Abstract:
A roll forming machine wherein a single operator can quickly replace roll forming stations to change the desired lateral profile and wherein adjustments to the lateral positions of the roll forming stations can be quickly effected. This is accomplished by mounting the roll forming elements on short tooling rail sections which in turn are mounted on longer mounting rails which are used as platforms whereby all the adjustments are preset so that all setup work is performed prior to installing the tooling rails. Because the tooling rail sections are shorter, they may be inserted in, and removed from, the machine by a single operator without requiring the partial disassembly, and subsequent reassembly, of the entry and shear assemblies.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     This invention relates to roll forming machines which form an indeterminate length panel of a desired lateral profile from a supply strip of sheet metal and, more particularly, to such a machine wherein a single operator can quickly replace roll forming stations to change the desired lateral profile and wherein adjustments to the lateral positions of the roll forming stations can be quickly effected.  
         [0002]     Roll forming machines are well known in the construction industry. Such a machine is typically mounted on the bed of a pickup truck, van, trailer, or the like, so that it can be transported to, and used at, the site where siding panels, roofing panels and rain gutters are to be installed. Typically, such a machine comprises a series of spaced forming stations, each having upper and lower shaping rollers between which a sheet metal strip is passed, so as to impart a desired shape, or lateral profile, to the sheet metal strip, which is uniform along the length of the sheet metal strip after it exits the machine. The strip is cut to its desired length as it exits the roll forming machine. Different combinations of rollers provide different lateral profiles to the strip. Conventionally, each machine is designed to provide a single predetermined lateral profile to the sheet metal strip.  
         [0003]     U.S. Pat. No. 5,425,259 discloses a roll forming machine where the forming stations are mounted on a set of rail structures which can be interchanged with a different set of rail structures to form a different lateral profile. This allows the operator to change lateral profiles without having to remove and replace each individual forming station. According to this patent, the rail structures on the right side of the machine are mounted directly to the machine frame by the use of mounting blocks that stay with the rail structures when changed for a different set of forming stations. The two rail structures on the left side of the machine are mounted directly to threaded adjustment traveler bar blocks and have to be realigned relative to the machine frame every time a set of rail structures is mounted into the machine. This realignment requires at least two adjustments. First, the rail structures on the left side have to be adjusted to ensure that they are parallel to the rail structures on the right side of the machine. Second, the first rail structure on the left side has to be adjusted to have a given offset relative to the second rail structure on the left side of the machine. This is accomplished by turning the nuts on the threaded adjustment traveler bar blocks on the first rail structure so that the first rail structure is moved left or right until the proper offset is achieved. While adjusting this offset, the first rail structure on the left side has to be kept parallel with the rail structures on the right side of the machine.  
         [0004]     The aforedescribed arrangement suffers from a number of disadvantages. For example, it requires two people and an average of three to four hours to replace the rail structures in order to change the lateral profile produced by the machine. There are three major reasons for this disadvantage. The first reason is that three of the four rail structures are long and heavy, requiring two people to remove and insert the rail structures from and into the machine. The second reason is that the shear and entry assemblies of the machine need to be partially disassembled and then reassembled to allow the long rail structures to be removed from and inserted into the machine. The third reason is that the rail structures must be mounted and realigned to the machine before being able to form the next lateral profile.  
         [0005]     It would therefore be desirable to have a roll forming machine wherein the lateral profile can be easily and quickly changed by a single person.  
       SUMMARY OF THE INVENTION  
       [0006]     According to this invention, there is provided a roll forming machine of the type which forms an indeterminate length panel of a desired lateral profile from a uniform width supply strip of sheet metal having a pair of parallel straight edges, the roll forming machine driving the supply strip along a predetermined path of travel through a plurality of roll forming stations. The inventive roll forming machine comprises a rigid framework including a pair of rigid parallel side frames interconnected one to the other by a plurality of rigid parallel upper and lower transverse members to form a rigid cage having an interior and a width between the side frames. A plurality of mounting blocks are each supported on a respective one of the lower transverse members adjacent a first one of the pair of side frames. Each of the mounting blocks has an upper horizontal surface and a plurality of spaced mounting holes extending into each mounting block from its upper surface. The plurality of mounting holes for each of the mounting blocks extend along a respective line orthogonal to the pair of side frames and have identical spacing on all of the plurality of mounting blocks. The upper horizontal surfaces of all of the plurality of mounting blocks lie along a single horizontal plane. A first mounting rail is secured to at least two of the plurality of mounting blocks by at least two mounting threaded members each extending through a respective opening in the first mounting rail and into a respective mounting hole in a respective one of the at least two mounting blocks. Each of the respective mounting holes occupies the same relative position in its respective mounting block so that the mounting rail is automatically parallel to the side frames of the machine. A first tooling rail is secured to the first mounting rail. At least one set of roll forming elements defining a roll forming station is secured to the first tooling rail. The first tooling rail with the at least one set of roll forming elements secured thereto is dimensioned so that it can be manipulated into and out of the cage vertically between an adjacent pair of upper transverse members. Thus, the removable sections are small enough to be handled by one person and, since they are removed vertically, the entry and shear assemblies of the machine remain intact during a tooling change.  
         [0007]     Also according to this invention, there is provided a roll forming machine of the type which forms an indeterminate length panel of a desired lateral profile from a uniform width supply strip of sheet metal having a pair of parallel straight edges, the roll forming machine driving the supply strip along a predetermined path of travel through a plurality of roll forming stations. The inventive roll forming machine comprises a rigid framework including a pair of rigid parallel side frames interconnected one to the other by a plurality of rigid parallel upper and lower transverse members to form a rigid cage having an interior and a width between the side frames. A first plurality of threaded shafts extends into the cage from a first one of the pair of side frames orthogonal to the pair of side frames and a first plurality of traveler bar blocks are each threadedly secured to a respective one of the first plurality of threaded shafts for movement therealong. A first mounting rail is secured to at least two of the first plurality of traveler bar blocks and a first tooling rail is secured to the first mounting rail. At least one set of roll forming elements defining a roll forming station is secured to the first tooling rail. The first tooling rail with the at least one set of roll forming elements secured thereto is dimensioned so that it can be manipulated into and out of the cage vertically between an adjacent pair of upper transverse members. Thus, the removable sections are small enough to be handled by one person and, since they are removed vertically, the entry and shear assemblies of the machine remain intact during a tooling change.  
         [0008]     In accordance with an aspect of this invention, there is provided an adjuster outside the cage which is coupled to the threaded shafts for controllably rotating the threaded shafts so that the traveler bar blocks, along with the mounting rails secured thereto, are movable toward and away from the first one of the pair of side frames.  
         [0009]     In accordance with a further aspect of this invention, the threaded shafts are divided into two groups and the adjuster includes a clutch coupled between the two groups of threaded shafts. Each group of threaded shafts is associated with a respective mounting rail. The clutch is selectively engageable and disengageable so that one of the mounting rails can be moved independently to provide an offset between the two mounting rails. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0010]     The foregoing will be more readily apparent from reading the following description in conjunction with the drawings in which like elements in different figures thereof are identified by the same reference numeral and wherein:  
         [0011]      FIG. 1  is a perspective view of an embodiment of the inventive roll forming machine showing the rigid cage structure;  
         [0012]      FIG. 2  is a top perspective view of the machine shown in  FIG. 1  without the upper transverse frame members and drive mechanism;  
         [0013]      FIG. 3  is a schematic top plan view of the inventive machine showing the right side rail structures;  
         [0014]      FIG. 4  is a perspective view of a mounting block used on the right side of the inventive machine;  
         [0015]      FIG. 5  is an exploded perspective view showing a tooling rail, a mounting rail and a pair of mounting blocks, illustrating how they are connected together and to lower transverse members of the framework of the inventive machine;  
         [0016]      FIG. 6  is a schematic top plan view of the inventive machine showing the left side mounting rail structures;  
         [0017]      FIG. 7  is a perspective view of a traveler bar block;  
         [0018]      FIG. 8  is a perspective view of the inventive adjustment mechanism for the traveler bar blocks on the left side of the inventive machine;  
         [0019]      FIGS. 9   a  and  9   b  are perspective views of the clutch in the adjustment mechanism shown in  FIG. 8 , with the clutch engaged and disengaged, respectively; and  
         [0020]      FIGS. 10   a  and  10   b  illustrate sample lateral profiles of roofing panels which can be formed by the inventive roll forming machine. 
     
    
     DETAILED DESCRIPTION  
       [0021]     Referring now to the drawings,  FIG. 1  shows a roll forming machine, designated generally by the reference numeral  10 , which incorporates structure according to the principles of this invention. Roll forming machines, per se, are well known in the art and therefore will not be described in detail herein, except for those portions of the machine  10  which particularly relate to the present inventive improvements. The machine  10  is designed to form an indeterminate length panel of a desired lateral profile from a uniform width supply strip of sheet metal (not shown) having a pair of parallel straight edges. As is known in the art, the machine  10  drives the supply strip along a predetermined path of travel through a plurality of roll forming stations. For purposes of illustration, the machine  10  is designed to form roofing panels.  FIGS. 10   a  and  10   b  show illustrative lateral profiles of roofing panels which can be formed by the machine  10 , depending upon which set of tooling is installed in the machine  10 .  
         [0022]     As shown, the machine  10  has a rigid framework including a pair of rigid parallel side frames  12 , 14  interconnected by a plurality of rigid upper and lower transverse members  16 , 18 , respectively, to form a rigid cage having an interior and a width between the side frames  12 , 14 . For future discussion purposes, the side of the machine  10  which is adjacent the side frame  12  will be referred to as the “right” side and the side of the machine  10  which is adjacent the side frame  14  will be referred to as the “left” side.  
         [0023]     On the lower transverse members  18  along the right side of the machine  10  are supported a plurality of mounting blocks  20  which are each bolted to a respective block  22  which is secured, as by welding, to a respective lower transverse member  18 . The pair of bolts  24  which secure a mounting block  20  to a respective block  22  extend through respective elongated slots  26  in the mounting block  20  and into internally threaded bores  28  in the block  22  so that the position of the mounting block  20  is adjustable. Such adjustability is effected by means of pusher set screws  30  to slide the mounting block  20  back and forth along a line orthogonal to the side frames  12 , 14 . Each of the mounting blocks  20  has an upper horizontal surface  32  and a plurality of internally threaded mounting holes  34  extending into the mounting block  20  from the upper horizontal surface  32 . The mounting holes  34  extend along a line orthogonal to the side frames  12 , 14  and are preferably equally spaced, illustratively on one-half (½) inch centers, along that line. The spacing of the mounting holes  34  is identical on all of the mounting blocks  20  and the upper horizontal surfaces  32  of all the mounting blocks  20  lie along a single horizontal plane.  
         [0024]     According to this invention, each of a first set of mounting rails  36  is secured to at least two of the mounting blocks  20 . Illustratively, there are two mounting rails  36  along the right side of the machine  10 . Each mounting rail  36  is a flat stiff bar of sheet metal formed with two sets of mounting holes. The first set of mounting holes  38  are countersunk through-bores for securing the mounting rails  36  to the mounting blocks  20  by means of threaded members, such as flat head screws,  40 . The mounting holes  38  are spaced the same as the spacing between the mounting blocks  20  and lie along a line substantially centered along each mounting rail  36 . The second set of mounting holes  42  are internally threaded bores equally spaced (illustratively on eight inch centers) along the same central line and are for securing the tooling rails to the mounting rails  36 , as will be described in full detail hereinafter. Each different lateral profile formed by a different set of tooling requires that the mounting rails  36  be secured to the mounting blocks  20  in specific ones of the mounting holes  34 , in accordance with a mounting chart set forth in the operator&#39;s manual provided with the machine  10 . The mounting rails are installed and set for a particular lateral profile without the presence of any tooling, resulting in an easier setup.  
         [0025]     The mounting rails  36  are used for supporting the roll forming tooling. According to this invention, short sections of tooling rail  44  are provided. Each tooling rail  44  is an angle bracket. At least one set of roll forming elements (or tooling)  46  defining a roll forming station is secured to each tooling rail  44 . Since the mounting holes  42  on the mounting rails  36  are spaced on eight inch centers and each tooling rail  44  must be secured to at least two of the mounting holes  42 , each tooling rail section  44  is chosen to be less than sixteen inches in length, but longer than about nine inches. This allows a tooling rail section  44  to be manipulated into and out of the machine  10  vertically between an adjacent pair of upper transverse members  16 . Each tooling rail  44  is provided with mounting through-holes  48  spaced on eight inch centers to match the spacing of the mounting holes  42 . To secure the tooling rail  44  to the mounting rail  36 , threaded members, such as screws or bolts,  50  extend through the holes  48  and into the holes  42 . The holes  48  are along a line parallel to the longitudinal axis of the tooling rail  44 , which line is uniquely located for each lateral profile so that the required offset is built into the tooling rail itself. Thus, as shown in  FIGS. 2 and 3 , there are illustratively two mounting rails  36  on the right side of the machine  10 . Depending on the lateral profile being formed by the tooling installed in the machine  10 , each of the mounting rails  36  is secured in a particular set of mounting holes  34 . The combination of the particular set of mounting holes  34  and the location of the line for the holes  48  in the tooling rails  44  determines the offset between the roll forming elements  46  on the two mounting rails  36 . Therefore, no final adjustments are required on the right side of the machine  10  when changing from one lateral profile to another.  
         [0026]     The mounting of the tooling on the left side of the machine  10  is arranged differently from the mounting on the right side. In particular, mounting rails  52 , of the same general construction as the mounting rails  36 , are permanently bolted to traveler bar blocks  54  which are in turn secured to threaded traveler nuts  56  mounted on threaded adjustment shafts  58 . Tooling rails  60 , of the same general construction as the tooling rails  44  and having roll forming elements  62  defining roll forming stations secured thereto, are secured to the mounting rails  52 . The mounting rails  52  and the tooling rails  60  have the same mounting hole configurations for their connection as do the mounting rails  36  and the tooling rails  44 , respectively, except that there is only a single line for the mounting holes on the tooling rails  60 . Thus, a tooling rail section  60 , like a tooling rail section  44 , can be manipulated into and out of the machine  10  vertically between an adjacent pair of upper transverse members  16 .  
         [0027]     The threaded adjustment shafts  58  extend into the rigid cage interior of the machine  10  from the side frame  14  orthogonally to the side frames  12 , 14 . The inner ends of the shafts  58  are journalled for rotation in the bearing blocks  64 . The outer ends of the shafts  58  extend through the bearing blocks  66  and are terminated by bevel gears  68 . Rotation of the threaded shafts  58  moves the traveler nuts  56 , along with the mounting rails  52  and their respective tooling rails  60 , toward and away from the side frame  12 , depending upon the direction of rotation of the shafts  58 . This provides a way to vary the distance between the roll forming stations on the left and right sides of the machine  10 . Rotation of the shafts  58  is effected by turning the crank handle  70  which is connected through gearing (not shown) to the first adjustment shaft  58  and to the transfer shaft  72 . The transfer shaft  72  extends orthogonally to the adjustment shafts  58  and is connected to their bevel gears  68  through the bevel gears  74  spaced along its length.  
         [0028]     As shown in  FIGS. 2 and 6 , there are illustratively two mounting rails  52  on the left side of the machine  10 . Each different lateral profile formed by a different set of tooling requires a different offset between the two left side mounting rails, as well as a different spacing between the roll forming stations on the left and right sides of the machine  10 . The operator&#39;s manual provided with the machine  10  includes a chart setting forth this offset and spacing. To accommodate the offset between the two mounting rails  52 , the transfer shaft  72  is formed as two sections with a clutch  76  interposed between the two sections so as to separate the two mounting rails  52 . The clutch  76  has two parts, a fixed half  78  and a sliding half  80 .  
         [0029]     Thus, when a new set of tooling is to be installed in the machine  10 , the set screw  82  on the collar  84  is loosened and the sliding half  80  of the clutch  76  is slid to the right, as viewed in  FIGS. 9   a  and  9   b , to separate the clutch teeth and disengage the two halves of the clutch  76 . With the clutch  76  disengaged, the crank handle  70  is turned to obtain the appropriate offset between the two mounting rails  52 . By adjusting the offset in this manner, it will be appreciated that the process of adjusting the offset is greatly simplified. The clutch  76  is then engaged by moving the sliding half  80  to the left and tightening the set screw  82 . The crank handle  70  is then turned to set the appropriate distance between the left and right side roll forming stations, in accordance with the desired lateral profile to be formed by the new set of tooling.  
         [0030]     Accordingly, there has been disclosed an improved roll forming machine wherein a single operator can quickly replace roll forming stations to change the desired lateral profile and wherein adjustments to the lateral positions of the roll forming stations can be quickly effected. While a preferred embodiment of the present invention has been disclosed herein, it will be appreciated by those of skill in the art that various modifications and adaptations to the disclosed embodiment are possible. It is therefore intended that this invention be limited only by the scope of the appended claims.