the art. As used herein a “roller” is intended to encompass any of various rolling cylinders, wheels, shafts, or other rolling mechanisms, whether segmented or continuous. Materials other than metals can be used for the roller surfaces of the support rollers such as, for example, hard rubber, plastics, polytetra-fluoroethylene (PTFE), and others, as will be appreciated by those of ordinary skill in the art.
In addition,
The coil of sheet material will rest on support rollers 34 and 35. Before the coil is rested, the rotatable mandrel 20 will be inserted into the coil. The rotatable mandrel 20 can comprise multiple (e.g., three) adjustable (expandable/contractable) portions such as, for example, scissor type mechanisms controlled by handle crank 24. The turning motion on the handle crank forces push tube 25 to exert pressure onto the scissor movement tube 19 which rides along a central arbor 20A. This action causes link bars 31 to move in a scissor action. The link bars are directly attached using a bolt and slot action to t-angles 21. Once the rotating force on the handle is applied, the motion will then cause the scissor mechanism to either extend or retract depending on the motion of the handle. The spring 18 is provided to keep pressure on the scissor mechanism to prevent unwanted movement when transporting this metal device from coil to coil and to make the use of the device easier. When the rotatable mandrel 20 is mounted inside the coil and placed on the decoiling device, the ends of the adjustable mandrel 20 protrude through the vertical openings 61A in the frame 61. The frame 61 is configured to substantially constrain displacement of the adjustable mandrel 20 in a direction perpendicular to the vertical direction to prevent the coil from jumping or dislodging from the decoiling device. In this regard, displacement of the adjustable mandrel can be substantially constrained by restricting the available lateral displacement of the mandrel to a distance equal to about four diameters of the central arbor 20A. This can be achieved, for example, by utilizing vertical openings (slots) 61A in the frame 61 that have a width of about four diameters of the central arbor 20A, or less.
Swing brackets 37 (shown in
In the example of
As shown in
In addition, one or both of the support rollers can be configured with manual drive portion 90 (shown in
Also shown in the example of
Also shown in
A locking handle 105 (friction mechanism) is used to release main sliding plate 101, which is connected to a slotted friction plate 103 via a movable bar 103A. The movable bar 103A extends through a slot in frame 61 and is connected to main sliding plate 101 via a hinge connection 103B. When the locking handle is turned ¼ turn, for example, frictional force from friction washer 106 is released from the friction plate 103. This allows sliding plate 101 to move transversely within the decoiler 1B along support rollers 34 and 35. As the sliding plate 101 moves inward, for example, the movable bar 103A swings at hinge 103B, and the locking handle 105 connected to an end of the movable bar 103A slides toward support roller 34. When the desired position of the sliding plate 101 is achieved such that the guide rollers 22 and 41 contact the coil, the locking handle 105 is then tightened. Friction washer 106 will apply frictional force between friction plate 103 and movable bar 103A and will maintain the position of main sliding plate 101. This adjustment mechanism allows the guide rollers 22 and 41 to contact the coil and apply pressure on the coil so as to prevent the coil from moving transversely and can thereby correct and/or prevent telescoping of the sheet material. An adjustable mandrel 20 such as previously described in this disclosure is also used with the exemplary decoiler 1B to prevent unwanted dislodging of the coil from the decoiling device.
As shown in
While this invention has been particularly described and illustrated with reference to exemplary embodiments thereof, it will be understood by those skilled in the art that changes in the above description or illustrations may be made with respect to form or detail without departing from the spirit or scope of the invention.
Claims
1. A device for decoiling a coil of sheet material, comprising:
- first and second support rollers on which to support a coil of sheet material, the first and second support rollers being oriented such that their rotation axes are parallel to a first direction;
- a frame that supports the first and second support rollers;
- a rotatable mandrel; and
- first and second guide members positionable at first and second sides of the frame, respectively, so as to limit movement of the coil of sheet material in the first direction.
2. The device according to claim 1, wherein the first and second guide members comprise first and second guide rollers, respectively.
3. The device according to claim 2, wherein each of the first and second guide rollers is positioned midway between the first and second support rollers, and wherein rotation axes of the first and second guide rollers are oriented in a vertical direction relative to a plane intersecting the rotation axes of the first and second support rollers.
4. The device of claim 1, wherein the frame is configured to allow displacement of the rotatable mandrel in a vertical direction relative to a plane intersecting the rotation axes of the first and second support rollers.
5. The device of claim 4, wherein the frame is configured to substantially constrain displacement of the rotatable mandrel in a direction perpendicular to the vertical direction.
6. The device of claim 4, wherein the frame comprises a retaining mechanism to prevent the rotatable mandrel from exceeding a maximum displacement in the vertical direction.
7. The device of claim 1, wherein the rotatable mandrel is expandable.
8. The device of claim 1, comprising an adjustment mechanism that permits at least one of the first and second guide members to be moved in the first direction.
9. The device of claim 1, wherein the rotatable mandrel comprises an arbor whose length is adjustable.
10. The device of claim 1, further comprising a motor configured to drive the first support roller via a drive mechanism coupled to the first support roller, wherein the drive mechanism includes a clutch mechanism.
11. A system for decoiling multiple coils of sheet material, comprising:
- multiple decoiling devices; and
- a support member that supports the multiple decoiling devices,
- wherein each decoiling device comprises:
- first and second support rollers on which to support a coil of sheet material, the first and second support rollers being oriented such that their rotation axes are parallel to a first direction;
- a frame that supports the first and second support rollers;
- a rotatable mandrel; and
- first and second guide members positionable at first and second sides of the frame, respectively, so as to limit movement of the coil of sheet material in the first direction.
12. The system of claim 11, comprising a mobile platform configured to be transportable from one location to another, wherein the mobile platform includes the support member.
13. The system of claim 12, wherein the mobile platform comprises a trailer or a truck.
14. The system according to claim 11, wherein the first and second guide members comprise first and second guide rollers, respectively.
15. The system according to claim 14, wherein each of the first and second guide rollers is positioned midway between the first and second support rollers, and wherein rotation axes of the first and second guide rollers are oriented in a vertical direction relative to a plane intersecting the rotation axes of the first and second support rollers.
16. The system of claim 11, wherein the frame is configured to allow displacement of the rotatable mandrel in a vertical direction relative to a plane intersecting the rotation axes of the first and second support rollers.
17. The device of claim 16, wherein the frame is configured to substantially constrain displacement of the rotatable mandrel in a direction perpendicular to the vertical direction.
18. The system of claim 16, wherein the frame comprises a retaining mechanism to prevent the rotatable mandrel from exceeding a maximum displacement in the vertical direction.
19. The system of claim 11, wherein the rotatable mandrel is expandable.
20. The system of claim 11, comprising an adjustment mechanism that permits at least one of the first and second guide members to be moved in the first direction.
Type: Application
Filed: Jan 23, 2006
Publication Date: Jul 26, 2007
Applicant: M.I.C. Industries, Inc. (Reston, VA)
Inventors: Frederick Morello (Johnstown, PA), Todd Anderson (Duncansville, PA)
Application Number: 11/336,822
International Classification: B65H 16/08 (20060101);