Ferrule rolling machine

Apparatus for forming a sheet metal strip into metal ferrules comprising edge guide means to feed a continuous metal strip into a pair of trim rolls to cut the metal strip to a desired width, and means engage the surplus portion of the metal strip and guide it through a controlled path to return to the edge guide means. A pair of notching or cutting rolls notch the metal strip transversely at axially spaced portions for forming ferrule sections in the continuous strip, and a plurality of pairs of forming rolls for engaging the strip and rolling it to substantially cylindrical shape, which pairs of rolls each have one resiliently positioned roll mounted on a frame by laterally extending support plates.

BACKGROUND OF INVENTION 
In the positioning of gutters and rainspouts on building structures, a 
plurality of metal ferrules are required for aiding in securing the 
gutters to but spaced from the building. These metal ferrules usually are 
elongate tubes having an axially extending split therein, and these 
ferrules have been somewhat costly to produce heretofore. The ferrules are 
used in quantities by builders and any reduction in the cost of the 
ferrule can result in an appreciable savings to persons working with large 
numbers of ferrules for use in positioning gutters on a variety of 
buildings as a part of building actions of such person. 
Prior types of sheet metal strip roll-forming apparatus have been known, 
and examples of them are shown in my own prior U.S. Pat. Nos. 3,785,191 
and 3,945,233. However, the apparatus shown in such prior patents is not 
designed for, nor adapted to provide metal ferrules, and it is desirable 
to produce uniform quality ferrules in large quantities by inexpensive 
forming actions on sheet metal strips. 
OBJECTS OF INVENTION 
The general object of the present invention is to provide relatively 
inexpensive, but effective roll apparatus for cutting a sheet metal strip 
to a desired width, cutting the metal strip into ferrule forming sections, 
and then gradually rolling the metal strip to ferrule shape and providing 
the individual ferrules desired. 
Another object of the invention is to position a pair of metal rolls in 
adjustable pressure rolling association and wherein the one roll is 
readily disengageable from the roll assembly. 
Another object of the invention is to position pairs of sheet metal forming 
and/or engaging and/or notching rolls in adjustable pressurized and/or 
spacing relationship by use of set screw members engaging a support means 
and a roll support shaft. 
Yet another object of the invention is to facilitate the formation of metal 
ferrules efficiently and effectively and at low cost from an elongate 
strip of scrap sheet metal which is readily processed or moved through the 
apparatus several times to sever edge strips therefrom and represent the 
remaining portion of the strip to the apparatus for further processing, 
including again severing an edge strip therefrom and processing such edge 
strip to form metal ferrules therefrom. 
The foregoing and other objects and advantages of the invention will be 
made more apparent as the specification proceeds.

SUBJECT MATTER OF INVENTION 
This apparatus for forming metal ferrules from sheet metal strips comprises 
edge guide means for feeding a metal strip into a pair of trim rolls to 
cut a predetermined width edge strip therefrom, and means usually are 
present to engage the surplus portion of the metal strip and guide it 
through a controlled path to return it back to the edge guide means for a 
further edge strip severing action, a pair of notching rolls for notching 
or scoring the metal strip transversely at axially spaced portions for 
forming ferrule sections in the continuous strip, and a plurality of pairs 
of forming rolls for engaging the strip and rolling it to substantially 
cylindrical shape, each pair of rolls having one resiliently positioned 
roll therein mounted on the frame of the apparatus by laterally extending 
support plates engaging the frame means by readily removable means. 
Attention now is particularly directed to the details of the structure 
shown in the drawings and the apparatus for forming metal ferrules from 
sheet metal strip is indicated as a whole by the numeral 10. This 
apparatus 10 includes a suitable frame means 12, and the apparatus is 
adapted to process a sheet metal strip to form metal ferrules therefrom. 
FIG. 5 shows a sheet metal strip or piece 14 engaging suitable edge guide 
rolls 16 positioned in alignment on the frame 12 which rolls position the 
sheet to pass through a pair of trim rolls 18 and 20 where the upper trim 
roll, in this instance, has a pair of edge flanges 22 and 24 formed 
thereon which edge flanges are bridged over and are closely aligned with 
the side edges of the trim roll 20 whereby as the sheet metal portion 14 
is moved along to be processed by the trim rolls 18 and 20, and an edge 
strip 26 is cut therefrom, the remaining section 28 of the sheet metal 
usually moves through a different controlled path from the edge strip 26 
that moves from the trim rolls 18 and 20 into the remaining portions of 
the apparatus for being progressively rolled and formed into the desired 
tubular metal ferrule 30 produced by the apparatus. 
FIG. 1 indicates that the residual sheet metal section 28, usually an 
elongate piece of sheet metal, is moved along a lower portion of the frame 
12 to engage and/or be supported on a plate 32 that has a reverse bend 34 
provided therein adjacent the end portion of the frame 12. A guide plate 
36 is positioned adjacent, above and usually parallel to this plate 32 at 
the bend or end portion therein, which guide plate 36 extends back along 
the apparatus below the plate 32, as indicated at 38, to guide the sheet 
section 28 back to the forward or input end of the apparatus. Then the 
leading end of the sheet section 28 can be manually grasped or be guided 
by other means, not shown, so as to be moved, guided, lifted or bent to 
move upwardly and rearwardly in the apparatus to come back into the 
position indicated in FIG. 5 for the metal sheet 14, but which sheet is 
now of reduced width to be again processed by having an edge section cut 
therefrom for working in the apparatus. 
Obviously the trim rolls 18 and 20 are so designed as to provide an edge 
strip 26 of desired width to provide the desired diameter of finished 
metal ferrule by the apparatus. 
From the trim rolls 18 and 20, the edge strip 26 moves into and is engaged 
by a pair of notching rolls 40 and 42 wherein the upper notching roll 40 
is cylindrical in its periphery but which has resilient pressure 
engagement with the lower notching roll 42 that is of cylindrical 
peripheral contour. A cutter bar or scoring blade 44 projects from the 
periphery of the roll 42 and extends the axial width of the roll, as 
indicated in FIG. 3, whereby the metal edge section being processed will 
have a scoring or notch mark provided thereon extending the width of the 
edge strip 26 at desired longitudinally spaced portions thereof. 
Preferably this lower notching roll 42 is mounted on a shaft 46 suitably 
journalled on the frame 12 in a fixed position. The upper notching roll 40 
is mounted on a shaft 48 by suitable bearing means 49, and this shaft 48 
is adjustable vertically on an axis perpendicular to the axis of the shaft 
46. FIGS. 3 indicates that a pair of set screws 50 engage support brackets 
52 that may be tubular, and wherein such support brackets 52 are secured 
to edge plates 54 fixed to a lower portion of the apparatus. Normally the 
tubular brackets 52 are larger in diameter than the shaft 48 so that as 
these set screws 50, that are in threaded engagement with the brackets are 
rotated, then the shaft 48, which is solely supported by the set screws 
50, can be moved vertically with relation to the shaft 46 and the cutting 
or notching pressure action provided between the blade 44 and notching 
roll 40 can be varied depending upon the gauge of metal being processed, 
the depth of the notch desired, etc. Thus, a very easily controlled 
notching pressure relationship is established between the means mounting 
the rolls 40 and 42 in the apparatus and the strip 26 has readily 
separable sections therein. 
A guide 56 is shown on the frame 12 to aid in controlling the feed of the 
edge strip 26 as it moves towards the notching rolls 40 and 42 whereas 
another guide 58 can engage the sheet section 28 to aid in feeding it into 
and guiding it along the path indicated in FIG. 1. 
A plurality of forming rolls or roll stands are present in the apparatus, 
and FIG. 4 indicates the construction and positioning of a typical pair of 
these forming rolls indentified by the numerals 60 and 62. Preferably six 
different pairs of forming rolls are provided and these rolls 60 and 62 
are the last pair of forming rolls wherein the sheet section 26 being 
processed is now in substantially tubular shape as indicated in FIG. 11. 
An adjustable pressure, easily disassembled apparatus is provided for 
positioning the rolls 60 and 62 in operative engagement and thus shafts 64 
and 66 for these rolls are journalled in suitable roller bearings 68 and 
70, a pair of which engage opposite ends of the shafts 64 and 66. The 
roller bearing 70 is of the type wherein a somewhat sizable radial length 
stationary peripheral ring is provided in the bearing and these stationary 
rings or collars then are secured, as by welding, to portions of the frame 
12 as indicated by the T-bars 72 of FIG. 4. Then to position the roll 60 
in operative engagement with the roll 62, the smaller diameter bearings 68 
each preferably have an end or edge plate or bracket 74 secured, as by 
welding, to a lower portion thereof to extend laterally therefrom. These 
edge plates 74 have apertures 76 therein and they are adapted to engage 
with threaded studs 78 secured to the outer rings of the bearings 70 and 
extending vertically upwardly therefrom to receive and position the edge 
plates 74 thereon. Normally the edge plates would just seat against the 
upper surface of these outer rings on the bearings 70, and the edge plates 
are held in operative position by springs 80 telescoped over the studs 78 
and secured in position by nuts 82 to provide an adjustable and releasable 
pressure retaining the rolls 60 and 62 in operative engagement. Hence, 
when desired, the nuts 82 can be readily removed, the springs 80 pulled 
off of the studs and the upper rolls of each of the roll stands can be 
removed for cleaning or adjustment purposes as desired. Inasmuch as only 
sheet metal material is to be operated on by the apparatus of the 
invention, the use of relatively lightweight rolls, shafts and springs is 
possible and still desirable and accurate rolling conditions and 
operations can be provided. 
FIGS. 6 through 11 show the progressive rolling action of the initial roll 
stand 60a, 62a, of FIG. 6, wherein the initial curvature at the edges of 
the edge strip 26 is started and then the remaining rolls 60b, 62b; 60c, 
62c; 60d and 62d; and 60e and 62e are provided to provide five forming 
actions with progressive shaping of the edge section into the tubular 
member desired as shown in the end or final roll stands 60 and 62 of FIG. 
11. 
It should be also understood that the metal ferrules being produced are 
longer in length than the distance between the adjacent roll stands used 
in processing the metal strip of the invention. Thus, all of the rolls, 
including the notching rolls 40 and 42 up through the final roll stand 60 
and 62 are all in such closely spaced relationships in a direction axially 
of the apparatus, that the metal strip is continually being engaged by two 
of the roll stands, but when only engaged with the final roll stands 60 
and 62, and as it leaves therefrom, the metal has been so shaped and 
worked during the processing by the apparatus that it has been severed 
into individual axial lengths at the transverse notches therein by such 
working and the individual ferrules will be propelled out from the roll 
stands 60 and 62 for receipt in any suitable container positioned 
thereadjacent. 
The apparatus is driven in the manner shown in U.S. Pat. No. 3,945,233. 
That is one support shaft for each pair of rolls projects slightly 
laterally of the frame and a common driven chain drive means or other 
known members engage the shafts for unitary power supply and drive action. 
This apparatus of the invention provides uniform quality ferrules, and the 
apparatus can be easily adjusted for working with different gauges of 
metal if desired, and the apparatus is efficient since it can take any 
suitable length and width piece of sheet metal, cut edge sections 
therefrom and process the cut edge sections into finished products. 
Usually the strip of metal being processed is of sufficient width that a 
plurality of edge cuts can be made therefrom and thus the apparatus of the 
invention conveniently returns the metal sheet being processed back to the 
entrance end of the apparatus for another pass therethrough after the 
first pass of the metal sheet is completed. The apparatus of the invention 
is easily adjusted in cutting pressure actions by the roll means shown in 
FIG. 3, and the sections processed can be varied in length dependent upon 
the particular rolls used to form the notching rolls 40 and 42 and the 
particular size and shape of the trim rolls 18 and 20. The apparatus is 
low in cost but effective in action. Hence, it is believed that the 
objects of the invention have been achieved. 
It should be realized that the metal strip 28 is led back to a position 
adjacent the guides 16 and rolls 18 and 20 by the means 32, 34, 36 and 38. 
It is only fed into the apparatus again when the prior strip 26 clears the 
apparatus. 
The adjustment of position of the shaft 48 can be achieved by any known 
means to enable the shaft to be moved relative to the fixed shaft 48 and 
the screws 50 could extend through the shaft 48, be secured to the shaft 
by top and bottom split lock rings 51, and the screw 50 not be in threaded 
engagement with the shaft. 
While one complete embodiment of the invention has been disclosed herein, 
it will be appreciated that modification of this particular embodiment of 
the invention may be resorted to without departing from the scope of the 
invention.