FOLDING MACHINE FOR FLAT MATERIALS

A folding machine for folding flat sheet metal material includes a series of bottom clamp heads and a series of top clamp heads are pivotally coupled to the bottom clamp heads. A bottom clamp is coupled to the bottom clamp heads, while a top clamp is coupled to the top claim heads. A bottom folding apron is mounted to the bottom clamp, while a top folding apron is mounted to the top clamp. A side loader assembly transfers sheet metal material into the folding machine for processing. A series of lifting tray assemblies reciprocate vertically between a raised position above the material working surface and a lowered position. Back gauges abut, grasp and hold the rearward edge of the sheet metal material when positioned upon the material working surface. The back gauges may move under the sheet metal material when the lifting assemblies are in their raised position.

CROSS REFERENCE TO RELATED APPLICATIONS

Not applicable.

Not applicable.

THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT

Not applicable.

TECHNICAL FIELD

The present inventive relates to a machine used to fold flat materials, and more particularly, a machine used to fold flat metal materials along extended fold lines and the method of folding such flat metal materials.

BACKGROUND OF THE INVENTION

Metal parts are oftentimes formed by bending or folding a length of flat material or sheet. The metal sheet may be folded multiple times in order to produce the finished product.

Machines that fold the flat metal material have been designed and produced to perform this task. A typical folding machine is shown in U.S. Pat. No. 11,541,442 B2, which is incorporated herein by reference in its entirety. These folding machines include a top clamp head or upper machine frame part and a bottom clamp head or lower machine frame part. The top clamp head and bottom clamp head moves relative to each other between a loading position when feeding the metal material and a working position when processing the metal material. The top clamp head has an upper bending beam or working tool. Similarly, the bottom clamp head has a lower bending beam or working tool. These working tools move to form the bend or fold in the material. A side insertion unit or beam extends between the top clamp head and the bottom clamp head. The side insertion unit includes a shuttle having pneumatic suction cups which hold the metal material and moves back and forth along the side insertion unit to position the metal material within the machine.

A problem with these machines is that they can only position and process one piece of metal material at a time. As such, the sequential processing of multiple pieces of metal material can be very time consuming.

A folding machine has been devised that bends several pieces of metal material at the same time. These machines multiple pieces of metal material into the machine prior to processing. However, the machine must still completely process the metal material before it moves the next series of metal material into the machine. Thus, there is still a significant stalling of the machine during each folding process.

Accordingly, it is seen that a need therefore exists for an improved folding machine which can process multiple pieces of metal material simultaneously. It is the provision of such therefore that the present invention is primarily directed.

BRIEF SUMMARY OF THE INVENTION

A folding machine for folding sheet metal material, the folding machine comprises a frame, at least one bottom clamp head coupled to the frame, at least one top clamp head pivotally coupled to the at least one bottom clamp head, a bottom clamp coupled to the at least one bottom clamp head, a top clamp coupled to the at least one top clamp head, a bottom folding apron coupled to the bottom clamp, a top folding apron coupled to the top clamp, a material working surface configured to support a sheet metal material, the material working surface being positioned adjacent the bottom clamp, at least one back gauge reciprocally movable between a first position distal the bottom clamp and a second position adjacent the bottom clamp, wherein the at least one back gauge is configured to engage a trailing edge of the sheet metal material, at least one lifting tray assembly configured to support the sheet metal material thereon, the at least one lifting tray assembly being reciprocally movable between a lower position and a raised position elevating the sheet metal material to a position above the material working surface allowing for the passage of the at least one back gauge beneath the sheet metal material as the back gauge moves from the second position to the first position, and a side loader assembly positioned between the bottom clamp head and the top clamp head, the side loader assembly including an elongated transfer shuttle beam and a transfer shuttle movable along the transfer shuttle beam between a loading position and an unloading position.

A method of operating a folding machine for folding a plurality of sheet metal materials comprising the steps of (A) loading a first sheet metal material into a folding machine, (B) indexing the first sheet metal material into a position for folding operation, (C) commencing the folding operation on the first sheet metal material, (D) loading a second sheet metal material into the folding machine while simultaneously continuing the folding operation of the first sheet metal material, (E) completing the folding operation of the first sheet metal material, (F) indexing the second sheet metal material into a position for folding operation, and (G) commencing the folding operation of the second sheet metal material.

DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS

With reference next to the drawings, there is a shown a folding machine 10 for folding flat sheet metal material M embodying principles of the invention in a preferred form.

The folding machine 10 includes a base or frame 12 upon which is mounted a series of bottom clamp heads or lower machine frame parts 14. A top surface of the bottom clam heads 14 form a generally co-planar material working surface 16. A series of top clamp heads or upper machine frame parts 20 is pivotally coupled to the bottom clamp heads 14 for movement between an open, material loading position and a closed, material working position. The top clamp heads 20 are moved through conventionally know pneumatic devices, hydraulic devices, or other mechanical means.

An elongated bottom clamp 22 is coupled to a distal end of the bottom clamp heads 14. Similarly, an elongated top clamp 24 is coupled to a distal end of the top claim heads 20. The bottom and top clamps 22 and 24 are configured to hold a piece of sheet metal material M therebetween when the top clamp heads 20 are in their closed position.

A bottom folding apron, lower bending beam, or working tool 26 is mounted to the bottom clamp 22 for pivotal movement relative to the bottom clamp 22. A top folding apron, lower bending beam, or working tool 28 is mounted to the top clamp 24 for pivotal movement relative to the top clamp 24. The relative movement between the top and bottom folding aprons 28 and 26 and their adjoining top and bottom clamps 24 and 22 creates the fold in the sheet metal material M held by the top and bottom clamps 24 and 22. The top and bottom folding aprons 28 and 26 are coupled to and moved through conventionally know pneumatic devices, hydraulic devices, or other mechanical means.

The folding machine 10 also includes a side loader assembly or side insertion unit 34 mounted to the bottom clamp head 14. The side loader assembly 34 has a transfer shuttle beam or central rail 36 extending between the top clamp head 20 and the bottom clamp head 14. The transfer shuttle beam 36 is mounted to the bottom clamp head 14 for back and forth or reciprocal, vertical movement between a lower engaging position and an upper transfer position. Alternatively, the transfer shuttle beam 36 may be mounted to the top clamp head, frame, be independent, self-supporting structure, or other mounting configurations. The side loader assembly 34 also includes a transfer shuttle 38 coupled to the transfer shuttle beam 36 for back and forth, or reciprocal horizontal movement along the longitudinal length of the transfer shuttle beam 36 between a loading position proximal an entry end of the folding machine 10 and an unloading position distal the entry end of the folding machine. The transfer shuttle 38 is of conventional design having pneumatic suction cups 40 which releasably hold the sheet metal material M. The suction cups 40 are coupled to a pneumatically operated vacuum source to create a negative air pressure associated with each suction cup 40. The transfer shuttle 38 is moved along the transfer shuttle beam 36 through a servo motor coupled to a linear timing belt system, although other means may also be used to create similar movements of the transfer shuttle. An infeed roller 42 is mounted to the bottom clamp head 14 associated with an entry end of the folding machine to help guide the sheet metal material M into the folding machine 10 during the in feeding process of the sheet metal material M, as best shown in FIG. 4. The construction of the folding machine thus far is similar to that shown in U.S. Pat. No. 11,541,442 B2 which is incorporated herein by reference in its entirety.

The folding machine 10 also includes a series of lifting tray assemblies 44 wherein the first two lifting tray assemblies 44 include a central lifting tray 46 and two oppositely disposed side lifting trays 48, while the last three lifting tray assemblies 44 include two dual lifting trays 50. Each central lifting tray 46, side lifting tray 48, and dual lifting tray 50 includes pneumatic devices, hydraulic devices, or other mechanical means, for vertically reciprocating the lifting trays 46, 48 and 50 in a vertical direction between a raised position above the material working surface 16 and a lowered position generally co-planar with the material working surface 16. Each lifting tray assembly 44 may include an attachment base or plate 52 and a pneumatic cylinder 54 coupled between the attachment base 52 and the corresponding central lifting tray 46, side lifting tray 48, or dual lifting tray 50 for vertical movement of the corresponding lifting trays.

The folding machine also includes conventionally known reciprocating back gauges 58 that abut, grasp and hold the rearward edge of the sheet metal material M when positioned upon the material working surface 16. The back gauges 58 incrementally move the sheet metal material M forwardly prior to and during the folding process with each incremental movement being associated with a fold of the sheet metal material M. The back gauges 58 are configured so as to have a height that allows the back gauges 58 to move beneath the sheet metal material M positioned upon the lifting tray assemblies while in the raised position. Thus, the back gauges 58 reciprocate, or move back and forth in a lateral direction relative to the transfer shuttle beam 36 between a forward position and a rearward position. Again, the back gauges 58 move through the actuation of pneumatic devices, hydraulic devices, or other mechanical means.

The actuation of the pneumatics, hydraulics, or other mechanical means for movement of the top clamp head 20, top folding apron 28, bottom folding apron 26, transfer shuttle beam 36, transfer shuttle 38, transfer shuttle suction cups 40, lifting tray assemblies 44, and back gauges 58 are all conventionally controlled by a computer or processor 60 that automates and coordinates the actuation of each component.

The folding machine 10 is intended to be utilized in conjunction with a supply table ST configured to support a vertical stack of sheet metal material M to be processed by the folding machine 10. The supply table ST is positioned adjacent the entrance end of the folding machine 10, as shown in FIGS. 1, 6B, 7B, and 9B.

In use, a stack of sheet metal material M is placed upon a supply table ST positioned adjacent the entry end of the folding machine 10. The folding machine 10 is then actuated to commence the folding process of each sheet of the sheet metal material M.

As shown in FIGS. 6A and 6B, with the top clamp head 20 in its closed position, the lifting tray assemblies 44 their lowered position, the back gauges 58 in their rearward position, and the transfer shuttle 38 in its loading position, the side loader assembly 34 is actuated so that the transfer shuttle beam 36 is moved to its lower engaging position. With the transfer shuttle beam 36 lowered, the suction cups 40 of the transfer shuttle 38 contact and engage the top surface of the topmost sheet metal material M of the stack of sheet metal materials so that the sheet metal material M releasably adheres to the suction cups 40 by means of the downstream suction of negative air pressure located within the suction cups 40.

As shown in FIGS. 7A and 7B, the side loader assembly 34 is then actuated so that the transfer shuttle beam 36 is raised to its upper transfer position, thereby lifting a first end of the sheet metal material M from the remaining stack of sheet metal materials. The lifting tray assemblies 44 are also moved to their raised position.

As shown in FIGS. 8A and 8B, the transfer shuttle 38 is then moved along the longitudinal length of the transfer shuttle beam 36 to its unloading position. The vacuum associated with the suction cups 40 is then stopped so that the sheet metal material M is released from the suction cups 40. The sheet metal material M is now resting upon or is positioned upon the raised lifting tray assemblies 44, specifically the central lifting tray 46, side lifting trays 48, and dual lifting trays 50 of each lifting tray assembly 44.

As shown in FIGS. 9A and 9B, the transfer shuttle is then moved back along the longitudinal length of the transfer shuttle beam 36 so that is returns to its loading position.

As shown in FIGS. 10A and 10B, with the lifting tray assemblies 44 still in their raised position, the back gauges 58 are moved back to their rearward position. The back gauges 58 pass beneath or below the raised sheet metal material M supported upon the raised lifting tray assemblies 44, i.e., the lifting tray assemblies 44 provide clearance beneath the raised sheet metal material M for return passage or movement of the back gauges 58. The lifting tray assemblies 44 are then moved downwardly to their lowered position whereby the sheet metal material M is now supported upon the material working surface 16 of the bottom clamp heads 14, as shown in FIG. 10C. The sheet metal material M may also be partially supported on the lowered lifting tray assemblies 44. The top clamp heads 20 are also pivoted to their open loading position to create a space between the bottom clamp 22 and the top clamp 24 for subsequent passage of the sheet metal material M.

With the sheet metal material M resting upon the material working surface 16 the back gauges 58 are moved forwardly so that they contact and grip the rearward or trailing edge of the sheet metal material M. The back gauges 58 are then moved or indexed forwardly until the sheet metal material M is properly positioned for its first fold wherein the top clamp heads 20 are pivoted to their closed or working position so that the bottom clamp 22 and top clamp 24 contact and hold the sheet metal material M therebetween. The bottom folding apron 26 and/or top folding apron 28 may then be actuated to create a first fold upon the sheet metal material M. The back gauges 58 may continually and incrementally move or index the sheet metal material M forwardly while the top clamp head 20 pivots slightly upwardly to temporarily or momentarily release the sheet metal material M to reposition the sheet metal material M for subsequent folds through actuation of the bottom folding apron 26 and/or top folding apron 28.

During the continuous folding actions of the bottom folding apron 26 and/or top folding apron 28, the lifting tray assemblies 44 are returned to their raised position, the vacuum upon the suction cups 40 is actuated, and the side loader assembly 34 is actuated to lower the transfer shuttle beam 36 to its lower engaging position in order to hold a second sheet metal material M now positioned at the top of the stack of sheet metal materials M. The entire sequencing of movements then reoccurs as previously described. Thus, while one piece of sheet metal material M is located along the front of the folding machine 10 associated with the bottom and top clamps 22 and 24, a second piece of sheet metal material M may be grasped and moved into an initial loaded position upon the raised lifting tray assemblies within the folding machine for processing.

Thus, one sheet metal material M is being processed through multiple folding operations by the folding machine 10, the folding machine 10 is also simultaneously loading another sheet metal material M within the folding machine 10. This is achieved through the raising of the material through the lifting tray assemblies 44 above the level of the material working surface 16 so that the back gauges 58 can move under and past the loaded sheet metal material to their rearward positions. As such, it is no longer necessary to complete the entire folding sequence of the first sheet metal material M prior to loading a second sheet metal material into the folding machine 10. This ability to both work and simultaneously load multiple sheets decreases the time associated with processing each sheet of sheet metal material M. Thus, the folding machine 10 may produce more finished products from the sheet metal materials M during a given time period, thereby reducing costs and increasing production.

It should be understood that the initial positions of the folding machine components, such as the top clamp heads 20, back gauges 58, lifting trays 44, transfer shuttle 38, shuttle beam 36, and other items have been described in a preferred method. However, these positions may be changed or altered without departing from the present invention. An important factor is that the lifting trays 44 raise the sheet metal material M so that the back gauges 58 may move beneath the sheet metal material M so that the second piece of sheet metal material may be loaded into the folding machine while the first piece of sheet metal material is being processed or folded. Obviously, these positions are also dependent upon where the components are located when the folding machine restarts or commences the folding machine after a pause.

It will be appreciated that the inventions are susceptible to modification, variation and change without departing from the spirit thereof.