Roll-Forming Machine Having Changeover Mechanism

Abstract

A roll-forming machine for manufacturing purlins from strip material comprises a setup changeover mechanism for converting between a setup that produces purlins having a C-shaped cross-sectional configuration and a setup that produces purlins having a Z-shaped cross-sectional configuration. The changeover mechanism includes an inboard linear actuator connected by an inboard linkage to a plurality of turrets associated with inboard sides of respective roll-forming stations, and an outboard linear actuator connected by an outboard linkage to a plurality of turrets associated with outboard sides of respective roll-forming stations, whereby the turrets are pivotally indexed by operation of the linear actuators to change position of forming rollers carried by the turrets. At least one of the linear actuators is connected to turrets both upstream and downstream from the linear actuator in a feed direction of the roll-forming machine. The linear actuators are driven by a shared control system whereby changeover of both the inboard and outboard sides of the roll-forming machine may be carried out simultaneously by inputting a single changeover command.

Description

FIELD OF THE INVENTION

The present invention relates generally to roll-forming machines through which a flat strip of stock material is fed to progressively bend the strip to provide the strip with a desired cross-sectional configuration, and more particularly to a changeover mechanism for changing the setup of a roll-forming machine to selectively provide different cross-sectional configurations.

BACKGROUND OF THE INVENTION

Roll-forming machines are commonly used to manufacture metal “purlins” and other elongated members used for roofing and siding in the construction industry. Purlins are typically made to have either a C-shaped cross-sectional configuration as shown in FIG. 1A or a Z-shaped cross-sectional configuration as shown in FIG. 1B. Common terminology associated with the C and Z purlin configurations is indicated in FIGS. 1A and 1B.

Roll-forming machines for manufacturing purlins are known to comprise a plurality of roll-forming stations arranged in succession along a material feed direction. The roll-forming stations include drive rollers powered by a motor for frictionally conveying a strip of material in the feed direction, and forming rollers positioned for engaging the strip as it passes through the roll-forming station to bend the strip. The roll-forming stations are said to have an “inboard” side on which the drive motor is located, and an opposite “outboard” side laterally spaced from the inboard side, such that the strip of material passes between the inboard and outboard sides as it travels in the feed direction through the roll-forming machine.

In order to change the setup of a roll-forming machine from a C-configuration setup to a Z-configuration setup, or vice versa, the positions and/or axes of rotation of the forming rollers must be changed. As may be understood by reference to FIGS. 1A and 1B, the lip bend and leg bend on one side of the strip are formed in an opposite direction in the C-configuration versus the Z-configuration. Thus, forming rollers on one side of the roll-forming machine are disposed differently in a C-configuration setup as compared to a Z-configuration setup. Also, because the lip bends in a C-shaped purlin are at a greater angle than those of a Z-shaped purlin, forming rollers on both sides of certain roll-forming stations are disposed differently in C-configuration setup versus a Z-configuration setup.

Changing over the setup of a roll-forming machine to produce a different cross-sectional configuration in a workpiece traditionally involved manually changing the forming rollers and/or their positions on the roll-forming stations, an operation that in many cases required several hours to complete. Various approaches to reducing changeover time have been proposed, as evidenced by U.S. Pat. Nos. 4,724,695; 4,787,232; 4,974,435; 5,829,294; 6,000,266; 6,148,654; and 6,216,514.

Among these, U.S. Pat. No. 4,974,435 discloses the use of a turret pivotally mounted on a support stand of a roll-forming station and carrying a plurality of forming rolls, whereby the turret may be manually pivoted and locked by an insertable pin in a selected rotational position to locate a selected forming roll in a functional position for engaging a strip of material to be formed. U.S. Pat. Nos. 4,787,232 and 6,216,514 describe the use of a pivotable turret having a single forming roll thereon which is repositioned from one functional position to another functional position by pivoting the turret. In the former patent (the '232 patent), the turret is pivoted manually and locked in place by an insertable pin. In the latter patent (the '514 patent), the turret is pivoted by a linear actuator mounted vertically on the stand with a distal end of the actuator plunger being coupled to the turret at a location spaced from the pivot axis of the turret, whereby full extension of the plunger corresponds to one position of the forming roll and full retraction of the plunger corresponds to another position of the forming roll.

U.S. Pat. No. 5,829,294 discloses a split-level roll-forming machine having a vertically movable support wherein changeover is effected by operating vertically extendable linear actuators to move the support up or down relative to an opposite support.

U.S. Pat. No. 6,148,654 teaches the use of a single forming roller eccentrically mounted on a rotatable knuckle support, wherein the knuckle support is connected to a worm gear driven by a worm shaft that also drives other worm gears connected to other knuckle supports of other roll-forming stations.

SUMMARY OF THE INVENTION

The present invention is directed to a roll-forming machine having a mechanism by which setup may be changed over between a C-configuration setup for manufacturing purlins having a generally C-shaped cross-sectional configuration and a Z-configuration setup for manufacturing purlins having a generally Z-shaped cross-sectional configuration. In accordance with an embodiment of the present invention, a roll-forming machine for bending a strip of material as the strip travels in a feed direction through the roll-forming machine generally comprises a plurality of roll-forming stations arranged in succession along the feed direction. At least one of the roll-forming stations includes a turret carrying a C-configuration forming roller and a Z-configuration forming roller, wherein the turret is pivotable about a turret axis to selectively locate either the C-configuration forming roller or the Z-configuration forming roller for engagement with a strip of material passing through the roll-forming station. A linear actuator is operatively connected to the turret by a linkage, whereby the linear actuator is operable for pivoting the turret to selectively locate the C-configuration roller or the Z-configuration roller for engagement with a passing strip of material.

In accordance with another aspect of the present invention, at least one of the roll-forming stations (an upstream station) includes an upstream-station turret having a C-configuration forming roller and a Z-configuration forming roller, at least one other subsequent roll-forming station (a downstream station) includes a downstream-station turret also having a C-configuration forming roller and a Z-configuration forming roller, and both turrets are connected by a linkage to the same linear actuator whereby the turrets may be pivoted simultaneously to selectively locate both of the C-configuration rollers or both of the Z-configuration rollers for engagement with a passing strip of material.

In accordance with another aspect of the present invention, the roll-forming machine may have a pair of linear actuators, one on an inboard side of the machine and one on an outboard side of the machine, each linear actuator being connected by an associated linkage to a plurality of inboard turrets or a plurality of outboard turrets, as the case may be. The inboard and outboard linear actuators may be connected to a single control system, whereby turrets on both sides of the roll-forming machine may be pivoted to changeover the setup.

The invention extends to a changeover method generally comprising the steps of operating an inboard linear actuator linked to a plurality of inboard turrets to pivot the plurality of inboard turrets from a first index setting to a second index setting; and operating an outboard linear actuator linked to a plurality of outboard turrets to pivot the plurality of outboard turrets from a first index setting to a second index setting.

BRIEF DESCRIPTION OF THE DRAWINGS

The nature and mode of operation of the present invention will now be more fully described in the following detailed description of the invention taken with the accompanying drawing figures, in which:

FIG. 1A is a cross-sectional view of a roll-formed member having a C-shaped cross-sectional configuration;

FIG. 1B is a cross-sectional view of a roll-formed member having a Z-shaped cross-sectional configuration;

FIG. 2 is a top plan view of a roll-forming machine formed in accordance with an embodiment of the present invention;

FIG. 3 is a sectional view taken generally along the line A-A in FIG. 2 showing an inboard side of the roll-forming machine;

FIG. 4 is a sectional view taken generally along the line B-B in FIG. 2 showing an outboard side of the roll-forming machine;

FIG. 5 is a perspective view showing forming roller portions of the first four inboard roll-forming stations of the roll-forming machine, in a C-configuration setup;

FIG. 6 is a view similar to that of FIG. 5, however the forming roller portions are shown in a Z-configuration setup;

FIG. 7 is a perspective view showing idler portions of the first eight outboard roll-forming stations of the roll-forming machine, in a C-configuration setup;

FIG. 8 is a view similar to that of FIG. 7, however the forming roller portions are shown in a Z-configuration setup;

FIG. 9 is a schematic diagram showing a control arrangement for a setup changeover mechanism of the roll-forming machine;

FIG. 10 is a detailed perspective view of a coupler for connecting upstream and downstream links of the changeover mechanism of the roll-forming machine;

FIG. 11 is a detailed side elevational view of the coupler shown in FIG. 10;

FIG. 12 is a rear elevational view showing a strip of sheet material as it emerges from a first roll-forming station of the roll-forming machine, wherein the first roll-forming station is in a C-configuration setup;

FIG. 13 is a view similar to that of FIG. 12, however the first roll-forming station is shown in a Z-configuration setup;

FIG. 14 is a rear elevational view facing showing a strip of sheet material as it emerges from a second roll-forming station of the roll-forming machine, wherein the second roll-forming station is in a C-configuration setup;

FIG. 15 is a view similar to that of FIG. 14, however the second roll-forming station is shown in a Z-configuration setup;

FIG. 16 is a rear elevational view facing showing a strip of sheet material as it emerges from a seventh roll-forming station of the roll-forming machine, wherein the seventh roll-forming station is in a C-configuration setup;

FIG. 17 is a view similar to that of FIG. 16, however the seventh roll-forming station is shown in a Z-configuration setup;

FIG. 18 is a rear elevational view showing a strip of sheet material as it emerges from the ninth roll-forming station of the roll-forming machine, wherein the ninth roll-forming station is in a C-configuration setup;

FIG. 19 is a view similar to that of FIG. 18, however the ninth roll-forming station is shown in a Z-configuration setup;

FIG. 20 is a rear elevational view showing a strip of sheet material as it emerges from a thirteenth roll-forming station of the roll-forming machine, wherein the thirteenth roll-forming station is in a C-configuration setup; and

FIG. 21 is a view similar to that of FIG. 20, however the thirteenth roll-forming station is shown in a Z-configuration setup.

DETAILED DESCRIPTION OF THE INVENTION

A roll-forming machine formed in accordance with an embodiment of the present invention is shown in top plan view in FIG. 2 and identified generally by reference numeral 10. FIGS. 3 and 4 depict roll-forming machine 10 in sectional views showing an inboard side (FIG. 3) and an outboard side (FIG. 4) as viewed along a material strip centerline defined by the machine. Roll-forming machine 10 comprises a loading station 12 for receiving a flat strip 8 of bendable material, followed by a plurality of roll-forming stations arranged in succession along a feed direction (left to right in FIGS. 2 and 3, and right to left in FIG. 4) along which strip 8 is driven and progressively formed to provide a desired cross-sectional shape. In the drawing figures, a first roll-forming station 14 has an inboard side 14A and an outboard side 14B; a second roll-forming station 16 has an inboard side 16A and an outboard side 16B; a third roll-forming station 18 has an inboard side 18A and an outboard side 18B; and a fourth roll-forming station 20 has an inboard side 20A and an outboard side 20B. In the present embodiment, the first four roll-forming stations form the lip bends to approximately 90° degrees in a C-shaped purlin, and to approximately 45° in a Z-shaped purlin.

Continuing in the feed direction, a fifth roll-forming station 22 includes an inboard side 22A and an outboard side 22B; a sixth roll-forming station 24 includes an inboard side 24A and an outboard side 24B; a seventh roll-forming station 26 includes an inboard side 26A and an outboard side 26B; and an eighth roll-forming station 28 includes an inboard side 28A and an outboard side 28B. At the fifth roll-forming station 22 (“pass five”), formation of the leg bends begins. Further progression and completion of the leg bends occurs as strip 8 travels through the sixth through thirteenth roll-forming stations. By way of illustration, pass seven is shown in FIGS. 16 and 17, pass nine is shown in FIGS. 18 and 19, and pass thirteen is shown in FIGS. 20 and 21.

Inboard-outboard side pair 30A, 30B forms a ninth roll-forming station 30; pair 32A, 32B forms a tenth roll-forming station 32; pair 34A, 34B forms an eleventh roll-forming station 34; pair 36A, 36B forms a twelfth roll-forming station 36, and pair 38A, 38B forms a thirteenth roll-forming station 38. Numerals 39 and 40 identify non-forming stations of machine 10. Station 39 provides a straightening pass to remove twist, bow, camber, and/or flaring developed over the length of strip 8 during forming. Finally, station 40 is a drive-out or discharge station that forces strip 8 out of roll-forming machine 10, typically onto a material conveyor positioned adjacent thereto. Other non-forming stations (not numbered) may be interspersed between forming stations to provide drive passes to force strip 8 through the machine.

The inboard sides 14A, 16A, 18A, and 20A of the first through fourth roll-forming stations (which form the lip bends) are mounted on an upstream inboard raft 11A, and their outboard counterparts 14B, 16B, 18B, and 20B are mounted on an upstream outboard raft 11B. Likewise, the inboard sides 22A, 24A, 26A, 28A, 30A, 32A, 34A, 36A, and 38A of the fifth through thirteenth roll-forming stations (which form the leg bends) are mounted on a downstream inboard raft 11C, and their outboard counterparts 22B, 24B, 26B, 28B, 30B, 32B, 34B, 36B, and 38B are mounted on a downstream outboard raft 11D. In order to adjust the web width and accommodate different strip widths, the lateral spacing between upstream rafts 11A and 11B is settable independently of the lateral spacing between downstream rafts 11C and 11D, as is known in the art of roll-forming machines.

As used herein, the terms “upstream” and “downstream” relate to the feed direction, and a first element is said to be upstream relative to a second element if the first element comes before the second element along the feed direction. Conversely, a first element is said to be downstream from a second element if the first element comes after the second element along the feed direction.

Reference is now made to FIGS. 5 through 8, which show the inboard and outboard sides of the first through fourth roll-forming stations, without the drive rollers and drive roller shafts for sake of clarity. FIGS. 7 and 8 further show the outboard sides of the fifth through eighth roll-forming stations, also without drive rollers and drive roller shafts. The inboard side 14A of the first-roll forming station includes an upstanding support 50A mounted on inboard raft 11A, and a forming roller 51 fixedly mounted on support 50A to rotate about a roller axis. In the embodiment shown, forming roller 51 is a tapered forming roller having a roller axis that extends in a lateral direction perpendicular to the material feed direction. The outboard side 14B of the first roll-forming station includes an upstanding support 50B carried on outboard raft 11B, and a turret 54 arranged adjacent support 50B. As may be seen in FIG. 12, a transversely extending drive roller shaft 60 is rotatably supported in rotary bearings supported by supports 50A and 50B, and turret 54 is mounted on an annular bearing cover 53 protecting the outboard rotary bearing, such that turret 54 is rotatable about a laterally extending turret axis 55 coinciding with the axis of drive roller shaft 60, and turret 54 is rotatable independently of drive roller shaft 60 (other turrets of roll-forming machine 10 may be mounted in similar fashion). Turret 54 includes a C-configuration roller 56 and a Z-configuration roller 58 at angularly spaced indices about turret axis 55. As used herein, “C-configuration index” refers to the angular position on a turret at which a roller or other tool, or blank space (no tool), is provided for helping to form a C-shaped cross-sectional configuration in a passing strip of material. Similarly, “Z-configuration index” refers to the angular position on a turret at which a roller or other tool, or blank space (no tool), is provided for helping to form a Z-shaped cross-sectional configuration in a passing strip of material. Thus, C-configuration roller 56 is placed at a C-configuration index of turret 54, and Z-configuration roller is placed at a Z-configuration index of turret 54. As will be apparent from reference to FIGS. 7 and 12, when turret 54 is pivoted to locate its C-configuration index at a functioning position with respect to strip 8, C-configuration roller 56 engages an outboard portion of the strip while roller 51 engages an inboard portion of the strip to begin forming a pair of upward lip bends in the strip. However, when turret 54 is pivoted about turret axis 55 to locate its Z-configuration index at a functioning position with respect to strip 8, as shown in FIGS. 8 and 13, then Z-configuration roller 58 engages an outboard portion of the strip to begin forming a downward lip bend on one side of the strip while roller 51 begins forming an upward lip bend on the opposite side of the strip. Rollers 56 and 58 may be tapered rollers having roller axes that extend in a lateral direction perpendicular to the material feed direction and parallel to the turret axis 55.

The second roll-forming station includes inboard and outboard upstanding supports 70A and 70B respectively mounted on rafts 11A and 11B. A forming roller 71 is mounted on inboard support 70A to rotate about a roller axis. In the illustrated embodiment, forming roller 71 is a cylindrical forming roller having a roller axis that extends at an inclined angle relative to horizontal in a plane normal to the feed direction. A turret 74 associated with outboard support 70B is rotatable about a laterally extending turret axis. Turret 74 of the second roll-forming station includes a C-configuration roller 76 and a Z-configuration roller 78 at angularly spaced indices about the turret axis of turret 74. When turret 74 is pivoted to locate its C-configuration index at a functioning position with respect to strip 8, as shown in FIGS. 7 and 14, C-configuration roller 76 engages the outboard lip begun by the first roll-forming station and progresses the upward lip bend while roller 71 engages the inboard lip for the same purpose. When turret 74 is pivoted to locate its Z-configuration index at a functioning position with respect to strip 8, as shown in FIGS. 8 and 15, then Z-configuration roller 78 engages the outboard lip begun by the first roll-forming station and progresses the downward lip bend while roller 71 engages the inboard lip and progresses the upward lip bend.

The third roll-forming station, like the first two stations, has a pair of upstanding supports 90A and 90B arranged opposite one another on rafts 11A and 11B. However, the third roll-forming station differs in that both the inboard side 18A and the outboard side 18B have a turret associated therewith. As may be seen in FIG. 5, an inboard turret 93 adjacent support 90A carries a C-configuration roller 95 and a Z-configuration roller 97. C-configuration roller 95 continues the inboard lip bend toward its target angle of 90°, while Z-configuration roller 97 completes the 45° lip bend commonly provided in purlins having a Z-shaped cross-section, as shown in FIG. 1B. Similarly, outboard side 18B includes a turret 94 adjacent support 90B that carries a C-configuration roller 96 for advancing the upward lip bend toward 90° for a C-shaped purlin and a Z-configuration roller 98 for completing the downward lip bend to 45° for a Z-shaped purlin. In some cases, a Z-shaped purlin having 50° lip bends may be desired. To allow for this, the Z-configuration roller 98 may be mounted by an offset keyway enabling adjustment of the lip bend angle. The axes of opposing C-configuration rollers 95 and 96 are mirror images of one another at an angle inclined from horizontal when viewed along the feed direction, while the axes of opposing Z-configuration rollers 97 and 98 are parallel to one another at the same angle from horizontal as the C-configuration roller axes when viewed along the feed direction.

The fourth roll-forming station includes a pair of upstanding supports 110A and 110B arranged opposite one another on rafts 11A and 11B. An inboard turret 113 adjacent support 110A carries a C-configuration roller 115 and an empty or blank space at its Z-configuration index. Likewise, an outboard turret 114 adjacent support 110B carries a C-configuration roller 116 and an empty or blank space at its Z-configuration index. As may be recalled, the lip bends in a C-shaped purlin (FIG. 1A) are formed to 90°, while the lip bends in a Z-shaped purlin are formed to 45° or 50°, thus explaining why the Z-configuration indices of turrets 113 and 114 are without tooling while the C-configuration indices have rollers. The C-configuration rollers 115 and 116 may be cylindrical rollers having vertical axes of rotation.

The outboard sides of the fifth through eighth roll-forming stations include respective turrets each carrying a C-configuration roller and a Z-configuration roller. Specifically, fifth station outboard side 22B includes a turret 134 adjacent an upstanding support 130B for carrying a C-configuration roller 136 and a Z-configuration roller 138; sixth station outboard side 24B includes a turret 154 adjacent an upstanding support 150B for carrying a C-configuration roller 156 and a Z-configuration roller 158; seventh station outboard side 26B includes a turret 174 adjacent an upstanding support 170B for carrying a C-configuration roller 176 and a Z-configuration roller 178; and eighth station outboard side 28B includes a turret 194 adjacent an upstanding support 190B for carrying a C-configuration roller 196 and a Z-configuration roller 198. In the embodiment shown, the outboard forming rollers of the fifth through seventh stations are tapered rollers having respective roller axes that extend in a lateral direction perpendicular to the material feed direction and parallel to their associated turret axis, wherein the taper angles are increased with each successive station. The outboard forming rollers 196 and 198 of the eighth station may be cylindrical rollers.

In similar fashion, the outboard sides 30B, 32B, 34B, 36B, and 38B of the ninth through thirteenth roll-forming stations include associated turrets each carrying a C-configuration roller and a Z-configuration roller. For example, the ninth roll-forming station shown in FIGS. 18 and 19 includes opposite inboard and outboard supports 210A and 210B, and a turret 214 adjacent outboard support 210B for carrying a C-configuration roller 216 and a Z-configuration roller 218. Also for example, the thirteenth roll-forming station shown in FIGS. 20 and 21 includes opposite inboard and outboard supports 290A and 290B, and a turret 294 adjacent outboard support 290B for carrying a C-configuration roller 296 and a Z-configuration roller 298.

In accordance with the present invention, the setup of roll-forming machine 10 can be changed from C-configuration setting to a Z-configuration setting, and vice versa, by operation of a changeover system that functions to pivot the turrets of the various roll-forming stations. The changeover system generally comprises an inboard linear actuator 41A for pivoting the inboard turrets and an outboard linear actuator 41B for pivoting the outboard turrets. As shown schematically in FIG. 9, the linear actuators 41A and 41B may be connected to a control system 42 having an input device and drive electronics by which an operator may enter a changeover command to the control system and the changeover command is converted to respective drive signals transmitted to linear actuators 41A and 41B. The use of a shared control system 42 for driving both actuators 41A, 41B enables an operator to change the setup configuration of roll-forming machine 10 by inputting a single changeover command to the control system, and it provides for simultaneous changeover of both the inboard and outboard sides of roll-forming machine 10.

Linear actuators 41A and 41B are each connected by respective linkages to associated turrets. Inboard linear actuator 41A is connected to inboard turrets 93 and 113, and outboard linear actuator 41B is connected to outboard turrets 54, 74, 94, 114, 134, 154, 174, 194, 214, 234, 254, 274, and 294. The inboard linkage is depicted as including a primary link 43A having a proximal end joined to a distal end of linear actuator 41A, and a distal end joined to an attachment block 44. The inboard linkage further includes an upstream connection link 45A fixed to attachment block 44 and connected to turrets 93 and 113 located upstream from linear actuator 41A on the third and fourth roll-forming stations. In the present embodiment, connection link 45A includes a plurality of link pins 46 pivotally joining connection link 45A with each turret to which the connection link is connected. As may be understood, when linear actuator 41A is extended as shown in FIG. 5, turrets 93 and 113 are pivoted so as to locate the C-configuration indices in their functioning positions, while the Z-configuration indices of turrets 93 and 113 are moved out of the way to respective non-functioning positions. Consequently, in FIG. 5, C-configuration rollers 95 and 115 are positioned to engage a passing strip 8, while Z-configuration roller 97 is not.

Reference is now made to FIG. 6, which illustrates changeover of the inboard sides of the first four roll-forming stations to a Z-configuration setup by retraction of linear actuator 41A. The linear actuator 41A pulls primary link 43A in the feed direction as the linear actuator is retracted, and the motion is transmitted through attachment block 44 to upstream connection link 45A. As link 45A is moved in the feed direction, link pins 46 engage turrets 93 and 113 to pivot the turrets, thereby locating the Z-configuration indices in their functioning positions, while the C-configuration indices of turrets 93 and 113 are moved out of the way to respective non-functioning positions. As a result, in FIG. 6, Z-configuration roller 97 on turret 93 is positioned to engage a passing strip 8 and the blank Z-configuration index on turret 113 is positioned to avoid further bending of the lip bend, while C-configuration rollers 95 and 115 are moved out of the way of the passing strip.

FIG. 7 shows the outboard sides of the first eight roll-forming stations in a C-configuration setup, with outboard linear actuator 41B retracted. The outboard linkage includes a primary link 43B having a proximal end joined to a distal end of outboard linear actuator 41B, and a distal end joined to an attachment block 44. The outboard linkage further includes a downstream connection link 47 fixed to attachment block 44 and an upstream connection link 45B coupled for movement with downstream connection link 47 by a coupler 48. Downstream connection link 47 is connected by link pins 46 to outboard turrets 134 (fifth station), 154 (sixth station), 174 (seventh station), 194 (eighth station), 214 (ninth station), 234 (tenth station), 254 (eleventh station), 274 (twelfth station), and 294 (thirteenth station) located downstream from linear actuator 41B (only the fifth through eighth roll-forming stations being shown in FIG. 7). Upstream connection link 45B is connected by link pins 46 to outboard turrets 54, 74, 94, and 114 located upstream from outboard linear actuator 41B on the first through fourth roll-forming stations. Accordingly, when linear actuator 41B is retracted as shown in FIG. 7, all outboard turrets are pivoted so as to locate the C-configuration indices in their functioning positions, while the Z-configuration indices of the outboard turrets are moved out of the way to respective non-functioning positions. Consequently, in FIG. 7, C-configuration rollers 56, 76, 96, 116, 136, 156, 176, and 196, as well as C-configuration rollers and tooling on outboard turrets of the ninth through thirteenth roll-forming stations, are positioned to engage a passing strip 8, while Z-configuration rollers 58, 78, 98, 118, 138, 158, 178, and 198, as well as Z-configuration rollers and tooling on outboard turrets of the ninth through thirteenth roll-forming stations, are located out of the way.

Reference is now made to FIG. 8, which illustrates changeover of the outboard sides of the first eight roll-forming stations to a Z-configuration setup by extension of linear actuator 41B, it being understood that changeover of the outboard sides of the ninth through thirteenth roll-forming stations also occurs upon extension of outboard linear actuator 41B. The linear actuator 41B pushes primary link 43B in the feed direction as the linear actuator is extended, and the motion is transmitted through attachment block 44 to downstream connection link 47, and through coupler 48 to upstream connection link 45B. As links 47 and 45B are moved in the feed direction, link pins 46 engage the outboard turrets and cause the turrets to pivot, thereby locating the Z-configuration indices in their functioning positions, while the C-configuration indices of the outboard turrets are moved out of the way to respective non-functioning positions. As a result, in FIG. 8, Z-configuration rollers 58, 78, 98, 118, 138, 158, 178, and 198, as well as Z-configuration rollers and tooling on outboard turrets of the ninth through thirteenth roll-forming stations, are positioned to engage a passing strip 8, while C-configuration rollers 56, 76, 96, 116, 136, 156, 176, and 196, as well as C-configuration rollers and tooling on outboard turrets of the ninth through thirteenth roll-forming stations, are located out of the way.

As mentioned above, the lateral spacing between upstream rafts 11A and 11B may be set independently of the lateral spacing between downstream rafts 11C and 11D. Accordingly, coupler 48 may be configured to permit laterally directed adjustment of upstream connection link 45B and downstream connection link 47 relative to one another. As may be seen in FIGS. 10 and 11, coupler 48 of the present embodiment includes a vertically arranged upstream plate 482 fixed to upstream connection link 45B and a horizontally arranged downstream plate 484 fixed to downstream connection link 47. A transversely extending slider plate 483 is fixed to upstream plate 482 and extends downward therefrom such that its lower end 487 slides on a low-friction bearing insert 488 provided in the downstream plate. Eccentric cam rollers 486 may be provided to engage slider plate 483 for further guidance and stability during movement of the slider plate along bearing insert 488. As may be understood, coupler 48 allows the upstream connection link 45B and downstream connection link 47 to be adjusted relative to one another in a lateral direction while maintaining connection between the links for transmitting linear actuator motion along the feed direction. One skilled in the art will readily recognize that a wide variety of configurations are possible for coupler 48 to allow lateral adjustment while maintaining in-line connection between the upstream and downstream connection links.

It is noted that linear actuators 41A and 41B may be positioned between the fourth and fifth roll-forming stations where the roll-forming operations transition from formation of the lip bends to formation of the leg bends. On the outboard side of roll-forming machine 10, this is also the location at which upstream connection link 45B meets downstream connection link 47 at coupler 48. In the embodiment shown, actuators 41A and 41B each have a stroke axis parallel to the feed direction but the actuators extend in opposite directions, with inboard linear actuator 41A extending opposite the feed direction and outboard linear actuator 41B extending in the feed direction. However, one skilled in the art will recognize that the stroke direction and location of actuators 41A and 41B may be changed without straying from the present invention. Other positions for actuators 41A and 41B are possible, and it is not necessary that both actuators be at the same position along the feed direction. By way of non-limiting example, outboard linear actuator 41B could be arranged to extend opposite the feed direction and outboard primary link 43B could be attached to the upstream link 45B instead of downstream link 47. By way of further non-limiting example, linear actuator 41A could be located upstream of third roll-forming station 18 to extend in the feed direction. Any suitable linear actuator may be used, including without limitation a mechanical linear actuator, an electromechanical linear actuator, a hydraulic linear actuator, or a pneumatic linear actuator.

As used herein, the term “linkage” is intended to broadly encompass any arrangement of structurally connected elements and links capable of transmitting linear displacement provided by a linear actuator from the actuator to at least one turret of a roll-forming station. A suitable linkage is shown and described in detail, however other linkages differing from that shown may be used.

While the invention has been described in connection with an example embodiment, the detailed description is not intended to limit the scope of the invention to the particular embodiment set forth, but, on the contrary, it is intended to cover such alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.

Claims

1. A roll-forming machine for bending a strip of material as the strip travels in a feed direction through the roll-forming machine, the roll-forming machine comprising:

a plurality of roll-forming stations arranged in succession along the feed direction;

the plurality of roll-forming stations including an upstream roll-forming station and a downstream roll-forming station after the upstream roll-forming station in the feed direction;

wherein the upstream roll-forming station includes an upstream-station turret having a C-configuration roller and a Z-configuration roller, the upstream-station turret being pivotable about a turret axis to selectively locate either the C-configuration roller or the Z-configuration roller for engagement with a strip of material passing through the upstream roll-forming station, wherein the C-configuration roller and the Z-configuration roller respectively function to bend a portion of the strip in opposite angular directions relative to a remaining portion of the strip;

wherein the downstream roll-forming station includes a downstream-station turret having a C-configuration roller and a Z-configuration roller, the downstream-station turret being pivotable about a turret axis to selectively locate either the C-configuration roller or the Z-configuration roller thereof for engagement with a strip of material passing through the downstream roll-forming station, wherein the C-configuration roller and the Z-configuration roller of the downstream-station turret respectively function to bend a portion of the strip in opposite angular directions relative to a remaining portion of the strip;

a linear actuator; and

a linkage connecting the linear actuator to the upstream-station turret and the downstream-station turret;

wherein the linear actuator is operable for simultaneously pivoting the upstream-station turret and the downstream station turret to selectively locate both of the C-configuration rollers or both of the Z-configuration rollers for engagement with a strip of material.

2. The roll-forming machine according to claim 1, wherein the C-configuration roller of the downstream-station turret further bends the portion of the strip bent by the C-configuration roller of the upstream-station turret relative to the remaining portion of the strip when the C-configuration rollers are selected, and the Z-configuration roller of the downstream-station turret further bends the portion of the strip bent by the Z-configuration roller of the upstream-station turret relative to the remaining portion of the strip when the Z-configuration rollers are selected.

3. The roll-forming machine according to claim 1, wherein the C-configuration roller of the downstream-station turret bends a different portion of the strip than was bent by the C-configuration roller of the upstream-station turret, and the Z-configuration roller of the downstream-station turret bends a different portion of the strip than was bent by the Z-configuration roller of the upstream-station turret.

4. The roll-forming machine according to claim 1, wherein the linear actuator is located after the upstream roll-forming station in the feed direction.

5. The roll-forming machine according to claim 4, wherein the linear actuator is located after the downstream roll-forming station in the feed direction.

6. The roll-forming machine according to claim 4, wherein the linear actuator is located before the downstream roll-forming station in the feed direction.

7. The roll-forming machine according to claim 6, wherein the linkage includes an upstream link for connecting the linear actuator to the upstream-station turret and a downstream link for connecting the linear actuator to the downstream-station turret.

8. The roll-forming machine according to claim 7, wherein the linkage further includes a coupler connecting the upstream link to the downstream link, wherein the coupler enables laterally directed adjustment of the upstream and downstream links relative to one another.

9. The roll-forming machine according to claim 1, wherein the C-configuration roller and the Z-configuration roller of the upstream-station turret are each a cylindrical roller having a respective rotational axis non-parallel to the turret axis of the upstream-station turret.

10. The roll-forming machine according to claim 9, wherein the C-configuration roller and the Z-configuration roller of the downstream-station turret are each a tapered roller having a respective rotational axis parallel to the turret axis of the downstream-station turret.

11. A roll-forming machine for bending a strip of material as the strip travels in a feed direction through the roll-forming machine, the roll-forming machine comprising:

a plurality of roll-forming stations arranged in succession along the feed direction;

at least one of the plurality of roll-forming stations including an inboard side and an outboard side opposite the inboard side, an inboard turret on the inboard side and an outboard turret on the outboard side;

wherein each of the inboard and outboard turrets has a C-configuration tool index and a Z-configuration tool index and is pivotal about a respective turret axis to selectively locate either the C-configuration index or the Z-configuration index thereof in a functioning position with respect to a strip of material as the strip passes through the at least one roll-forming station;

an inboard linear actuator;

an inboard linkage connecting the inboard linear actuator to the inboard turret;

an outboard linear actuator;

an outboard linkage connecting the outboard linear actuator to the outboard turret; and

a control system operating the inboard and outboard linear actuators for pivoting the inboard turret and the outboard turret to selectively locate both of the C-configuration indices or both of the Z-configuration indices in their respective functioning positions.

12. The roll-forming machine according to claim 11, wherein the inboard turret includes a C-configuration roller at the C-configuration index thereof and a Z-configuration roller at the Z-configuration index thereof, and the outboard turret includes a C-configuration roller at the C-configuration index thereof and a Z-configuration roller at the Z-configuration index thereof.

13. The roll-forming machine according to claim 12, wherein the C-configuration rollers have respective rotational axes that are mirror images of one another as viewed along the feed direction.

14. The roll-forming machine according to claim 12, wherein the Z-configuration rollers have respective rotational axes that are parallel to one another as viewed along the feed direction.

15. The roll-forming machine according to claim 11, wherein the inboard linear actuator and the outboard linear actuator are arranged to extend in opposite directions relative to one another.

16. A roll-forming machine for bending a strip of material as the strip travels in a feed direction through the roll-forming machine, the roll-forming machine comprising:

a plurality of roll-forming stations arranged in succession along the feed direction;

at least one of the plurality of roll-forming stations including a turret having a C-configuration angular index and a Z-configuration angular index, the turret being pivotable about a turret axis to selectively locate either the C-configuration index or the Z-configuration index in a functioning position with respect to a strip of material as the strip passes through the at least one roll-forming station;

a linear actuator; and

a linkage connecting the linear actuator to the turret;

wherein the linear actuator is operable for pivoting the turret to selectively locate either the C-configuration index or the Z-configuration index in the functioning position.

17. The roll-forming machine according to claim 16, wherein the linear actuator has a stroke axis parallel to the feed direction.

18. The roll-forming machine according to claim 16, wherein the linear actuator is selected from a group consisting of a mechanical linear actuator, an electromechanical linear actuator, a hydraulic linear actuator, and a pneumatic linear actuator.

19. The roll-forming machine according to claim 16, wherein the turret includes a Z-configuration roller at the Z-configuration index, and the Z-configuration index has offset means for allowing the Z-configuration roller to be mounted on the turret at a chosen offset position.

20. The roll-forming machine according to claim 16, wherein the turret includes a C-configuration roller at the C-configuration index and a Z-configuration roller at the Z-configuration index.

21. The roll-forming machine according to claim 16, wherein the turret includes a C-configuration roller at the C-configuration index and the Z-configuration index is without tooling.

22. A method of changing over a roll-forming machine from a C-configuration setup to a Z-configuration setup, the roll-forming machine having a plurality of roll-forming stations arranged in succession along a feed direction for progressively bending a strip of material passing through the roll-forming machine in the feed direction to impart either a C-shaped cross-sectional configuration or a Z-shaped cross-sectional configuration to the strip, the method comprising the steps of:

operating an inboard linear actuator linked to a plurality of inboard turrets to pivot the plurality of inboard turrets from a C-configuration index setting to a Z-configuration index setting; and

operating an outboard linear actuator linked to a plurality of outboard turrets to pivot the plurality of outboard turrets from a C-configuration index setting to a Z-configuration index setting.

23. The method according to claim 22, wherein the step of operating an inboard linear actuator and the step of operating an outboard linear actuator are performed by way of a control system connected to the inboard and outboard linear actuators.

24. A method of changing over a roll-forming machine from a Z-configuration setup to a C-configuration setup, the roll-forming machine having a plurality of roll-forming stations arranged in succession along a feed direction for progressively bending a strip of material passing through the roll-forming machine in the feed direction to impart either a C-shaped cross-sectional configuration or a Z-shaped cross-sectional configuration to the strip, the method comprising the steps of:

operating an inboard linear actuator linked to a plurality of inboard turrets to pivot the plurality of inboard turrets from a Z-configuration index setting to a C-configuration index setting; and

operating an outboard linear actuator linked to a plurality of outboard turrets to pivot the plurality of outboard turrets from a Z-configuration index setting to a C-configuration index setting.

25. The method according to claim 24, wherein the step of operating an inboard linear actuator and the step of operating an outboard linear actuator are performed by way of a control system connected to the inboard and outboard linear actuators.