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(11) | EP 3 473 348 A1 |
| (12) | EUROPEAN PATENT APPLICATION |
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| (54) | RECONFIGURABLE MACHINE FOR ROLL-FORMING SHEET METAL AND METHOD FOR RECONFIGURING THEREOF |
| (57) A machine (100, 180) for roll-forming sheet metal, comprising: a motor (101); a bench
(103) comprising a first carriage (110, 112) and a second carriage (111, 113), each
of the first and the second carriages (110, 111, 112, 113) being configured to support
attaching and detaching at least one framework (200, 201) for roll-forming sheet metal,
and the bench (103) being configured to adjust a separation (115) between the first
carriage (110, 112) and the second carriage (111, 113); a shaft (102) coupled with
the motor (101); and first and second gears (120, 121) coupled with the shaft (102);
the shaft (102) is configured to actuate rollers (210, 211) of the at least one framework
(200, 201) when the at least one framework (200, 201) is attached to at least one
of the first and the second carriages (110, 111, 112, 113). Also, an assembly (300,
301a, 301b) for roll-forming sheet metal, and a method for configuring a machine (100,
180) for roll-forming sheet metal.
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TECHNICAL FIELD
[0001] The present invention relates to the field of roll-forming metallic components. More particularly, the present invention relates to a machine for roll-forming sheet metal that may be reconfigured to be adapted to the dimensions and/or the geometry of the sheet metal. The present invention also relates to an assembly comprising the machine and a method for reconfiguring such machine.
STATE OF THE ART
[0002] Sheet metal is a component that is often used in many industries for a wide range of applications. Generally, sheet metal must be shaped so that it may be used as a final product. Roll-forming processes make possible to shape sheet metal in series and, thus, mass production may be provided in a cost-effective manner.
[0003] Roll-forming processes entail the use of one or more machines for roll-forming such components. To this end, the one or more machines are provided with sets of rollers that sequentially shape the sheet metal. The sets of rollers are arranged such that a plurality of roll-forming stations are provided; each of these roll-forming stations generally comprises one roller or two rollers between which the sheet metal passes in order to be subject to a change in its shape.
[0004] In some cases, a machine for roll-forming sheet metal includes a framework with a plurality of rollers extending between two sides or supporting structures. In some other cases, a machine for roll-forming sheet metal includes two frameworks, and each of these two frameworks includes a plurality of rollers extending from one side or supporting structure of the framework (i.e. each roller having an end not coupled with any side of the framework). The structural differences of these two types of machines aside, the machines at least differ in how they process the sheet metal (i.e. the shaping they apply to the sheet metal) and what are the size and geometrical limitations of the sheet metal that they can process.
[0005] It may occur that a single piece of sheet metal that is to be manufactured must be subject to several roll-forming processes before reaching its final shape; alternatively or additionally it may occur that a single manufacturing plant manufactures different products made of sheet metal. In both scenarios, a plurality of machines for roll-forming are necessary to manufacture such products since each machine features particular characteristics that make it suitable for a determined roll-forming process. In this sense, only limited adjustments may be made to each machine and, therefore, often the machines cannot be adapted to carry out roll-forming processes with different characteristics, thereby requiring different machines in order to manufacture the product/s.
[0006] There is an interest in providing a machine for roll-forming sheet metal that may be reconfigured such that roll-forming processes with different characteristics may be carried out with the same machine. Further, there is also an interest in providing a method for reconfiguring a reconfigurable machine for roll-forming sheet metal that is both simple and cost-effective.
DESCRIPTION OF THE INVENTION
[0007] A first aspect of the invention relates to a machine for roll-forming sheet metal, comprising: a motor; a bench comprising a first carriage and a second carriage, each of the first and the second carriages being configured to support attaching and detaching at least one framework for roll-forming sheet metal, and the bench being configured to adjust a separation between the first carriage and the second carriage; a shaft coupled with the motor; and first and second gears coupled with the shaft; the shaft is configured to actuate rollers of the at least one framework when the at least one framework is attached to at least one of the first and the second carriages.
[0008] The first and the second carriages are provided with means for attaching and detaching a framework for roll-forming. The machine may thus receive, for example, a first framework that is attached to at least one of the carriages (e.g. the first carriage, the second carriage, or both the first and the second carriages) so as to carry out a first roll-forming process; upon finishing the first roll-forming process, the first framework may be detached from the at least one of the carriages and a second framework is attached to at least one of the carriages (e.g. the first carriage, the second carriage, or both the first and the second carriages) so as to carry out a second roll-forming process. Different frameworks are provided with different structural features for making possible to roll-form sheet metal with different roll-forming characteristics.
[0009] Since the separation between the first and the second carriages on the bench can be adjusted, frameworks that are to be attached to both carriages at once (for instance, frameworks that include a pair of opposed sides and a plurality of rollers extending between both sides) may be attached to the same machine even if they feature different widths (the widths being regarded as a sum of the thickness of each of the sides and the separation between the two sides). Also, when the roll-forming process is carried out by a pair of frameworks such that a first framework is detachably attached to the first carriage and a second framework is detachably attached to the second carriage, the separation between the first and the second carriages may be adjusted so as to modify a separation between the first and the second frameworks (and, hence, the distance between rollers of the first and the second frameworks is made longer or shorter). In this sense, the machine supports reconfiguration by adjusting the separation between the carriages.
[0010] The machine for roll-forming sheet metal may receive different detachable frameworks for roll-forming sheet metal so as to carry out roll-forming processes with different characteristics. Accordingly, fewer machines are necessary for manufacturing one or more products made of sheet metal, thereby resulting in cost savings and space being freed up (only the frameworks need be stored rather than multiple machines).
[0011] In preferred embodiments, the machine further comprises at least one linear actuator for moving at least one of the first and the second carriages, thereby adjusting the separation. The separation between the first carriage and the second carriage is in a direction of a transversal axis of the bench.
[0012] The bench is provided with at least one linear actuator for adjusting the position of one of the first and the second carriages thereby making possible to adjust the separation between the two. The sheet metal is fed to the machine along a longitudinal axis of the bench for its processing. Accordingly, the separation between the first carriage and the second carriage is in a direction that is perpendicular to a direction in which the sheet metal is fed to the machine. As the separation between the carriages is adjusted, differently sized sheet metals may be processed with the same machine since a wide range of detachable frameworks may thus be attached to the carriages.
[0013] In some of these preferred embodiments, the at least one linear actuator comprises: a first linear actuator for moving the first carriage; and a second linear actuator for moving the second carriage.
[0014] Both the first and the second carriages may be moved owing to the first and the second linear actuators, thereby providing the machine with additional reconfiguration options.
[0015] In some preferred embodiments, each linear actuator of the at least one linear actuator comprises a rack-and-pinion.
[0016] Each rack-and-pinion of the at least one linear actuator may be provided with one or more servo-controlled motors; preferably two servo-controlled motors are provided, one on each side of each rack-and-pinion so as to reduce the risk that the rack-and-pinions get displaced or rotated while roll-forming sheet metal. The rack-and-pinions may move the carriages symmetrically, asymmetrically, and even at the same time and at the same direction if necessary.
[0017] In some other preferred embodiments, each linear actuator of the at least one linear actuator comprises a ball screw.
[0018] In preferred embodiments, the first gear is configured to engage with at least one gear of the at least one framework to actuate the rollers thereof.
[0019] The motor makes the first gear of the machine rotate, by means of the shaft, so that torque provided by the motor may be applied to the rollers of the at least one framework. The at least one framework comprises at least one gear, and preferably comprises at least one set of gears for actuating each roller thereof (the gears of the set of gears are engaged) upon coupling the at least one gear to the first gear of the machine.
[0020] In some embodiments, the at least one framework comprises a first framework; the first framework comprises a plurality of rollers and at least one gear; each of the first and the second carriages is configured to support attaching and detaching the first framework; and the first gear is configured to engage with the at least one gear of the first framework to actuate the plurality of rollers thereof.
[0021] The first framework can be secured to the machine by being attached to the first and the second carriages. Preferably, each roller of the plurality of rollers of the first framework extends between two supporting structures of the first framework.
[0022] The separation between the first and the second carriages must be adjusted based on the width or size of the first framework so that the first framework may be attached to the machine.
[0023] In some of these embodiments, the at least one framework further comprises a second framework; the second framework comprises a plurality of rollers and at least one gear; each of the first and the second carriages is further configured to support attaching and detaching the second framework; and the second gear is configured to engage with the at least one gear of the second framework to actuate the plurality of rollers thereof.
[0024] The second framework can be secured to the machine by being attached to the first and the second carriages. Preferably, each roller of the plurality of rollers of the second framework extends between two supporting structures of the second framework.
[0025] The second framework may be provided after the first framework along a longitudinal axis of the first and second carriages; in this sense, the second framework may be positioned such that one end thereof is close or in physical contact with one end of the first framework. Accordingly, after processing sheet metal in the first framework, the machine may process the sheet metal in the second framework.
[0026] In some embodiments, the at least one framework comprises: a first framework comprising a plurality of rollers and at least one gear; and a second framework comprising a plurality of rollers and at least one gear; the first carriage is configured to support attaching and detaching the first framework, and the second carriage is configured to support attaching and detaching the second framework; and the first gear is configured to engage with the at least one gear of the first framework to actuate the plurality of rollers thereof, and the second gear is configured to engage with the at least one gear of the second framework to actuate the plurality of rollers thereof.
[0027] The separation between the first and the second carriages may be adjusted according to the separation between the first and the second frameworks that is preferred. In this sense, one factor that determines the characteristics of the roll-forming process is the separation between the rollers of the first and the second frameworks.
[0028] Each of the first gear and the second gear makes the rollers of the first and the second frameworks rotate, respectively.
[0029] In some embodiments, the machine further comprises a third gear and a fourth gear; the at least one framework further comprises: a third framework comprising a plurality of rollers and at least one gear; and a fourth framework comprising a plurality of rollers and at least one gear; the first carriage is further configured to support attaching and detaching the third framework, and the second carriage is further configured to support attaching and detaching the fourth framework; and the third gear is configured to engage with the at least one gear of the third framework to actuate the plurality of rollers thereof, and the fourth gear is configured to engage with the at least one gear of the fourth framework to actuate the plurality of rollers thereof.
[0030] The same machine may receive two pairs of frameworks (e.g. the first and the second frameworks are provided parallel to each other with a separation along a transversal axis of the bench, and the third and the fourth frameworks are also provided parallel to each other with a separation along a transversal axis of the bench and attached after the first and the second frameworks, respectively, along a longitudinal axis of the bench). Such configuration allows to carry out two roll-forming processes consecutively.
[0031] In some embodiments, the machine further comprises a third gear; the at least one framework further comprises a third framework; the third framework comprises a plurality of rollers and at least one gear; the first carriage is further configured to support attaching and detaching the third framework, and the second carriage is further configured to support attaching and detaching the third framework; and the third gear is configured to engage with the at least one gear of the third framework to actuate the plurality of rollers thereof.
[0032] The machine may also support a configuration in which a first pair of frameworks (e.g. the first and the second frameworks) is provided such that each the frameworks are arranged parallel and separated along a transversal axis of the bench (each framework attached to one of the first and the second carriages), and a third framework is provided next to the first pair of frameworks along a longitudinal direction of the bench. Accordingly, the machine may carry out two different roll-forming processes one right after the other.
[0033] The third framework is attached to both the first and the second frameworks. Preferably, each roller of the plurality of rollers of the third framework extends between two supporting structures of the third framework.
[0034] In some embodiments, the first carriage has an opening formed therein; and the first gear of the machine protrudes from the opening of the first carriage and is configured to move together with the first carriage when the first carriage is moved. In some of these embodiments, the second carriage has an opening formed therein; and the second gear of the machine protrudes from the opening of the second carriage and is configured to move together with the second carriage when the second carriage is moved. Additionally, in some of these embodiments, each of the first and the second carriages has a second opening formed therein; and the third gear and/or the fourth gear of the machine protrude from the second opening of one of the first and the second carriages.
[0035] As the gears of the machine are within the opening/s of the carriages and protrude therefrom, when a carriage of the first and the second carriages is moved, so does the gear associated therewith. This means that even if the position of the carriages and/or the separation between the first and the second carriages are/is modified, the respective gear/s are still operable since they are moved along the shaft (along a transversal axis of the bench, that is the same axis along which the separation or the position of the carriages is adjusted), hence the shaft may actuate the rollers of a framework that is attached to the machine.
[0036] In some embodiments, each of the first and the second carriages comprises a plurality of clamps for supporting attachment and detachment of the at least one framework.
[0037] Preferably, the clamps are hydraulic swing clamps. Hydraulic swing clamps may be operated with ease in order to attach or detach frameworks, thereby making possible to reconfigure the machine quickly.
[0038] In some other embodiments, each of the first and the second carriages comprises a plurality of holes for supporting attachment and detachment of the at least one framework, the holes of the plurality of holes being adapted to receive at least one of: a bolt, a screw, and a stud.
[0039] A second aspect of the invention relates to a method for configuring a machine for roll-forming sheet metal, comprising: providing the machine with a motor and a bench; providing the bench with a first carriage and a second carriage; adjusting a separation between the first carriage and the second carriage; attaching a first framework for roll-forming sheet metal to at least one of the first and the second carriages; and providing a shaft coupled with the motor, and first and second gears coupled with the shaft, the shaft being configured to actuate rollers of the first framework.
[0040] The separation between the first and the second carriages is adjusted based upon the width of the first framework, or the separation between the first framework and some other framework that is to be attached to machine. The separation is adjusted by operating at least one linear actuator (i.e. first linear actuator) coupled with the first carriage; in some embodiments, the machine may be provided with another linear actuator (i.e. second linear actuator) coupled with the second carriage that may also be operated to adjust the separation between the carriages. In some embodiments, each linear actuator comprises a rack-and-pinion, whereas, in some other embodiments, each linear actuator comprises a ball screw.
[0041] The shaft has coupled therewith one or more gears. One of the one or more gears engage with at least one gear of the first framework in order to actuate the rollers thereof.
[0042] Upon applying the torque provided by the motor to the rollers of the first framework, the machine may carry out a roll-forming process with the first framework.
[0043] In some embodiments, attaching the first framework to at least one of the first carriage and the second carriage comprises attaching the first framework to each of the first carriage and the second carriage.
[0044] The first framework may comprise a plurality of rollers extending between two supporting structures thereof. When this is the case, the first framework is preferably attached to both the first and the second carriages so that, upon carrying out a roll-forming process, the first framework does not move relative to the machine.
[0045] In some other embodiments, the method further comprises: attaching a framework in addition to the first framework to the second carriage. In these embodiments, the first framework is attached to the first carriage.
[0046] When the roll-forming process is carried out with a pair of frameworks, each framework is attached to one of the first and the second carriages so that the two frameworks are separated according to the selected separation.
[0047] In some embodiments, the method further comprises: detaching the first framework from each carriage of the first carriage and the second carriage that the first framework is attached to; readjusting the separation between the first carriage and the second carriage; and attaching a second framework for roll-forming sheet metal to at least one of the first carriage and the second carriage. Also, in these embodiments, the shaft is further configured to actuate rollers of the second framework.
[0048] Upon completing a roll-forming process, the first framework may be detached from each carriage it is attached to (e.g. the first carriage, the second carriage, or both the first and the second carriages) so that the first framework can be hoisted. After hoisting the first framework, the separation between the first and the second carriages may be readjusted if necessary; this depends on the width of the framework to be attached to the machine or the separation that is to be provided with respect to another framework to be attached to the machine as well.
[0049] Similar advantages as those described for the first aspect of the invention may also be applicable to the second aspect of the invention.
[0050] A further aspect of the invention relates to an assembly for roll-forming sheet metal, comprising: a machine according to the first aspect of the invention; and at least one framework for roll-forming sheet metal comprising a plurality of rollers, the at least one framework being detachably attached to at least one carriage of the machine.
[0051] In some embodiments of the invention, the at least one framework for roll-forming sheet metal comprises a first framework and a second framework; the first framework is detachably attached to a first carriage of the machine; and the second framework is detachably attached to a second carriage of the machine.
[0052] Similar advantages as those described for the first aspect of the invention may also be applicable to the third aspect of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0053] To complete the description and in order to provide for a better understanding of the invention, a set of drawings is provided. Said drawings form an integral part of the description and illustrate an embodiment of the invention, which should not be interpreted as restricting the scope of the invention, but just as examples of how the invention can be carried out. The drawings comprise the following figures:
Figures 1A-1C show, from different viewing angles, a machine for roll-forming sheet metal in accordance with an embodiment of the invention.
Figure 2 shows a close-up of gears of the machine of Figures 1A-1C.
Figure 3 shows a close-up of attaching means of carriages of the machine of Figures 1A-1C.
Figure 4 shows a set of gears of a framework for roll-forming sheet metal coupled with the machine of Figures 1A-1C.
Figures 5A-5B show a framework for roll-forming sheet metal attachable to a machine in accordance with the present disclosure.
Figure 6 shows a framework for roll-forming sheet metal attachable to a machine in accordance with the present disclosure.
Figure 7 shows two frameworks for roll-forming sheet metal attachable to a machine in accordance with the present disclosure.
Figure 8 shows an assembly for roll-forming sheet metal in accordance with an embodiment of the invention.
Figures 9A-9B show assemblies for roll-forming sheet metal with two different separations between carriages.
Figure 10 shows a close-up of attaching means of an assembly.
Figure 11 shows a machine for roll-forming sheet metal in accordance with an embodiment of the invention.
Figure 12 shows an assembly for roll-forming sheet metal in accordance with an embodiment of the invention.
Figure 13 shows, in a block diagram form, a method in accordance with an embodiment of the invention.
DESCRIPTION OF WAYS OF CARRYING OUT THE INVENTION
[0054] Figures 1A-1B show a machine 100 for roll-forming sheet metal in accordance with an embodiment of the invention, from two different perspectives; Figure 1C shows a plan view of the machine 100 (i.e. seen from the top).
[0055] The machine 100 comprises a motor 101, a shaft 102 coupled with the motor 101, a bench 103, a first carriage 110, a second carriage 111, a first gear 120, a second gear 121, a first rack-and-pinion 130, and a second rack-and-pinion 131.
[0056] Both the first and the second carriages 110, 111 are provided on the bench 103 such that respective greatest dimensions thereof extend along a longitudinal axis of the bench 103. The sheet metal to be roll-formed is fed to the machine 100 along the longitudinal axis of the bench 103. The first and the second carriages 110, 111 are spaced by a separation 115 in a direction along a transversal axis of the bench 103. The separation 115 may be adjusted by means of one or both of the first and the second rack-and-pinions 130, 131 and, hence, make possible to attach different frameworks for roll-forming sheet metal or change a separation between two frameworks for roll-forming sheet metal so as to vary how the sheet metal is to be shaped. The first rack-and-pinion 130 is configured to move the first carriage 110 in a direction corresponding to a transversal axis of the bench 103, and the second rack-and-pinion 131 is configured to move the second carriage 111 in the direction corresponding to the transversal axis of the bench 103. Each of the first and second rack-and-pinions 130, 131 is coupled with two servo-controlled motors for moving the first and the second carriages 110, 111, respectively; in other examples, each rack-and-pinion is coupled with one servo-controlled motor.
[0057] The first carriage 110 has a first opening 116 formed therein; the second carriage 111 has a second opening 117 formed therein. The first gear 120 protrudes from the first carriage 110 through the first opening 116, whereas the second gear 121 protrudes from the second carriage 111 through the second opening 117. When a framework for roll-forming is attached to one or both of the first and the second carriages 110, 111, at least one gear of the framework becomes engaged with one of the first and the second gears 120, 121 so that the rollers of the framework rotate as torque from the motor 101 is applied thereto.
[0058] Further, the first carriage 110 comprises first attaching means 150 and a first plurality of bolts 160 for positioning a framework thereon. To this end, the framework may be provided with one or more openings for receiving one bolt of the first plurality of bolts 160, for example, so that the framework can be attached to the first carriage aligned with the first attaching means 150 and the first gear 120. The second carriage 111 comprises second attaching means 151 and a second plurality of bolts 161 for positioning a framework thereon so that a framework may be attached thereto aligned. In some cases, a framework is attached to both the first and the second carriages 110, 111.
[0059] Figure 2 shows a close-up of the first and the second gears 120, 121 of the machine 100 of Figures 1A-1C.
[0060] The first and the second gears 120, 121 are coupled with the shaft 102 that, in turn, is coupled with the motor 101 so as to provide a rotary motion to the first and the second gears 120, 121. Each of the first and the second gears 120, 121 is provided with a housing 125, 126.
[0061] When the first and/or the second carriages 110, 111 are/is moved (with linear actuators such as the first and/or the second rack-and-pinions), so does the respective gear/s 120, 121 (along the length of the shaft 102). The first and the second gears 120, 121 are moved together with their respective housings 125, 126 so that they may engage with the gear of a framework to be attached to at least one carriage, irrespective of the position of the at least one carriage relative to the bench.
[0062] Figure 3 shows a close-up of attaching means 150, 151 of the first and the second carriages 110, 111 of the machine 100 of Figures 1A-1C.
[0063] The attaching means 150 of the first carriage 110 comprise a first plurality of hydraulic swing clamps 150 (only one hydraulic swing clamp 150 is shown in Figure 3), and the attaching means 151 of the second carriage 111 comprise a second plurality of hydraulic swing clamps 151.
[0064] The hydraulic swing clamps 150, 151 make possible to detachably attach a framework for roll-forming to a carriage of the machine 100. Upon positioning a framework on at least one of the first and the second carriages 110, 111, the first plurality and/or the second plurality of hydraulic swing clamps 150, 151 are/is operated to attach the framework to the carriage/s. When the machine 100 needs be reconfigured so as to use one or more different frameworks, the first plurality and/or the second plurality of hydraulic swing clamps 150, 151 are/is operated to detach the framework currently attached to the carriage/s, thereby making possible to remove the framework from the machine 100 and provide the one or more frameworks that are to be used, which are then secured to the machine 100 with the first plurality and/or the second plurality of hydraulic swing clamps 150, 151.
[0065] The hydraulic swing clamps 150, 151 are preferably arranged close to the location where the gears of the machine are provided: by being closer to such location, the frameworks may be attached more reliably since the forces produced by a motor could displace the frameworks otherwise.
[0066] Figure 4 illustrates a set of gears 220 of a framework for roll-forming sheet metal when it is coupled with the machine 100 of Figures 1A-1C.
[0067] The set of gears 220 of a framework (not shown, only the set of gears 220 is shown for illustrative purposes only) comprises a plurality of gears configured to apply torque to each of the rollers of the framework. The set of gears 220 includes a gear 221 that engages with the second gear 121 of the machine 100 when the framework is installed on the machine 100. As the second gear 121 rotates owing to the torque of the motor 101, the gear 221 and the remaining gears of the set of gears 220 rotate as well, thereby applying torque to the rollers of the framework.
[0068] Figures 5A-5B show, from two different perspectives, a framework 200 for roll-forming sheet metal that is attachable to a machine according to the present disclosure.
[0069] The framework 200 comprises a plurality of rollers 210 for roll-forming sheet metal. Each roller of the plurality of rollers 210 extends between a first side or supporting structure 216 and a second side or supporting structure 217 of the framework 200. The first side or supporting structure 216 and/or the second side or supporting structure 217 may comprise a plurality of sides or supporting structures (such as the plurality of second sides or supporting structures 217) aligned with each other. Each roller 210 includes a shaft that rotates the roller 210 as the shaft rotates as a result of a torque being applied thereto.
[0070] The framework 200 further comprises at least one set of gears 220 for the operation of the plurality of rollers 210 when it is attached to a machine (such as the machine 100 of Figures 1A-1C). To this end, the framework 200 also includes a first opening 230 and a second opening 231. The first opening 230 is formed as a portion that is cut out from the perimeter of the framework 200; since the framework 200 only comprises one set of gears 220 on a first side thereof, no gear needs to engage with any set of gears on a second side of the framework 200, thus the first opening 230 makes that a gear of a carriage not engaging with the set of gears 220 may protrude therefrom and hence not block the framework 200 from being attached to a machine. The first opening 230 may be partially covered with a protective mechanical component so as to avoid that an operator or a component may come into contact with a gear of the machine (a gear that does not engage with the set of gears 220).
[0071] The set of gears 220 of the framework 200 may engage with a gear of the machine through the second opening 231: one gear of the set of gears 220 may go through the second opening 231, or the gear of the machine may go through the second opening 231 in order to engage the gear of the machine with the gears of the framework 200. The framework 200 may be attached to two carriages of the machine in order to reduce the movements it undergoes while the roll-forming process takes place. The set of gears 220 may be covered with a protective housing.
[0072] Further, the framework 200 comprises means 240 for being hoisted so that a crane, for example, may elevate and lower the framework 200 when it is to be attached to the machine or detached from it. When the framework 200 is lowered so as to be positioned on top of the machine, some openings 235 of the framework 200 are adapted to receive a positioning bolt of the carriages of the machine (such as the bolts 160, 161 of Figures 1A-1C, and Figure 4) for correctly placing the framework 200 on the carriage or carriages. Each opening 235 may be provided with a mechanical component (such as a metallic plate-like element) partially filling the opening 235, and which preferably features a funnel-like shape for aligning the framework 200 with the carriages when receiving positioning bolts thereof. The framework 200 has to be aligned with the carriages so that the opening 230 and an opening formed in at least one of the carriages match and, thus, the gears of the machine and the framework 200 engage.
[0073] The plurality of rollers 210 are arranged such that the framework 200 is provided with fourteen roll-forming stations. It is readily apparent that other frameworks within the scope of the present disclosure may be provided with more or fewer roll-forming stations.
[0074] The framework 200 also comprises a mechanical component 219 for correcting alterations in the shape of the sheet metal after it has been subject to the roll-forming process, in particular alterations resulting from stresses that are produced within the sheet metal as it is roll-formed.
[0075] Figure 6 shows a framework 201 for roll-forming sheet metal that is attachable to a machine according to the present disclosure.
[0076] The framework 201 is adapted to detachably attach to one carriage of a machine (such as the machine 100 of Figures 1A-1C). The framework 201 comprises a plurality of rollers 211 extending from a side or supporting structure 218 of the framework 201; each of the rollers 211 has an end thereof free (i.e. not coupled with another side or supporting structure) in contrast to the plurality of rollers 210 of the framework 200. The different arrangements of the rollers of the two frameworks 200, 201 of Figures 5 and 6 make possible different sheet metal roll-forming processes. Each roller 211 includes an overhanging shaft that rotates the roller 211 as the shaft rotates owing to a torque being applied thereto. The plurality of rollers 211 are arranged along a lengthwise direction of the framework 201 such that twelve roll-forming stations are provided. It is readily apparent that other frameworks within the scope of the present disclosure may be provided with more or fewer roll-forming stations.
[0077] The framework 201 also comprises a set of gears (the set of gears 220 as seen in Figure 7 with reference to framework 201a), an opening for coupling the gears of the framework 201 to a gear of the machine, means 240 for being hoisted, one opening for engaging the gears of the framework 201 with the gear of the machine, and at least one another opening 235 for aligning the framework 201 with the carriage of the machine.
[0078] As it can be appreciated from Figure 6, each roll-forming station may have two rollers 211 provided one on top of the other, or only one roller 211. Single-roller roll-forming stations are useful for certain shaping processes or profiling of sheet metal. This also applies to frameworks such as the framework 200 of Figure 5.
[0079] Figure 7 shows two frameworks 201a, 201b for roll-forming sheet metal that are attachable to a machine according to the present disclosure.
[0080] The two frameworks 201a, 201b correspond to the framework 201 of Figure 6. Each of the two frameworks 201a, 201b is to be attached to one carriage of a machine for roll-forming sheet metal. A separation 290 between the two frameworks 201a, 201b when they are to be attached to the carriages determines the accepted size/s of the sheet metal to be roll-formed. In this sense, the separation 290 shall be provided as a separation (e.g. the separation 115 of Figures 1A-1C) between the two carriages on the bench. The effect of the separation 290 can be better appreciated in Figures 9A-9B.
[0081] Figure 8 shows an assembly 300 for roll-forming sheet metal in accordance with an embodiment of the invention.
[0082] The assembly 300 of Figure 8 comprises a machine for roll-forming sheet metal (such as the machine 100 of Figures 1A-1C) and a framework 200a (similar to the framework 200 of Figure 5) attached to the second carriage 111 of a bench 103, by means of at least two hydraulic swing clamps 151 (not seen due to the perspective). In this embodiment, the plurality of hydraulic swing clamps 150 of the first carriage 110 and two hydraulic swing clamps 151 of the second carriage 111 do not attach the framework 200a to any carriage.
[0083] A separation 115 shall be adjusted prior to the attachment of the framework 200a so that it can be secured to the first and the second carriages 110, 111.
[0084] Figures 9A-9B show, in a 2D view, assemblies 301a, 301b for roll-forming sheet metal with two different separations between carriages.
[0085] The assembly 301 a of Figure 9A comprises a machine (such as the machine 100 of Figures 1A-1C), a first framework (such as the framework 201a of Figure 7) attached to a first carriage 110, and a second framework (such as the framework 201b of Figure 7) attached to a second carriage 111. The first framework comprises a plurality of rollers 211 a that becomes operable when a set of gears 220a thereof is coupled with a motor 101 of the machine; the second framework comprises a plurality of rollers 211b that becomes operable when a set of gears 220b thereof is coupled with the motor 101.
[0086] A separation 115a between the first and the second carriages 110, 111 is such that the rollers 211 a of the first framework are separated from the rollers 211b of the second framework. Such separation between rollers 211a, 211b determines characteristics of the roll-forming process that the assembly 301 a will carry out on the sheet metal to be roll-formed. When there is a wide separation 115a such as in the assembly 301a of Figure 9A, a mechanical supporting component 330 is preferably added between the first and the second frameworks so that the sheet metal to be roll-formed may be supported on such component 330; accordingly, a portion of the weight of the sheet metal can rest on the mechanical supporting component 330 thereby alleviating the stress in the sheet metal. The mechanical supporting component 330 may feature a U shape and be placed upside down, for example.
[0087] With respect to Figure 9B, which shows the assembly 301b that is similar to the assembly 301a of Figure 9A, a separation 115b between the first and the second carriages 110, 111 is smaller than the separation 115a of the assembly 301a of Figure 9A. This, in turn, results in little or no separation at all between the rollers 211a of the first framework and the rollers 211b of the second framework, something which also determines characteristics of the roll-forming process that the assembly 301b will carry out on the sheet metal to be roll-formed. Therefore, even when two or more assemblies for roll-forming sheet metal comprise the same frameworks, the corresponding machine may be reconfigured by adjusting the separation between the first and the second carriages and, hence, produce different roll-forming processes.
[0089] The assembly comprises a machine (like the machine 100 of Figures 1A-1C), a framework 200 (like the one of Figure 5) attached to one of first and second carriages of the machine by means of a first set of hydraulic swing clamps 151 a. This first set of hydraulic swing clamps 151a, in contrast to a second set of hydraulic swing clamps 150a, 150b, 151b, retains the framework 200 from moving relative to one of the first and the second carriages. The protruding parts of the first set of hydraulic swing clamps 151 a overlap a portion of the surface of the framework 200.
[0090] The framework 200 comprises a plurality of openings 260 that are aligned with some hydraulic swing clamps of the second set of hydraulic swing clamps 150b, 151b and which feature a size that does not allow these hydraulic swing clamps 150b, 151b to clamp the framework 200 to the first and the second carriages. This is so to provide the machine with different possible configurations. When each of two frameworks is to be attached to one of the first and the second carriages, the hydraulic swing clamps of the first carriage attach one framework to it, whereas the hydraulic swing clamps of the second carriage attach the other framework to it. When a framework such as the framework 200 is to be attached to the machine, the inner-most hydraulic swing clamps 150b, 151b (each set of two hydraulic swing clamps corresponds to a different carriage) could preclude the framework 200 from being attached to the machine due to the size thereof; the outer-most hydraulic swing clamps 150a, 151a may have an arrangement more convenient for the proper attachment of the framework 200. To this end, in some examples a framework comprises one or more openings to let attaching means of carriages go through, thereby not blocking the attachment (with other attaching means) of the framework to the machine.
[0091] In some embodiments, instead of using hydraulic swing clamps 150a, 150b, 151a, 151b for attaching the framework 200 to the first and the second carriages, screws may be used for attaching said framework 200. In such embodiments, the framework 200 may not include the plurality of openings 260 since the screws may be provided only at those positions where they are to attach the framework 200 to the carriages.
[0092] Further, in Figure 10 there is also illustrated a positioning bolt 161 being received in the mechanical component filling the opening 235 that serves the purpose of aligning the framework 200 with at least one of the carriages.
[0093] Figure 11 shows a machine 180 for roll-forming sheet metal in accordance with an embodiment of the invention.
[0094] The machine 180 comprises a motor 101, a shaft 102 coupled with the motor 101, a bench 103, a first carriage 112, a second carriage 113 that is separated from the first carriage 112 by a separation 115, a first gear 120, a second gear 121, a third gear 122, and a fourth gear 123. The first and the second gears 120, 121 are coupled with the shaft 102 such that the shaft 102 goes through both gears 120, 121. The third and the fourth gears 122, 123 are also coupled with the shaft 102, however they are coupled by means of the first and the second gears 120, 121, respectively; to this end, the third gear 122 engages with at least one gear that is directly or indirectly (i.e. through another gear or gears) engaged with the first gear 120, whereas the fourth gear 123 engages with at least another one gear that is directly or indirectly engaged with the second gear 121, accordingly the machine does not require an additional shaft and/or motor for operating the third and fourth gears 122, 123.
[0095] The first carriage 112 comprises two openings from which the first and the third gears 120, 122 protrude so that each may engage with at least one gear of a framework for roll-forming sheet metal. The second carriage 113 also comprises two openings from which the second and the fourth gears 121, 123 protrude so that each may engage with at least one gear of a framework for roll-forming sheet metal. Further, each of the first and the second carriages 112, 113 comprises a plurality of attaching means 155, 156 for the attachment of a framework thereto; in this example, the attaching means 155, 156 comprise clamps, preferably hydraulic swing clamps.
[0096] With the first and/or the second gears 120, 121, one framework (e.g. framework 200 or 200a of Figures 5A-5B and 8) or two frameworks (e.g. frameworks 201, 201a, 201b of Figures 6 and 7) may be operable. In addition, with the third and/or the fourth gears 122, 123, one framework or two frameworks, that may be placed next to the frameworks (along a direction parallel to a longitudinal axis of the bench 103) operated by the first and the second gears 120, 121, may also be operable as appreciated in Figure 12. This provides the machine 180 with an additional degree of reconfiguration since two different roll-forming processes may be carried out consecutively: a same sheet metal is subject to a second roll-forming process after being subject to a first roll-forming process.
[0097] The machine 180 further comprises ball screws 132 for moving the first carriage 112 in a direction parallel to a transversal axis of the bench 103, and for moving the second carriage 113 in a direction parallel to a transversal axis of the bench 103. The separation 115 may be adjusted by moving the first and/or the second carriages 112, 113.
[0098] Figure 12 shows an assembly 301 for roll-forming sheet metal in accordance with an embodiment of the invention.
[0099] The assembly 301 includes a machine such as the machine 180 of Figure 11. The assembly further includes first and second frameworks 201c, 201d (similar to frameworks 201, 201a, 201b of Figures 6 and 7) for carrying out a first roll-forming process, and a third framework 200b (similar to frameworks 200, 200a of Figures 5A-5B and 8) for carrying out a second roll-forming process.
[0100] The third framework 200b is attached to the first and the second carriages 112, 113 and is provided right next to an end of the first and the second frameworks 201c, 201d. Accordingly, once a sheet metal has been subject to the first roll-forming process, it is subject to the second roll-forming process.
[0101] With regards to the third framework 200b, the same features a reduced width and thus it may do without an opening (such as the first opening 230 of Figure 5A) for not being blocked by the first gear 120 upon attachment of the third framework 200b to the first and the second carriages 112, 113.
[0102] Figure 13 shows, in a block diagram form, a method 400 in accordance with an embodiment of the invention.
[0103] The method 400 allows to configure a machine for roll-forming sheet metal and includes:
- a step of providing 401 a machine with a motor and a bench, the machine being suitable for roll-forming sheet metal;
- a step of providing 402 a shaft and coupling it with the motor, that is, providing a shaft coupled with the motor;
- a step of providing 403 the bench with a first carriage and a second carriage. The first and the second carriages are adapted to support attachment and detachment of at least one framework for roll-forming sheet metal;
- a step of adjusting 404 a separation between the first and the second carriages in accordance with a size of at least one framework;
- a step of attaching 405 a first framework for roll-forming sheet metal to at least one of the first and the second carriages. The first framework may become attachable to the at least one of the first and the second carriages owing to the separation having been adjusted 404 in the previous step.
- a step of detaching 406 the first framework from each carriage it is attached to, namely, the at least one of the first and the second carriages. The first framework may be detached after finishing a roll-forming process with the same. The first framework may be lifted from the machine with a crane, for example, in order to free up the machine;
- a step of readjusting 407 the separation between the first and the second carriages.
- a step of attaching 408 a second framework for roll-forming sheet metal to at least one of the first and the second carriages. Upon finishing the attachment, the machine may be used with the second framework for carrying out a roll-forming process.
[0104] In this text, the term "comprises" and its derivations (such as "comprising", etc.) should not be understood in an excluding sense, that is, these terms should not be interpreted as excluding the possibility that what is described and defined may include further elements, steps, etc.
[0105] The invention is obviously not limited to the specific embodiment(s) described herein, but also encompasses any variations that may be considered by any person skilled in the art (for example, as regards the choice of materials, dimensions, components, configuration, etc.), within the general scope of the invention as defined in the claims.
1. A machine (100, 180) for roll-forming sheet metal, comprising:
a motor (101);
a bench (103) comprising a first carriage (110, 112) and a second carriage (111, 113), each of the first and the second carriages (110-113) being configured to support attaching and detaching at least one framework (200, 201) for roll-forming sheet metal, and the bench (103) being configured to adjust a separation (115) between the first carriage (110, 112) and the second carriage (111, 113);
a shaft (102) coupled with the motor (101); and
first and second gears (120, 121) coupled with the shaft (102);
the shaft (102) is configured to actuate rollers (210, 211) of the at least one framework (200, 201) when the at least one framework (200, 201) is attached to at least one of the first and the second carriages (110-113).
2. The machine (100, 180) of claim 1, further comprising at least one linear actuator
for moving at least one of the first and the second carriages (110-113), thereby adjusting
the separation (115); wherein the separation (115) between the first carriage (110,
112) and the second carriage (111, 113) is in a direction of a transversal axis of
the bench (103).
3. The machine (100, 180) of any of claims 1-2, wherein the first gear (120) is configured
to engage with at least one gear (220, 221) of the at least one framework (200, 201)
to actuate the rollers (210, 211) thereof.
4. The machine (100, 180) of claim 3, wherein:
the at least one framework (200, 201) comprises a first framework (200, 200a, 200b);
the first framework (200, 200a, 200b) comprises a plurality of rollers (210) and at least one gear (220, 221);
each of the first and the second carriages (110-113) is configured to support attaching and detaching the first framework (200, 200a, 200b); and
the first gear (120) is configured to engage with the at least one gear (220, 221) of the first framework (200, 200a, 200b) to actuate the plurality of rollers (210) thereof.
5. The machine (100, 180) of claim 4, wherein:
the at least one framework (200, 201) further comprises a second framework (200, 200a, 200b);
the second framework (200, 200a, 200b) comprises a plurality of rollers (210) and at least one gear (220, 221);
each of the first and the second carriages (110-113) is further configured to support attaching and detaching the second framework (200, 200a, 200b); and
the second gear (121) is configured to engage with the at least one gear (220, 221) of the second framework (200, 200a, 200b) to actuate the plurality of rollers (210) thereof.
6. The machine (100, 180) of claim 3, wherein:
the at least one framework (200, 201) comprises:
a first framework (201, 201a, 201c) comprising a plurality of rollers (211, 211a) and at least one gear (220a, 221); and
a second framework (201, 201b, 201d) comprising a plurality of rollers (211, 211b) and at least one gear (220b, 221);
the first carriage (110, 112) is configured to support attaching and detaching the first framework (201, 201a, 201c), and the second carriage (111, 113) is configured to support attaching and detaching the second framework (201, 201b, 201d); and
the first gear (120) is configured to engage with the at least one gear (220a, 221) of the first framework (201, 201a, 201c) to actuate the plurality of rollers (211, 211a) thereof, and the second gear (121) is configured to engage with the at least one gear (220b, 221) of the second framework (201, 201b, 201d) to actuate the plurality of rollers (211, 211b) thereof.
7. The machine (100, 180) of claim 6, further comprising a third gear (122) and a fourth
gear (123); wherein:
the at least one framework (200, 201) further comprises:
a third framework (201, 201a, 201c) comprising a plurality of rollers (211, 211a) and at least one gear (220a, 221); and
a fourth framework (201, 201b, 201d) comprising a plurality of rollers (211, 211b) and at least one gear (220b, 221);
the first carriage (110, 112) is further configured to support attaching and detaching the third framework (201, 201a, 201c), and the second carriage (111, 113) is further configured to support attaching and detaching the fourth framework (201, 201b, 201d); and
the third gear (122) is configured to engage with the at least one gear (220a, 221) of the third framework (201, 201a, 201c) to actuate the plurality of rollers (211, 211a) thereof, and the fourth gear (124) is configured to engage with the at least one gear (220b, 221) of the fourth framework (201, 201b, 201d) to actuate the plurality of rollers (211, 211b) thereof.
8. The machine (100, 180) of claim 6, further comprising a third gear (122); wherein:
the at least one framework (200, 201) further comprises a third framework (200, 201 a, 201b);
the third framework (200, 201a, 201b) comprises a plurality of rollers (210) and at least one gear (220, 221);
the first carriage (110, 112) is further configured to support attaching and detaching the third framework (200, 200a, 200b), and the second carriage (111, 113) is further configured to support attaching and detaching the third framework (200, 200a, 200b); and
the third gear (122) is configured to engage with the at least one gear (220, 221) of the third framework (200, 200a, 200b) to actuate the plurality of rollers (210) thereof.
9. The machine (100, 180) of any of claims 1-8, wherein:
the first carriage (110, 112) has an opening (116) formed therein;
the second carriage (111, 113) has an opening (117) formed therein;
the first gear (120) of the machine (100, 180) protrudes from the opening (116) of the first carriage (110, 112) and is configured to move together with the first carriage (110, 112) when the first carriage (110, 112) is moved; and
the second gear (121) of the machine (100, 180) protrudes from the opening (117) of the second carriage (111, 113) and is configured to move together with the second carriage (111, 113) when the second carriage (111, 113) is moved.
10. The machine (100, 180) of any of claims 1-9, wherein each of the first and the second
carriages (110-113) comprises a plurality of clamps for supporting attachment and
detachment of the at least one framework (200, 201).
11. A method for configuring a machine (100, 180) for roll-forming sheet metal, comprising:
providing the machine (100, 180) with a motor (101) and a bench (103);
providing the bench (103) with a first carriage (110, 112) and a second carriage (111, 113);
adjusting a separation (115) between the first carriage (110, 112) and the second carriage (111, 113);
attaching a first framework (200, 201) for roll-forming sheet metal to at least one of the first and the second carriages (110-113); and
providing a shaft (102) coupled with the motor (101), and first and second gears (120, 121) coupled with the shaft (102), the shaft (102) being configured to actuate rollers (210, 211) of the first framework (200, 201).
12. The method of claim 11, wherein attaching the first framework (200, 201) to at least
one of the first carriage and the second carriage (110-113) comprises attaching the
first framework (200) to each of the first carriage and the second carriage (110-113).
13. The method of any of claims 11-12, further comprising:
detaching the first framework (200, 201) from each carriage (110-113) of the first carriage (110, 112) and the second carriage (111, 113) that the first framework (200, 201) is attached to;
readjusting the separation (115) between the first carriage (110, 112) and the second carriage (111, 113); and
attaching a second framework (200, 201) for roll-forming sheet metal to at least one of the first carriage (110, 112) and the second carriage (111, 113);
wherein the shaft (102) is further configured to actuate rollers (210, 211) of the second framework (200, 201).
14. An assembly (300, 301a, 301b) for roll-forming sheet metal, comprising:
a machine (100, 180) according to any of claims 1-10; and
at least one framework (200, 201) for roll-forming sheet metal comprising a plurality of rollers (210, 211), the at least one framework (200, 201) being detachably attached to at least one carriage (110-113) of the machine (100, 180).
15. The assembly (301a, 301b) of claim 14, wherein:
the at least one framework (200, 201) for roll-forming sheet metal comprises a first framework (201, 201a, 201c) and a second framework (201, 201b, 201d);
the first framework (201, 201a, 201c) is detachably attached to a first carriage (110, 112) of the machine (100, 180); and
the second framework (201, 201b, 201d) is detachably attached to a second carriage (111, 113) of the machine (100, 180).