A bending apparatus

Abstract: An apparatus method for bending channel cross-­ section strip or panel material in which the material is passed between an infeed roller set 10, 16, 18, an intermediate roller set 12, 20, 22 and an outfeed roller set 14, 24, 26. At least one of the rollers of each roller set has two axially spaced annular projections which define an accommodation space for the flanges of the strip material. The axial spacing between these annular projections is reduced between the infeed and outfeed roller sets to enable the panel cross-section to be retained over a wide range of panel materials and curvatures.

Description: The present invention relates to a bending apparatus and method for giving a longitudinal curvature of a predetermined radius to a length of thin, constant channel cross-section profile strip or panel of performable material. Such material is often used for lining walls and ceilings and it is sometimes necessary to produce a longitudinal curvature in such strip or panel material. US-A-4154077 discloses, for this purpose, an apparatus which includes an infeed roller set, an outfeed roller set and an intermediate roller set, each set having a main roller and a support roller, whereby the main rollers of the infeed and outfeed roller sets engage with one surface of the strip or panel and the main roller of the intermediate roller set engages with the opposite surface of the strip or panel. The intermediate roller set is offset with respect to the infeed and outfeed roller sets and drive means are provided for driving at least one of the main rollers and/or at least one of the support rollers. Whilst such an apparatus is generally satisfactory, it is not always possible for the preformed cross-section of the strip or panel material to be exactly retained whatever is the chosen radius of curvature, to allow for subsequent mounting of the curved panels. Any deviation in cross-section or dimensional shape would render the panels unacceptable. With the known apparatus, in the general effort to control the cross-sectional panel shape, the mating supporting rollers have been added to each main roller to enclose and support the panel cross-section in all its critical areas. However, due to the unpredictable behaviour and spring back of the panel material it has not yet been possible to produce entirely satisfactory results. Any successful compensation to the panel cross-section at a given radius of curvature has only been any good for one type of panel material, whereas differences in material thickness, metal alloy and curvature have prohibited general application of this bending technique. The apparatus of the present invention comprises the features of the preamble of claim 1 and is characterised in that the main roller of at least the infeed and outfeed roller sets is provided with a main roller portion of axial length and axially spaced annular cheeks axially outwardly of said main roller portion and the support roller of at least the infeed and outfeed roller sets is provided with axially spaced annular enlargements, said annular cheeks and enlargements of each set touching and defining accommodation spaces positioned axially outwardly of said main roller portion one for each of the side flanges of the strip or panel, the annular enlargements and cheeks forming each of said spaces having a shape whereby, in use, the outer surfaces of the side flanges conform thereto and the frontal surfaces of the free ends of said flanges abut or nearly abut the cheeks, the volume and shape of the corresponding accommodation spaces of the infeed roller set and the outfeed roller set being identical or nearly identical, but the axial distance between the axially outermost points of the sides of the accommodation spaces of said outfeed roller set being smaller than the corresponding distance for said infeed roller set, such as to produce, in use, an arcuate profiled strip or panel of which the shortest distance between the free ends of the profiled flanges of that strip or panel after a bending operation is equal or substantially equal to the corresponding distance before the bending operation. With this reduction in the distances it has been found possible to retain the panel cross-section over a wide range of panel materials and curvatures. The reduction in the distances is relatively small, being preferably between 0.5 and 4 % reduction between the infeed roller set and the outfeed roller set. It has been found, surprisingly, that using the apparatus according to the invention the apparently illogical and seemingly impossible restriction in the shape and dimension compensates for all the possible spring back or material behaviour, within a very useful range. Advantageously the intermediate roller sets are also provided with axially spaced annular enlargements which define accommodation spaces identical or substantially identical to that of the infeed roller set and preferably these annular enlargements have an axial distance therebetween which is smaller than the corresponding distance for the infeed roller set but larger than the outfeed roller set. Desirably the rollers of at least one of the roller sets each consist of two or more roller sections, so that the annular enlargements defining the accommodation spaces can be adjusted axially with respect to one another whereby the mutual distance between at least the two accommodation space forming sections of a roller set is adjustable, to modify the percentage reduction of the distance between the outer points of the sides of the relevant accommodation spaces. The present invention also provides a bending method for giving a predetermined longitudinal curvature to a length of thin, constant, given channel cross-section profile strip or panel of permanently deformable material, said cross-section including a web and two side flanges of a given shape, said longitudinal curvature being about an axis which is transverse to the longitudinal axis of the strip or panel and parallel to the web, said method including the steps of feeding the strip through an infeed, an intermediate and an outfeed roller set, of which the intermediate roller set is offset in position with respect to the others, characterised in that one of the rollers in each of said infeed and said outfeed roller sets is provided with annular axially spaced enlargements and the other roller thereof has a main roller portion and is provided with annular axially spaced cheeks axially upwardly of the main roller portion which define with the other roller of the set an accommodation space axially outwardly of the main roller portion, for each of the side flanges of the strip or panel, said spaces each having a shape conforming at least to the outer side of the flange, and said accommodation spaces for at least the infeed roller set being sized to correspond exactly to the cross-section of the profiled strip or panel to be curved, with the frontal end surfaces of the side flanges, abutting confronting parts of the infeed and outfeed roller sets, the volume and shape of the corresponding accommodation spaces of the infeed and outfeed roller sets being identical or nearly identical; the axial distance between the accommodation spaces of the intermediate roller set and/or the corresponding distance of the outfeed roller set being such that it is reduced with respect to the corresponding distance of the infeed roller set, ensuring that the reduction is not compensated by a lengthening of the profiled side flanges in a direction transverse to the length of the strip or panel or by external deformation of the profiled side flanges or other part of the strip or panel, and choosing the amount of reduction as a function of the material, the dimensions and/or the shapes of the strip or panel and of the required bending radius, so as to produce an arcuate profiled strip or panel of which the shortest distance between the free ends of the profiled flanges of that strip or panel after the bending operation is equal or substantially equal to the corresponding distance before the bending operation. In order that the present invention may more readily be understood, the following description is given, merely by way of example, preference being made to the accompanying drawings, in which:- Figure 1 is a schematic side elevation of one embodiment of the apparatus according to the invention, taken in cross-section transverse to the axis of the roller sets; and Figures 2, 3 and 4 are elevations of the infeed roller set, the intermediate roller set and the outfeed roller set respectively. Referring now to Figure 1, it will be seen that the apparatus includes an infeed roller set 10, an intermediate roller set 12 and an outfeed roller set 14. The infeed roller set includes a main roller 16 and a support roller 18, the intermediate set includes a main roller 20 and a support roller 22 and the outfeed roller set 14 includes a main roller 24 and a support roller 26. The roller sets are adjustable relative to one another on bearing assemblies 28,30,32 to allow the roller sets to be adjusted. In fact only roller set 12 needs to be adjustable or alternatively both roller sets 10 and 14 need to be adjustable to give the desired curvature to the strip material indicated at 34, which is fed from right to left as indicated by the arrow 35. If reference is made to Figure 2, for example, it will be seen that the roller sets 10 includes the main roller 16 and support roller 18 with a small clearance left therebetween for the passage of the strip material. The support roller 18 has a pair of axially spaced enlargements 36 and the main roller 16 has a pair of co-operating annular cheeks 38. The main roller 16 is shown as having a axial length B1 and the annular enlargements 18 are shown as having being spaced by an axial distance A1 which is, of course, larger than B1 and defines a pair of accommodation spaces 40. Referring now to Figure 3, it will be seen that the main roller 20 of the intermediate roller set 12 is also provided with annular enlargements 42, the support roller 22 having annular cheeks 24 which define, with the annular enlargements 42, accommodation spaces 46. Figure 4 illustrates that the structure of the outfeed roller set 14 is generally similar to the infeed roller set 10, the support roller having annular enlargements 48, the main roller 24 having annular cheeks 50 defining with the annular enlargements 48 accommodation spaces 52. The respective distances A1, A2, A3 between the annular enlargements decrease over the subsequent roller sets 10, 12, 14. In one particular construction according to the invention in which, in each instance, the main roller of each set has a diameter of 82 mm, the distances A1, A2, and A3 are 84, 83.2 and 82.4 mm respectively. Similarly the axial lengths of B1, B2, B3 of the main rollers reduce and in this embodiment as mentioned above, these distances are 74, 73.2 and 72.4 mm respectively. It should be understood that these dimensions are purely illustrative. The reduction in the distance A1 - A3 is about 1.9% and reduction in the axial length B1 - B3 is about 2.2%. It has been found that this construction ensures that the cross-section of the strip or panel material is exactly retained whatever the chosen curvature and whatever the material and thickness of the panel itself. It will be seen that the dimensions (volume and shape) of the accommodation space of each of the roller sets remains substantially identical and exactly corresponds to the relevant portion the cross-sectional panel dimensions. In theory one would have thought that the structure illustrated in which there is significant reduction in the dimensions A1 - A3 and the dimensions B1 - B3 going beyond the initial panel dimensions would not be possible. Surprisingly, however, this seemingly impossible restriction in the shape compensates for all possible spring back or material behaviour within a very useful range.

Claims: A bending apparatus for giving a longitudinal curvature of a predetermined radius to a length of a thin, constant, given channel cross-section profiled strip or panel of permanently deformable material (34), said given channel cross-section including a web and two side flanges of a given shape, said longitudinal curvature being about an axis which is transverse to the longitudinal axis of the strip of panel and parallel to the web, said apparatus comprising an infeed roller set (10), an outfeed roller set (14) and an intermediate roller set (12), each roller set (10,12,14) having a main roller (16,20,24) and a support roller (18,22,26), whereby the main rollers (16,24) of the infeed and outfeed roller sets (10,14) engage with one surface of the strip or panel and the main roller (20) of the intermediate roller set (12) engages with the opposite surface of the strip or panel; the position of the intermediate roller set (12) being offset with respect to the infeed and outfeed roller sets (10,14) and driving means for driving at least one of the main rollers (16,20,24) and/or at least one of the support rollers (18,22,26), characterised in that the main roller of at least the infeed and outfeed roller sets (10,14) is provided with a main roller portion (16) of axial length (B1) and axially spaced annular cheeks (38) axially outwardly of said main roller portion and the support roller (18,26) of at least the infeed and outfeed roller sets (10,14) is provided with axially spaced annular enlargements (36), said annular cheeks (38) and enlargements (36) of each set touching and defining accommodation spaces (40,52) positioned axially outwardly of said main roller portion (16) one for each of the side flanges of the strip or panel, the annular enlargements (36) and cheeks (38) forming each of said spaces (40,52) having a shape whereby, in use, the outer surfaces of the side flanges conform thereto and the frontal surfaces of the free ends of said flanges abut or nearly abut the cheeks (38), the volume and shape of the corresponding accommodation spaces (40,52) of the infeed roller set (10) and the outfeed roller set (14) being identical or nearly identical, but the axial distance (A3) between the axially outermost points of the sides of the accommodation spaces (40,52) of said outfeed roller set (14) being smaller than the corresponding distance (A1) for said infeed roller set (10), such as to produce, in use, an arcuate profiled strip or panel (34) of which the shortest distance between the free ends of the profiled flanges of that strip or panel after a bending operation is equal or substantially equal to the corresponding distance before the bending operation. Apparatus according to claim 1, characterised in that the intermediate roller set rollers (20, 22) are also provided with axially spaced annular enlargements (42) which define accommodation spaces (46) identical or substantially identical to those (40) of said infeed roller set (10). Apparatus according to claim 2, characterised in that the axial distance (A2) between the accommodation spaces of the intermediate roller set is smaller than the corresponding distance (A1) for the infeed roller set (10) but larger than the corresponding distance (A3) for the outfeed roller set (14). Apparatus according to claim 3, characterised in that the reduction of said distance (A3) for the outfeed roller set (14) with respect to the corresponding distance (A1) for the infeed roller set (10) is about twice the reduction of the corresponding distance (A2) for the intermediate roller set (12) with respect to the distance (A1) for the infeed roller set (10). Apparatus according any one of claims 1-4 characterised in that the annular enlargements defining the accommodation spaces are uniformly shaped and wherein the axial distance between the annular enlargements is different for each roller pair. Apparatus according to claim 5, characterised in that the rollers of at least one of the roller sets each consist of two or more roller sections, so that the annular enlargements defining the accommodation spaces can be adjusted axially with respect to one another whereby the mutual distance between at least the two accommodation space forming sections of a roller set is adjustable, to modify the amount of reduction of the distance between the outer points of the sides of the relevant accommodation spaces. Apparatus according to any preceding claim, characterised in that the axial distance (A3) between the accommodation spaces of the outfeed roller set is between 0.5 and 4 % less than that (Al) of the infeed roller set. Apparatus according to any preceding claim and further comprising position adjusting means (28,30,32) for changing the position of at least one of said roller sets with respect to the other roller sets to adjust the radius of curvature. A bending method for giving a predetermined longitudinal curvature to a length of thin, constant, given channel cross-section profile strip or panel of permanently deformable material (34), said cross-section including a web and two side flanges of a given shape, said longitudinal curvature being about an axis which is transverse to the longitudinal axis of the strip or panel (34) and parallel to the web, said method including the steps of feeding the strip through an infeed (10), an intermediate (12) and an outfeed roller set (14), of which the intermediate roller set (12) is offset in position with respect to the others (10,14), characterised in that one of the rollers in each of said infeed and said outfeed roller sets (10,14) is provided with annular axially spaced enlargements (36,48) and the other roller thereof has a main roller portion (16) and is provided with annular axially spaced cheeks (38,50) axially upwardly of the main roller portion (16) which define with the other roller of the set an accommodation space (40,52) axially outwardly of the main roller portion (16), for each of the side flanges of the strip or panel (34), said spaces (40,52) each having a shape conforming at least to the outer side of the flange, and said accommodation spaces (40) for at least the infeed roller set (10) being sized to correspond exactly to the cross-section of the profiled strip or panel (34) to be curved, with the frontal end surfaces of the side flanges, abutting confronting parts of the infeed and outfeed roller sets (10,14), the volume and shape of the corresponding accommodation spaces (40,52) of the infeed and outfeed roller sets (10,14) being identical or nearly identical; the axial distance (A2) between the accommodation spaces (46) of the intermediate roller set and/or the corresponding distance (A3) of the outfeed roller set (14) being such that it is reduced with respect to the corresponding distance (A1) of the infeed roller set (10), ensuring that the reduction is not compensated by a lengthening of the profiled side flanges in a direction transverse to the length of the strip or panel or by external deformation of the profiled side flanges or other part of the strip or panel, and choosing the amount of reduction as a function of the material, the dimensions and/or the shapes of the strip or panel and of the required bending radius, so as to produce an arcuate profiled strip or panel of which the shortest distance between the free ends of the profiled flanges of that strip or panel after the bending operation is equal or substantially equal to the corresponding distance before the bending operation. A method according to claim 9, characterised in that said reduction in distance between the infeed roller set (10) and the outfeed roller set (14) is between 0.5 and 4 %.

Inventors: BRUGMAN JOHANNUS ANTONIUS HENR, BRUGMAN, JOHANNUS ANTONIUS HENRICUS
Applicants: HUNTER DOUGLAS IND BV, HUNTER DOUGLAS INDUSTRIES B.V.
Application year: 1990
Main classification: B21D7
IPC codes: B21D5