Abstract:
An apparatus for serially making formed parts from a web of deformable material with a stud mounted therein having a plurality of progressive die forming stations for forming multiple parts from the web by advancing the web through each forming station. In one embodiment, the apparatus has feeding, driving and transfer mechanisms for controlling the feeding and insertion of studs at spaced locations into the web.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]    This Application claims the benefit of U.S. patent application Ser. No. 60/049,847, filed Jun. 17, 1997.  
     
    
     
       BACKGROUND OF THE INVENTION  
         [0002]    1. Field of the Invention  
           [0003]    This invention relates to a progressive die machine having a stud-feeding apparatus mounted thereto which is configured to drive a stud, bolt, nut or other fastener into a web being passed through the progressive die machine.  
           [0004]    2. Description of the Related Art  
           [0005]    Progressive die machines have long been known in the art to comprise a fixed lower die and an upper die which is reciprocally movable with respect to the lower die. The upper die is typically slidably mounted within rails which constrain the upper die to vertical movement therein. In addition, a motor having an output shaft is provided. The output shaft typically has a distal end provided with a concentrically-mounted plate thereon which, in turn, has an eccentrically-mounted pin adjacent an outer radial edge thereof. Further, a ram is provided which has one end mounted to an upper surface of the die and an opposite end having a bearing which is journaled to the pin of the motor. Thus, as rotational motion is imparted to the output shaft by the motor, the pin is rotated as well and traces a circular path. As a result, the ram, in conjunction with the upper die, is moved reciprocally within the rails with respect to the lower die.  
           [0006]    Each rotation of the output shaft of the motor is referred to as the “stroke” of the machine and ranges between 0 and 360 degrees. Thus, the point at which the pin on the plate of the motor output shaft is located at the uppermost vertical position with respect to the plate is referred to as the 0 degree position or “top dead center” (TDC). At TDC, the upper die is positioned the greatest extent above the lower die. The point at which the pin on the plate of the motor output shaft is located adjacent to the lowermost vertical position with respect to the plate is referred to as the 180 degree position. In the 180 degree position, the upper die is positioned adjacent to the lower die and is the position whereby the forming operations are performed on the web. Between the 0 and 180 degree positions, the upper die is lowered with respect to the lower die and between the 180 and 360 degree positions, the upper die is raised with respect to the lower die.  
           [0007]    The upper and lower dies cooperate to define several forming stations therein. Each forming station includes an individual forming tool and a die which are configured and dimensioned so that a particular predetermined operation can be performed on a web fed between the upper and lower dies. The web is typically an elongated strip of material provided as a feedable supply adjacent the machine, such as on a spool. The progressive die machine typically includes a feeding apparatus mounted adjacent the lower die which sequentially advances the web between the upper and lower dies and through each of the forming stations therein.  
           [0008]    The number of forming stations is determined by the number of forming operations necessary to form a desired part. A portion of each of the forming tools are located on the upper die and are driven in unison in reciprocal fashion by the ram. Thus, a forming operation is performed at each forming station during each stroke of the ram.  
           [0009]    Following each stroke, the web is advanced so that each portion of the web is positioned within the next successive forming station in the machine. When a portion of the web has passed each forming station in the progressive die machine, a desired part is formed. The last station in the machine typically includes a severing tool and a discharge chute. The severing tool cuts the formed part from the web so that the formed part can fall into the discharge chute and be accumulated therein.  
           [0010]    The above-described machine typically forms a completed part. However, it has been found that some parts require additional manufacturing operations to be performed thereon before the part is ready for shipping to customers. One such additional operation is the staking of a stud, such as a threaded fastener, into the formed part after it has been completed. Typically, an aperture is provided in the part by the progressive die machine and the stud is located in the aperture after the progressive die machine has completed the forming process. The staking of the stud often requires an additional manufacturing apparatus and/or substantial human intervention to complete the part which can add to the per unit cost of producing the part. Prior art progressive die machines have been insufficient in providing a solution to this problem.  
           [0011]    In addition, the formed part may have a geometrical configuration which makes the staking of a stud therein prohibitively difficult. For example, a part can be provided with a C-shaped configuration whereby the stud is desired to be located within an interior surface thereof. Depending upon the clearance provided within the interior surface, it is often difficult to accurately stake the stud therein. Thus, the formed part must either not include the stud or the formed part must be bent to a lesser degree than is required. After the part has been formed by the progressive die machine, the stud must be staked therein by a separate apparatus and process, and then the part must be further bent to place the formed part within required tolerance limits.  
           [0012]    Additional problems are encountered by the progressive die machines. Changes in a wide variety of uncontrollable characteristics can cause the formation of parts which do not fall within tolerances required by a particular application for a part. Such tolerances can be of critical importance because a part which falls outside of these tolerances can cause a catastrophic failure in the system or machine in which the part is ultimately installed. Some examples of the uncontrollable characteristics encountered by prior art progressive die machines include: changes in thickness in the web material from which the parts are formed, flaws in the web material, wear on the forming tools and dies and foreign matter located on the web material. These characteristics can cause the formation of unacceptable parts by the progressive die machine which can often go undetected by the machine or its operator during use.  
         SUMMARY OF THE INVENTION  
         [0013]    The invention relates to an apparatus for serially making formed parts from a web of deformable material with a stud mounted therein comprising a plurality of progressive die forming stations for forming multiple parts from the web by advancing the web through each forming station, a feeding mechanism for feeding studs seriatim to a predetermined dispensing position adjacent to the web, a driving mechanism adjacent to the web for inserting studs in spaced locations into the web, a transfer mechanism operably connected to the feeding mechanism for receiving studs from the feeding mechanism and for transferring studs to the driving mechanism, and a cutting station for severing the web after the web has passed through the die forming stations to separate the formed individual stud-bearing parts from the web.  
           [0014]    The driving mechanism can be located adjacent to one of the die forming stations whereby the studs are inserted into the web as the parts are formed in the progressive die forming stations. The die forming stations can further comprise a movable die having a driving ram associated therewith to reciprocate the movable die between a retracted and a deforming position to deform the web as the web is advanced through the forming stations. The driving ram is preferably operably connected to the driving mechanism to actuate the driving mechanism for inserting a stud into the web when the movable die is moved between the retracted and deforming positions. The operable connection between the driving ram and the driving mechanism preferably comprises one of a flange and a socket disposed on the movable die, and the other of the flange and the socket located on the driving mechanism whereby when the movable die is moved between the retracted and the deforming positions the flange is received in the socket.  
           [0015]    The feeding mechanism can be positioned adjacent one of the forming stations and is operably interconnected with the driving ram to index the seriatim feeding of the studs when the movable die is moved between the retracted and deforming positions. The feeding mechanism can comprise a shuttle car movable between a receiving position and a dispensing position and having an opening for receiving one of the studs therein when in the receiving position. The opening in the shuttle car is preferably aligned with a conduit in the feeding mechanism. One end of the conduit is preferably aligned with the opening in the shuttle car when in the dispensing position and the other end of the conduit is preferably aligned with the transfer mechanism. The shuttle car can have a cam follower and a cam operably connected to the driving ram in register with the cam follower for moving the shuttle car from the receiving position to the dispensing position as the movable die moves between the retracted and deforming positions.  
           [0016]    The feeding mechanism can further comprise an actuator mounted adjacent to the shuttle car and adapted to move the stud out of the opening in the shuttle car into the conduit when the shuttle car is moved to the dispensing position. The actuator can comprise a pressurized air nozzle in register with the opening of the shuttle car in the dispensing position whereby air exiting the nozzle moves the stud into the conduit. The feeding mechanism can further comprise a lever mounted adjacent to an end of the conduit having a stop thereon movable between an obstructing position and a release position and a cylinder having an axially-movable piston having an actuator portion thereon in register with the lever. The piston is preferably movable between a first position wherein the actuator portion positions the lever in the obstructing position and a second position wherein the actuator portion positions the lever in the release position and forces the stud out of an exit of the conduit and into the transfer mechanism. The piston can further comprise a stud-receiving indentation which receives the stud as the piston moves from the first position to the second position for restricting the movement of the stud in a single linear direction.  
           [0017]    The transfer mechanism can be positioned adjacent one of the forming stations and operably interconnected with the driving ram to index the seriatim feeding of the studs between the feeding mechanism and the driving mechanism when the movable die is moved between the retracted and deforming positions. The transfer mechanism can comprise a support plate and at least one set of gripping members mounted to the support plate and adapted to selectively grip a stud. The support plate is preferably mounted for movement of the at least one set of gripping members between the feeding mechanism and the driving mechanism. The at least one set of gripping members receive and grip a stud from the feeding mechanism, travel with the support plate to the driving mechanism, and release the stud at the driving mechanism. The transfer mechanism can further comprise an arm mounted to the support plate through a ratchet mechanism to selectively position the support plate at a number of discrete positions between the feeding mechanism and the driving mechanism. The arm can have a flange operably coupled to the driving ram so that the arm positions the support plate at a next discrete position as the movable die moves between the retracted and deforming positions. The at least one set of gripping members can comprise multiple sets of gripping members mounted to the support plate. One of the sets of gripping members can be positioned at the feeding mechanism while another of the sets of gripping members can be simultaneously positioned at the driving mechanism at each discrete position of the support plate.  
           [0018]    The driving mechanism is preferably positioned adjacent one of the forming stations and is operably interconnected with the driving ram to index the seriatim insertion of the studs into the web when the movable die is moved between the retracted and deforming positions. The driving mechanism can comprise a driving mechanism housing, a hammer slidably mounted within the housing and adjacent to the transfer mechanism for forcing each of the studs into the web, and a lever mounted to the housing for movement between a rest position and an insertion position and having a first end and a second end. The first end is operably connected to the driving ram and the second end is in register with the hammer. The hammer receives one of the studs when the lever is in the rest position and is moved by the lever to insert the stud into the web when the lever moves between the rest and insertion positions. The lever is moved between the rest position and the insertion position when the movable die is moved between the retracted position and the deforming position.  
           [0019]    The die forming stations can further comprise a movable die having a driving ram associated therewith to reciprocate the movable die between a retracted and a deforming position to deform the web as the web is advanced through the forming stations. The driving ram preferably is operably connected to the driving mechanism to actuate the driving mechanism for inserting a stud into the web when the movable die is moved between the retracted and deforming positions. The operable connection between the driving ram and the driving mechanism preferably comprises one of a flange and a socket disposed on the movable die, and the other of the flange and the socket located on the driving mechanism. Thus, when the movable die is moved between the retracted and the deforming positions, the flange is received in the socket.  
           [0020]    In an additional aspect, the invention relates to a method for serially making formed parts from a web of deformable material with a stud mounted therein comprising the steps of providing a plurality of progressive die forming stations for forming multiple parts from the web, advancing the web through each forming station, feeding multiple studs seriatim to a predetermined dispensing position adjacent to the web, inserting each stud at spaced locations into the web, and severing the web after the web has passed through the die forming stations to separate the formed individual stud-bearing parts from the web.  
           [0021]    The method can comprise additional steps such as: providing a movable die with a driving ram associated therewith, and reciprocating the movable die between a retracted and a deforming position to deform the web as the web is advanced through the forming stations. At least one stud can be indexed toward the dispensing position when the movable die is moved between the retracted and deforming positions. At least one stud can be inserted into the web when the movable die is moved between the retracted and deforming positions. A stud can be moved from the dispensing position to an insertion position adjacent to the web when the movable die is moved between the retracted and deforming positions. The dimensional relationship between the first and second dies in the deforming position can be adjusted responsive to a remote signal.  
           [0022]    Other objects, features, and advantages of the invention will be apparent from the ensuing description in conjunction with the accompanying drawings.  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0023]    In the drawings:  
         [0024]    [0024]FIG. 1 is a diagrammatic view from a side elevational perspective showing a progressive die machine according to the invention which has a stud-staking apparatus, a bending apparatus, and a measuring apparatus located adjacently or mounted thereto;  
         [0025]    [0025]FIG. 2 is a fragmentary top plan view of a portion of a lower die of the progressive die machine of FIG. 1 which illustrates a stud-staking assembly contained therein and has a portion of the lower die shown in cross section to provide a clear illustration of the assembly;  
         [0026]    [0026]FIG. 3 is an enlarged fragmentary top plan view of the stud-staking assembly shown in FIG. 2 provided with a portion thereof in cross section to provide additional illustration of a cylinder urging an infed stud into engagement with a rotary feed mechanism located adjacently thereto;  
         [0027]    [0027]FIG. 4 is cross-sectional view of the stud-staking assembly taken along lines  4 - 4  of FIG. 2 showing a stud positioned in a conduit while an upper die is in a raised position with respect to the lower die of the progressive die machine;  
         [0028]    [0028]FIG. 5 is a cross-sectional view of the stud-staking assembly taken along lines  5 - 5  of FIG. 2 showing the stud positioned in a conduit while the upper die is in a lowered position with respect to the lower die of the progressive die machines;  
         [0029]    [0029]FIG. 6 is an enlarged perspective view of a slidable car shown in FIGS.  4 - 5  which is adapted to be moved by the upper die during operation of the progressive die machine;  
         [0030]    [0030]FIG. 7 is a side elevational view of the rotary feed mechanism of FIG. 2 shown with the upper die in a raised position with respect to the lower die;  
         [0031]    [0031]FIG. 8 is a side elevational view of the rotary feed mechanism of FIG. 2 shown with the upper die in a lowered position with respect to the lower die whereby a stud is urged into a web material passing between the upper and lower dies;  
         [0032]    [0032]FIG. 9 is an enlarged perspective view of a lever and rotatable plate portion of the rotary feed mechanism of FIG. 2;  
         [0033]    [0033]FIG. 10 is a cross-sectional view of the rotary feed mechanism of FIG. 2 showing the interengagement of a pin on a housing with an aperture on the rotatable plate;  
         [0034]    [0034]FIG. 11 is an enlarged end view of the pin of FIG. 10;  
         [0035]    [0035]FIG. 12 is a diagrammatic side elevational view of a pair of gripping arms on the rotary feed mechanism shown in receipt of a stud therein;  
         [0036]    [0036]FIG. 13 is a diagrammatic side elevational view of the gripping arms of FIG. 12 shown biased into an open position wherein a stud is released from retention therein;  
         [0037]    [0037]FIG. 14 is a side elevational view of a stud-driving assembly which is shown adapted to drive a stud into the web material passing between the upper and lower dies;  
         [0038]    [0038]FIG. 15 is a rear elevational view of the stud-driving assembly of FIG. 14;  
         [0039]    [0039]FIG. 16 is a front elevational view of the bending apparatus of FIG. 1 shown in a lowered position with respect to the upper die;  
         [0040]    [0040]FIG. 17 is a diagrammatic front view of the bending apparatus of FIG. 16 shown in a raised position;  
         [0041]    [0041]FIG. 18 is a front cross-sectional view of the measuring apparatus of FIG. 1;  
         [0042]    [0042]FIG. 19 is a diagrammatic view of the measuring apparatus of FIG. 18; and  
         [0043]    [0043]FIG. 20 is a diagrammatic view of the stroke of the progressive die machine of FIG. 1.  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0044]    Referring now to the drawings and to FIG. 1 in particular, a progressive die machine  10  is shown comprising a lower die  12  and an upper die  14  which is connected to a ram  16 . It will be understood that the progressive die machine  10  is generally configured and operates as described in the “Background of the Invention” section. Thus, it will be further understood that the ram  16  is interconnected to a conventional motive apparatus (not shown) which imparts a reciprocal motion to the ram  16 . The reciprocal motion imparted to the ram  16  in turn reciprocates the upper die  14  with respect to the lower die  12  in accordance with what is generally known to those skilled in the art relating to progressive die machines.  
         [0045]    A web of material  18  is shown in FIG. 1 being fed longitudinally between the lower and upper dies  12  and  14 , respectively. Further, several forming stations are formed on the lower and upper dies  12  and  14 , some of which are shown by reference numerals  20 - 36 . A progressive die machine  10  further includes an advancing mechanism (not shown) whereby the web  18  is advanced between the lower and upper dies  12  and  14  in discrete steps so that a particular portion of the web  18  is positioned adjacent each of the forming stations  20 - 36 . It will be understood that the forming stations  20 - 36  perform a particular tooling, contouring, or other forming operation on a particular portion of the web  18 . It will be further understood that additional or fewer forming stations  20 - 36  can be provided without departing from the scope of this invention. It will also be understood that the forming stations  20 - 36  can also be idle stations or have other functions besides forming.  
         [0046]    [0046]FIG. 1 shows the web  18  having several individual portions thereof located adjacent forming stations  20 - 36 . The web  18  is shown being formed into a part having a stud  38  mounted into the web at forming station  20  and eventually being bent into a C-shaped configuration by later forming stations. The staking of the stud  38  into the web  18  at forming station  20  is performed by a stud-staking apparatus  42  which is described in greater detail below and shown in FIGS.  2 - 15 .  
         [0047]    The part  40 , having the stud  38  staked therein, is finally formed into a C-shaped configuration as it approaches forming station  32  by a bending apparatus  44  which performs a final bending operation on the part  40  to provide the C-shaped configuration thereto. A measuring apparatus  46  is located downstream from the forming stations  20 - 36 . The measuring apparatus  46  measures the final dimensions of each part  40  passing therethrough and provides a signal through feedback loop  48 , which, in turn, signals a PLC  50  to control the bending apparatus  44 . The PLC  50  notes dimensions or other characteristics measured by the measuring apparatus  46  and determines whether the parts  40  passing through the measuring apparatus  46  are within a set of predetermined tolerance limits. It will be understood that, although the measuring apparatus  46  is shown between the lower and upper dies  12  and  14 , the measuring apparatus can also be a separate component located downstream therefrom.  
         [0048]    If the parts  40  passing through the measuring apparatus are not within the predetermined tolerance limits, the PLC  50  sends a signal to the bending apparatus  44  to provide a greater or lesser degree of bending to the part  40  located at the bending apparatus  44 . All parts  40  later fed through the bending apparatus  44  are thereby formed by the bending apparatus in accordance with the signal from the PLC  50 . The bending apparatus  44  is shown in FIGS.  16 - 17 . The measuring apparatus  46  is shown in FIG. 18. This process is described in greater detail in FIG. 19.  
         [0049]    As shown in FIGS.  2 - 15 , the stud-staking apparatus  42  comprises a positioning mechanism  52  and a staking mechanism  54 . The positioning mechanism  52  is adapted to receive a stud  38  and position the stud  38  within the staking mechanism  54  whereby the staking mechanism  54  can then mount the stud  38  within a part  40  formed within the web  18 .  
         [0050]    The positioning mechanism  52  is shown in detail in FIGS.  2 - 3  and comprises an elongated body  56  having a first end  58  and a second end  60 . The first end  58  of the body  56  includes a transverse passage  62  which extends laterally across the elongated body  56 . The passage  62  has a first end  64  and a second end  66 . An aperture  68  is formed in the first end  58  of the body  56  which extends into the passage  62  intermediate the first and second ends  64  and  66  thereof. The aperture  68  extends into a conduit  70  which extends axially from the first end  58  of the body  56  and is interconnected by a fitting  72  to a source of pressurized fluid, preferably air. It will be understood that the source of pressurized air interconnected to fitting  72  can either be supplied as a continuous stream or as intermittent bursts of air as required.  
         [0051]    As shown in FIGS.  2 - 3  and in greater detail in FIGS.  4 - 5 , a conduit  74  extends upwardly from the first end  58  of the body  56  and is in communication with the first end  64  of the passage  62  therein. It will be understood that the conduit  74  is of sufficient size to allow a stud  38  to travel axially therethrough without restriction. The conduit  74  has a first end  76  and a second end  78 . The first end  76  is preferably interconnected to a supply of studs  38  whereby the studs  38  can be selectively supplied to the first end  76  of the conduit  74 . It will be understood that the supply of studs interconnected to the first end  76  of the conduit  74  can comprise a magazine of studs, a manual supply, or an automatic supply whereby studs are supplied to the first end  76  of the conduit  74  such as by compressed air being blown behind the stud so that the stud  38  travels toward the second end  78  of the conduit  74 . The second end  78  of the conduit  74  can be provided with an inwardly-extending frustoconical wall as shown in FIGS.  4 - 5  so that a stud  38  is centered axially with respect to the second end  78  of the conduit  74  as the stud  38  enters therein.  
         [0052]    A car  80  is slidably mounted to the first end  58  of the body  56  so that the car  80  can traverse generally parallel with the passage  62  therein. As shown in FIGS.  4 - 5  and in greater detail in FIG. 6, the car  80  comprises an elongated body  82  having a first end  84  and a second end  86 . The car  80  further is provided with an upper surface  88  thereon. The upper surface  88  is provided with a first aperture  90  adjacent the first end thereof. The first aperture  90  extends downwardly within the body  82  of the car  80  into a bore  92  which has a lateral cross section adapted to substantially conform to an outline shape of a stud  38 . The second end  86  of the body  82  has a laterally- and forwardly-extending flange  94  which is provided with a ramped surface  98  which, in turn, terminates in a vertical surface  100 .  
         [0053]    The car  80  is mounted for slidable movement to the first end  58  of the body  56  between a first and a second position as shown in FIGS. 4 and 5, respectively. A spring  178  is mounted adjacent the second end  86  of the car  80  and the first end  58  of the body  56 . A distal end  182  of the spring  178  abuts the second end  86  of the car  80  and biases the car  80  axially outwardly with respect to the spring  178 .  
         [0054]    In the first position shown in FIG. 4, the progressive die machine  10  is in an open position wherein the upper die  14  is in a raised position with respect to the lower die  12 . As shown in FIG. 4, the upper die  14  is provided with a downwardly-depending flange  184  having a distal end  186  provided with an angular surface  188  thereon. The angular surface  188  of the flange  184  preferably conforms generally with the angular orientation of the ramped surface  98  of the car  80 . When the upper die  14  is raised with respect to the lower die  12 , the flange  184  does not contact the car  80 . Thus, the outward bias of the spring  178  causes the car  80  to be biased into the first position wherein the aperture  90  and bore  92  of the car  80  are concentrically aligned with the second end  78  of the conduit  74 . Thus, a stud  38  can be delivered through the first end  76  of the conduit  74  and into the bore  92  of the car  80  through the second end  78  of the conduit  74 .  
         [0055]    In the second position shown in FIG. 5, the upper die  14  has been lowered with respect to the lower die  12  which, in turn, lowers the flange  184  with respect to the car  80 . As the flange  184  is lowered, the angular surface  188  on the distal end  186  of the flange  184  is lowered as well so that the angular surface  188  of the flange  184  contacts the ramped surface  98  of the flange  94 . As the upper die  14  moves toward the lower die  12 , the downward urging of the angular surface  188  of the flange  184  against the ramped surface  98  of the flange  94  causes the car  80  to be moved toward the second position shown in FIG. 5 which also urges the second end  86  of the car  80  against the distal end  182  of the spring  178 . The distal end  186  of the flange  184  eventually is lowered a sufficient extent so that the flange  184  abuts the vertical surface  100  of the flange  94  and retains the car  80  in the second position shown in FIG. 5 whereby the bore  92  is aligned with an axial conduit  108  in the body  56 . Further, the laterally-extending bore  105  is aligned with the conduit  70  via aperture  68 .  
         [0056]    When the upper die  14  is raised with respect to the lower die  12 , the distal end  186  of the flange  184  is retracted from contact with the flange  94  on the car  80 . Once the flange  184  has been lifted a sufficient extent, the angular surface  188  on the distal end  186  thereof once again abuts the ramped surface  98  of the flange  94  which causes the car  80  to be slid towards the first position in conjunction with the outwardly biased distal end  182  of the spring  178  acting against the second end  86  of the car  80 . Once the flange  184  is lifted out of engagement with the flange  94 , the car  80  is biased into the first position once again by the spring  178  as shown in FIG. 4.  
         [0057]    The conduit  108  extends between the first and second ends  58  and  60  of the body  56  which has a first end  110  and a second end  112 . The first end  110  of the conduit  108  is preferably concentrically aligned with the conduit  68  in the first end  58  of the body  56 . The second end  112  of the conduit  108  preferably includes a curved turn  114  which, in turn, terminates in a lateral extension  116 . The conduit  108  is defined by sidewalls  118  which preferably have a cross section substantially conforming to that of a stud  38 . In addition, the sidewalls  118  each include a laterally-extending ledge  120  which is adapted to receive a radially-extending body of a stud  38  so that a stud  38  can slide through the conduit  108  in a controlled fashion without accidentally becoming lodged therein. It will be understood that the conduit  108  interconnects the passage  62  in the first end  58  of the body  56  with the staking mechanism  54  located adjacent an exit point of the lateral extension  116  in the second end  60  of the body  56 .  
         [0058]    As shown in FIG. 3, the second end  60  of the body  56  further includes a transverse passage  122  which extends laterally outwardly from the second end  60  of the body  56  preferably in axial alignment with the lateral extension  116  of the conduit  108 . A cylinder  124  having a piston  126  is mounted to the body  56  in concentric alignment with the passage  122  in the second end  60  thereof. A distal end  128  of the piston  126  is provided with a rounded indentation  130 . A radius of curvature of the indentation  130  preferably generally corresponds with an outer radius of a body of a stud  38 . It will be understood that the piston  126  is axially movable with respect to the cylinder  124  between a first position wherein the distal end  128  of the piston  126  is positioned within the passage  122  and a second position wherein the distal end  128  of the piston  126  is extended within the lateral extension  116  of the conduit  108  a sufficient extent to urge a stud  38  located within the lateral extension  116  outwardly therefrom.  
         [0059]    The distal end  128  of the piston  126  is preferably of a width which extends substantially across the width of the passage  122  in the second end  60  of the body  56 . At a point intermediate the distal end  128  of the piston  126  and the cylinder  124 , the width of the piston  126  preferably decreases to a narrow portion  132 . The transition from the wider distal end  128  of the piston  126  and the narrow portion  132  of the piston  126  is preferably formed by a ramped surface  134  as shown in FIG. 3.  
         [0060]    As shown in FIG. 2, it will be understood that the cylinder  124  is preferably a pneumatic cylinder whereby the introduction of pressurized fluid to an end  136  of the cylinder  124  causes the piston  126  to be axially extended therefrom. The cylinder  124  preferably has a return spring (not shown) located therein to retract the piston  126  within the cylinder  124  when the pressure of the fluid acting on the end  136  of the cylinder  124  is reduced to a sufficient degree. The cylinder  124  is preferably interconnected to a source of pressurized fluid, such as air, by conduits  138  and  140  which preferably have a relief valve  142  positioned therebetween. A fitting  144  on an opposite end  146  fluidly interconnects the conduit  140  to a manifold  148  which has an additional fitting  150  interconnected to the source of pressurized fluid. It will be understood that the relief valve  142  is preferably a discharge facility for pressurized air which, when actuated, relieves any back pressure in the conduit  138  to the atmosphere which allows the piston  126  to retract quickly within the cylinder  124 . Thus, the piston  126  can be extended and retracted from the cylinder  124  at a high velocity in a relatively short period of time. After the burst is relieved by the relief valve  142 , the supply of pressurized air can be recharged from the manifold  148 .  
         [0061]    Referring now to FIG. 3, the second end  60  of the body  56  further includes a recess  152  located intermediate the conduit  116  and passage  122  and the second end  60  of the body  56 . The recess  152  preferably extends laterally across the second end  60  thereof and has first and second openings  154  and  156  which interconnect the recess  152  with the passage  122  and the lateral extension  116 , respectively. A lever  158  is pivotably-mounted within the recess  152  to the body  56  by a pin  160  located intermediate the first and second openings  154  and  156 . The lever  158  comprises an elongated body  162  having a first end  164  and a second end  166 . Each of the first and second ends  164  and  166  of the body  162  is provided with a flange  168  thereon, each of which extends toward the first end  58  of the body  56 .  
         [0062]    The lever  158  is pivotable between a first position wherein the flange  168  on the first end  164  of the body  162  extends into the passage  122  and a second position wherein the flange  168  on the second end  166  of the body  162  extends into the conduit  116 . It will be understood when the lever  158  is located in the second position the flange  168  on the second end  166  of the body  162  extends into the conduit  116  a sufficient extent so as to prevent a stud  38  from exiting therefrom.  
         [0063]    As the piston  126  is extended from the cylinder  124 , the stud  38  is urged against the flange  168  of the second end  166  and causes the stud  38  to pivot the lever  158  out of obstruction of the conduit  116 . The lever  158  is allowed to pivot because the extension of the piston  126  brings the narrow portion  132  into alignment with the first end  164  providing clearance therefor.  
         [0064]    As shown in FIGS.  1 - 3  and in greater detail in FIGS.  7 - 15 , the staking mechanism  54  includes a rotary feed mechanism  190  mounted adjacent the exit point of the lateral extension  116  in the second end  60  of the body  56 . The rotary feed mechanism  190  comprises a cylindrical body  192  having a circular plate  194  rotatably mounted thereto. The plate  194  has several gripping members  196  positioned adjacent an outer radial edge  198  of the plate  194 . It will be understood that the figures show eight gripping members  196  mounted in a spaced relationship to the plate  194  about edge  198 , however, additional or fewer gripping members  196  can be mounted to the plate  194  without departing from the scope of this invention. The gripping members  196  are preferably mounted to the plate  194  so that a pair of gripping members  196  are located directly opposite from one another along a diametrical axis which passes through the center of the plate  194 . It will be understood that a gripping member  196  can be positioned adjacent the lateral extension  116  of the conduit  108  at the second end  60  of the body  56  whereby a stud  38  exiting the lateral extension  116  is received directly by the gripping member  196  positioned adjacently thereto. It will be further understood that a gripping member  196  located on the opposite side of the plate  194  is positioned in an inverted orientation directly beneath the web  18  at forming station  20 .  
         [0065]    Referring to FIGS.  7 - 9 , the plate  194  of the rotary feed mechanism  190  is rotatably mounted upon a shaft  200  of a housing  202 . It will be understood that the housing  202  can be fixedly mounted to the lower die  12  or can be provided with its own support adjacently thereto without departing from the scope of this invention. In addition to the plate  194 , the rotary feed mechanism  190  further comprises a ratchet  204 , a lever  206 , and a stud-driving assembly  208  (see FIGS. 14 and 15).  
         [0066]    The ratchet  204  is provided on a rearward surface of the plate  194  in concentric alignment with the shaft  200  and has several tangentially-extending teeth  210  thereon. The teeth  210  are each defined by a ramped surface  212  which extends tangentially and radially outwardly from a body  214  of the ratchet  204  and terminates in a rounded peak  216 . A side of the peak  216  opposite from the ramped surface  212  extends radially toward the body  214  and terminates in a rounded groove  218 . Each groove  218  extends smoothly into the ramped surface  212  of the next successive tooth  210  on the ratchet  204 . It will be understood that the number of teeth  210  on the ratchet  204  preferably corresponds to the number of gripping members  196  provided on the plate  194 .  
         [0067]    The lever  206  comprises an elongated body  220  which has a central aperture  222  journaled upon the shaft  200  and having a first end  224  and a second end  226 . The lever  206  further has a forward surface  228  facing the plate  194  and a rearward surface  230  facing the ratchet  204 .  
         [0068]    The first end  224  of the body  220  of the lever  206  is preferably provided with a laterally-extending rounded flange  232  which is preferably mounted to one of the lower die  12  and the housing  202  via a biasing member  234  which biases the first end  224  of the lever  206  in a counterclockwise fashion about the shaft  200 . The lever  206  is preferably movable between a raised position and a lowered position with respect to the shaft  200  as shown in FIGS. 7 and 8, respectively.  
         [0069]    As shown in FIGS.  9 - 11 , the forward surface  228  of the second end  226  of the lever  206  is provided with a forwardly extending flange  236 . The flange  236  preferably has a forward surface  238  thereon which protrudes therefrom between a first end  240  and a second end  242 .  
         [0070]    As shown in FIGS.  7 - 9 , a laterally-extending flange  242  is provided on the elongated body  220  of the lever  206  intermediate the first and second ends  224  and  226  thereof. The flange  224  has a rounded distal end  246 . A latch  248  having a first end  250  and a second end  252  is pivotably mounted to the distal end  246  of the flange  244  adjacent the forward surface  228  thereof. The pivotable mounting of the latch  248  to the flange  244  can be accomplished in any conventional manner such as by a pin  254  mounted within an aperture  256  as shown in FIG. 9. The second end  252  of the latch  248  preferably has a rounded end which preferably corresponds in outer radius to the groove  218  of the teeth  210  in the ratchet  204 . A torsion spring  257  is provided between the lever  206  and the latch  248  which biases the latch  248  into a corresponding groove  218 .  
         [0071]    The plate  194  has a radial groove  195  therein which has several pins  272  (see FIGS.  10 - 11 ) located in a spaced circumferential relationship. The pins  272  extend through each of the gripping members  196  and prevent overtravel thereof when the gripping members  196  close.  
         [0072]    The plate  194  of the rotary feed mechanism  190  is preferably discretely lockable in a number of positions whereby each of the gripping members  196  can be positioned adjacent both the exit point of the lateral extension  116  of the conduit  108  of the positioning mechanism  52  and adjacent the point at which the stud  38  is staked into the web  18  adjacent the opposite portion of the plate  194 . This location of the various positions of the plate  194  is accomplished by a locating mechanism  258  mounted to the housing  202  as shown in FIG. 10. The locating mechanism  258  comprises a pin  260  having a central portion provided with a radially-extending lip  262 . The pin  260  is mounted within a bore  264  of the housing  202  and biased outwardly therefrom by a spring  266 . The pin  260  preferably has a distal end provided with a rounded cam surface  268  thereon.  
         [0073]    The plate  194  further comprises a set of apertures  270 . The set of apertures  270  are located adjacent the radial edge  198  of the plate  194  and are located at each portion of the plate  194  containing a gripping member  196  and are adapted to receive the pin  260  of the locating mechanism  258  so that, as the plate  194  rotates, the pin  260  in the locating mechanism  258  can engage successive apertures  270  in the plate  194 .  
         [0074]    A stud  38  contained in a gripping member  196  is rotated about the shaft  200  and moved from a position adjacent the lateral extension  116  of the conduit  108  through a number of discrete positions to a position whereby the stud can be inserted into the web  18  by the stud-driving assembly  208 . The lever  206  is mounted upon the shaft  200  so that the latch  248 , pivotably mounted to the rearward surface  230  of the flange  244 , is engaged within a groove  218  of one of the teeth  210  on the ratchet  204  and held in place by the bias of the spring  257 . The pin  260  is biased outwardly of the bore  264  and is positioned within one of the apertures  270  on the plate  194  to retain the plate  194  in a particular discrete position.  
         [0075]    As shown in FIGS.  14 - 15 , the stud-driving assembly  208  is preferably mounted adjacent the plate  194  on an opposite side thereof from the lever  206  so that the action of the stud-driving assembly as it stakes a stud  38  within the web  18  does not interfere with the rotation of the plate  194  or the other components of the staking mechanism  54 . The stud-driving assembly  208  comprises a housing  470 , a lever  472 , and a hammer  474 .  
         [0076]    The housing  470  comprises a body  476  which can be formed integrally with the lower die  12  or as a separate component mounted adjacently thereto which has a longitudinal recess  478 , and a lateral recess  480 . The lever  472  is mounted within the longitudinal recess  478 , and the hammer  474  is mounted within the lateral recess  480 .  
         [0077]    The lever  472  comprises an elongated body  482  having a first end  484  and a second end  486 . The first end  484  of the lever  472  is provided with a rounded flange  488  thereon. The second end  486  of the lever  472  is also provided with a rounded flange  490 . The lever  472  is pivotably mounted to the body  470  within the recess  478  in any conventional manner such as by a pin  492  mounted to the housing  470  which extends through an aperture  494  in the elongated body  482 .  
         [0078]    The hammer  474  comprises a body  496  provided with a recess  498  configured to receive the rounded flange  490  on the second end  486  of the lever  472 . The body  496  of the hammer  474  further includes a laterally-extending beam  500  which has a distal end  502  provided with a vertical extension  504  thereon. The extension  504  has a distal end  506  which is adapted to contact a radially-extending body of a stud  38 .  
         [0079]    In assembly, the hammer  474  is slidably mounted within the lateral recess  480  of the housing  470  for slidable movement therein between a lowered position and a raised position as shown in FIG. 14. The rounded flange  490  of the second end  486  of the lever  472  is positioned within the recess  498  of the hammer  474  so that pivotable movement of the lever  472  actuates the hammer  474  between the lowered and raised positions. A spring  508  can be mounted in any suitable position, such as between the housing  470  and hammer  474 , to bias the hammer  474  into the lowered position. The rounded flange  488  on the first end  484  of the lever  472  preferably extends beyond the longitudinal recess  478  of the housing  470  and is adapted to be contacted by a depending flange  510  provided as a portion of a forming tool on the upper die  14 . Thus, as the upper die  14  is moved toward the lower die  12 , the depending flange  510  contacts the rounded flange  488  on the first end  484  of the lever  472  and urges the first end  484  downwardly. This causes the lever  472  to be pivoted about the pin  492  and urges the rounded flange  490  on the second end  486  upwardly. Because the rounded flange  490  of the second end  486  of the lever  472  is engaged within the recess  498  on the hammer  474 , the hammer  474  is urged upwardly in conjunction with the second end  486 .  
         [0080]    It will be understood that, when the second end  486  of the lever  472  is in a lowered position, the distal end  506  of the extension  504  of the hammer  474  is positioned beneath the gripping member  196  located directly beneath the web  18 . As the second end  486  of the lever  472  is pivoted upwardly by the action of the depending flange  510  against the first end  484  of the lever  472 , the hammer  474  is urged upwardly as well. The distal end  506  of the extension  504  of the hammer  474  thereby contacts the radially-extending body of the stud  38  retained within the gripping member  196  and urges the stud  38  out of the gripping member  196  and into the web  18 . It will be understood that the stud  38  can preferably include an annular groove  512  adjacent the body of the stud  38  to aid the interengagement of the stud  38  with the web  18  as shown in FIG. 15.  
         [0081]    The gripping members  196  are preferably adapted to releasably retain a stud  38  therein, but upon sufficient force provided to the radially-extending body of the stud  38 , the gripping members  196  are adapted to release the stud  38  therefrom. FIGS.  12 - 13  show the gripping members  196  in greater detail. The gripping members  196  comprise first and second arms  280  and  282 , respectively, each of which is pivotably mounted to the plate  194  by a pin  284  mounted within an aperture  286  located in each of the arms  280  and  282 . A spring  288  extends between the first and second arms  280  and  282  to bias the arms  280  and  282  into a closed position wherein the arms  280  and  282  are positioned directly adjacent one another. In the closed position, the arms  280  and  282  can retain a stud  38  therebetween.  
         [0082]    Each of the arms  280  and  282  include a raised wall  290  having a cam surface  292  thereon. The wall  290  and cam surface  292  are preferably formed on the arms  280  and  282  in a mirror image of one another. Thus, it will be understood that whether a stud  38  is urged laterally or axially between the raised walls  290  on the first and second arms  280  and  282 , the urging of the body of the stud  38  against the raised walls  290  causes the stud  38  to force the first and second arms  280  and  282  apart against the bias of the spring  288 . Once the stud  38  clears the cam surface  292  thereon, the bias of the spring  288  biases the first and second arms  280  and  282  back to the closed position and closes the arms  280  and  282  around the stud  38  to retain the stud  38  therebetween. Indentations  294  are provided on each arm  280 ,  282  which are closed around a corresponding pin  272  on the plate  194  to prevent overtravel of the arms  280 ,  282  as they close.  
         [0083]    The operation of the stud-staking apparatus  42  will now be described as shown in FIGS.  2 - 15 . Referring to FIGS.  2 - 6 , a stud  38  is fed through the first end  76  of the conduit  74  and into the bore  92  of the car  80  via the second end  78  of the conduit  74 . As the upper die  14  is lowered toward the lower die  12 , the distal end  186  of the flange  184  abuts the flange  94  on the car  80 . As the upper die  14  is further lowered, the angular surface  188  on the flange  184  contacts the ramped surface  98  of the flange  94  on the car  80 . The action of the angular surface  188  of the flange  184  against the ramped surface  98  causes the car  80  to be moved toward the second end  66  of the passage  62  in the first end  58  of the body  56  as shown in FIGS. 2, 4 and  5 .  
         [0084]    When the stud  38  in the bore  92  is aligned with the aperture  68  in the passage  62 , pressurized air is supplied through the aperture  68  via conduit  70  and fitting  72  to the bore  92  in the car  80 . This causes the stud  38  to be “blown” into the conduit  108  in the body  56 .  
         [0085]    The radially-extending head of the stud  38  preferably rests on the ledge  120  of the side walls  118  of the conduit  108 . The stud  38  travels through the conduit  108  via the burst of pressurized air supplied through the conduit  70 .  
         [0086]    It will be understood that the piston  126  of the cylinder  124  is positioned in the retracted position so that the distal end  128  thereof does not extend into the lateral extension  116  of the conduit  108 . The stud  38  travels toward the second end  60  of the body  56  and through the turn  114  and into the lateral extension  116 . The flange  168  located on the second end  166  of the lever  158  extends into the lateral extension  116  and prevents the stud  38  from exiting the lateral extension  116 .  
         [0087]    When it is desired to insert the stud  38  located in the lateral extension  116  into a gripping member  196  of the rotary feed mechanism  190 , the cylinder  124  is supplied with a burst of pressurized air from the conduit  138  via the end  136  thereof. The piston  126  is axially extended from the cylinder  124 . As the piston  126  is extended, the flange  168  on the first end  164  of the lever  158  rides against the piston  126 . The flange  168  of the first end  164  of the lever  158  is further urged along the ramped surface  134  of the piston  126  as a result of the extension thereof. As the flange  158  passes the ramped surface  134  and onto the narrow portion  132  thereof, the distal end  128  of the piston  126  extends into the lateral extension  116  of the conduit  108 . In addition, as the piston  126  is urged forwardly, it contacts the stud  38  and pushes it forwardly, causing the lever  158  to be pivoted about pin  160 . As a result, the flange  168  of the second end  166  of the lever  158  is pivoted out of obstruction of the lateral extension  116 . The lever  158  is allowed to pivot because the narrow portion  132  has been positioned adjacent the second end  166  due to the movement of the piston  126 . The narrow portion  132  provides the necessary clearance to allow the stud  38  to be pivoted out of the lateral extension  116 .  
         [0088]    As the piston  126  is further extended from the cylinder  124 , the indentation  130  on the distal end  128  of the piston  126  further pushes the stud  38  located in the lateral extension  116 . The piston  126  is extended so that the stud  38  is engaged within the rounded indentation  130  and is pushed out of the lateral extension  116  of the conduit  108  and into the gripping member  196  located adjacent the exit of the lateral extension  116 .  
         [0089]    Once a stud  38  has been positioned onto a gripping member  196 , it is the function of the rotary feed mechanism  190 , and particularly the plate  194 , to carry the stud  38  retained within the gripping members  196  from a position adjacent the exit of the lateral extension  116  of the conduit  108  to a position whereby the hammer  474  on the stud-driving assembly  208  can push the stud  38  into the web  18  to complete the staking of the stud  38  therein. As shown in FIGS.  7 - 8 , several gripping members  196  are shown intermediate these two positions which carry studs  38  awaiting insertion into the web  18 .  
         [0090]    The rotation of the plate  194  through its discrete positions will now be described. It will be understood that the second end  252  of the latch  248  of the lever  206  is engaged within a groove  218  of one of the teeth  210  of the ratchet  204  which thereby retains the lever  206  in a particular position with respect to the ratchet  204  as shown in FIGS.  7 - 8  and in greater detail in FIG. 9. The plate  194  is releasably engaged to the lever  206  by the locating mechanism  258 . More particularly, the cam surface  268  on the pin  260  is biased outwardly of the bore  264  in the housing  202  by the spring  266 . As shown in FIG. 10, the pin  260  is lodged within one of the first apertures  270  on the plate  194  to retain the plate  194  in a desired locked position with respect to the housing  202 .  
         [0091]    The upper die  14  is preferably provided with a downwardly-depending flange  294  having a distal end  296  provided on the forming station located adjacent the rotary feed mechanism  190  as shown in FIGS.  7 - 8 . As the upper die  14  is moved toward the lower die  12 , the distal end  296  of the flange  294  contacts the rounded flange  232  on the first end  224  of the lever  206  and urges it downwardly. As the first end  224  of the lever  206  is pivoted downwardly, the distal end  252  of the latch  248  travels upwardly along the ramped surface  212  of the next successive tooth  210  on the ratchet  204 . When the first end  224  is pivoted downwardly a sufficient extent by the flange  294  on the upper die  14 , the distal end  252  of the latch  248  passes over the peak  216  on the next successive tooth  210  and is urged falls by the bias of spring  257  into the groove  218  of the next successive tooth  210  of the ratchet  204 .  
         [0092]    Once the flange  294  of the upper die  14  is lifted away from the lower die  12 , the first end  224  of the lever  206  is again biased toward its raised position. As the first end  224  of the lever  206  travels towards the raised position, the distal end  252  of the latch  248  is engaged within the groove  218  of the next successive tooth  210  of the ratchet  204 . As the first end  224  of the lever  206  travels toward the raised position, the engagement of the distal end  252  of the latch  248  in the groove  218  of the next successive tooth  210  of the ratchet  204  by the action of spring  257  urges the plate  194  to rotate to the next successive position. As the plate  194  begins rotating as a result of the force imparted thereto by the lever  206 , the pin  260  is urged out of engagement with the aperture  270  in the plate  194  and rides along the surface of the plate  194 . As the plate  194  approaches the next successive position, the pin  260  of the locating mechanism  258  is biased into the next successive aperture  270  on the plate  194  and locks the plate  194  in the next successive discrete position.  
         [0093]    The operation of the stud-driving assembly  208  will now be described as shown in FIGS. 14 and 15. As the upper die  14  is moved toward the lower die  12 , the depending flange  510  on the upper die contacts the rounded flange  488  located on the first end  484  of the lever  472 . As the depending flange  510  is urged further downwardly by the upper die  14 , the lever  472  is pivoted about the pin  492  so that the rounded flange  490  on the second end  486  of the lever  472  is urged upwardly. Because the hammer  474  receives the second end  486  of the lever  472  within the recess  498  thereof, the hammer  474  is urged upwardly within the lateral recess  480  of the housing  470  against the bias of the spring  508 .  
         [0094]    As the hammer  474  is moved upwardly by the second end  486  of the lever  472 , the distal end  506  of the extension  504  of the hammer  474  contacts the stud  38  located in the gripping member  196  which is located adjacent the web  18 . As the hammer  474  is urged further upwardly by the second end  486  of the lever  472 , the arms  280  and  282  of the gripping member  196  are forced apart against the bias of spring  288  by the action of the radially extending body of the stud  38  against the cam surface  292  on the arms  280  and  282 . The distal end  506  of the extension  504  thereby urges the stud  38  upwardly and free from engagement with the arms  280  and  282  of the gripping member  196  and into a pre-formed aperture in the web  18  where the stud  38  is lodged therein.  
         [0095]    As the upper die  14  is moved upwardly with respect to the lower die  12 , the flange  510  is lifted away from the first end  484  of the lever  472 . The bias of the spring  508  thereby urges the hammer  474  downwardly within the lateral recess  480  of the housing  470  which, in turn, urges the second end  486  of the lever  472  downwardly therefrom. This downward pivoting of the second end  486  of the lever  472  repositions the first end  484  into the raised position as shown by the phantom outline in FIG. 14.  
         [0096]    It will be understood that the length and configuration of the flanges  184 ,  294 , and  510  can be selected so as to provide the actuation of the car  80 , lever  206 , and the lever  472  at the proper time to provide optimal results from the progressive die machine  10  during the operation thereof.  
         [0097]    The bending apparatus  44  is shown in a lowered position in FIG. 16 and in a raised position in FIG. 17. It will be understood that when the bending apparatus  44  is located in the lowered position, less bend to the part  40  is formed to the part  40 . In addition, when the bending apparatus  44  is positioned in the raised position, a more acute bend is provided to the part  40 .  
         [0098]    Referring to FIGS.  16 - 17 , the bending apparatus  44  comprises a stepper motor  300 , a motion converter  302 , and an adjustable floor device  304 . It will be understood that, although the bending apparatus  44  is shown in FIG. 1 at forming station  32 , the bending apparatus  44  can be provided at any position in the progressive die machine  10  without departing from the scope of this invention. It will be further understood that the bending apparatus  44  can be configured as a separate device and retrofitted to a progressive die machine  10  or the progressive die device can be integrally manufactured with the progressive die machine  10 .  
         [0099]    The bending apparatus  44  is adapted to be located within the progressive die machine  10  between the lower and upper dies  12  and  14 , respectively. It will be understood that the stepper motor  300  and the adjustable floor device are mounted to the lower die  12  by any conventional manner which is well known in the art. It will be further understood that the motion converter  302  is mounted between the motor  300  and the adjustable floor device  304 .  
         [0100]    The motor  300  can be any suitable device such as a housing  306  which contains a rotatable assembly which imparts rotary motion to an output shaft  308  extending axially therefrom. Preferably, the motor  300  is a direct current (DC) stepper motor which can accurately provide precise amounts of rotation to the output shaft  308  in discrete and/or continuous intervals.  
         [0101]    The motion converter  302  comprises any suitable device for conversion of rotary motion to rectilinear motion. For example, as shown in FIG. 16, the motion converter  302  comprises a housing  310  adapted to receive the output shaft  308  at a first end  312  and having a second end  314  from which an output shaft  316  extends. The housing  310  preferably contains components which are commercially available and well known to convert rotary motion imparted to the output shaft  308  to linear motion which extend and retract the output shaft  316  axially with respect to the housing  310 .  
         [0102]    The adjustable floor device  304  comprises a lower portion  318  and an upper portion  320  mounted between a pair of stationary walls  322 . The walls  322  are fixedly mounted to the lower die  12 . The lower portion  318  includes a ramped surface  324  which abuts the upper portion  320 . The lower portion  318  further has an end  326  mounted to a bracket  328  which, in turn, has a proximal end  330  adjacent the output shaft  316  of the motion converter  310 . It will be understood that any axial movement imparted to the output shaft  316  of the motion converter  310  is imparted to the lower portion  318  of the adjustable floor device  304 .  
         [0103]    The upper portion  320  is slidably mounted within a recess  332  in the walls  322  so that the upper portion is movable with respect to the walls  322  but limited to a vertical direction. The upper portion  320  further has a lower surface  334  thereon which abuts the ramped surface  324  on the lower portion  318 . A spring  336  is mounted axially on a shoulder fastener  338  which, in turn, is mounted to the upper portion  320  so that the shoulder fastener  338  downwardly biases the upper portion  320 . The shoulder fastener  338  extends between the lower die  12  and the upper portion  320  through a longitudinal slot (not shown) in the lower portion  318  to allow for movement of the lower portion  318  with respect to the upper portion  320 . The PLC  50  provides motion control to the motor  300 .  
         [0104]    It will be understood that the forming station  32  shown in FIG. 16 includes a tool  344  thereon which generally comprises a downwardly depending flange mounted to the upper die  14  and having a lower surface  346  thereon which is adapted to form an upper limit to the contouring operation performed by the bending apparatus  44 . Further, the upper portion  320  of the adjustable floor device  304  includes an upper surface  348  thereon which is adapted to provide a lower limit to the contouring operation performed by the bending apparatus  44 .  
         [0105]    It will be understood that a part  40  formed by the web  18  is located between the lower and upper dies  12  and  14 , respectively, as shown in FIG. 16. As is described elsewhere in this specification, the PLC  50  can send a signal to the motor  300  through connection  342  to impart a predetermined degree of rotation to the output shaft  308 . The rotation of the shaft  308  is converted to axial movement of the output shaft  316  which is thereby extended or retracted depending upon the direction of rotation of the output shaft  308 . A spring return (not shown) can be provided to urge the lower portion  318  toward the motor  300 .  
         [0106]    If the output shaft  316  is retracted toward the housing  310 , the lower portion  318  is also slid toward the motion converter  302 . The interaction between the ramped surface  324  of the lower portion  318  and the lower surface  334  of the upper portion  320  causes the upper portion  320  to be lowered with respect to the walls  322 . The upper surface  348  of the upper portion  320  is thereby lowered a predetermined distance.  
         [0107]    If the output shaft  316  is extended away from the housing  310 , as shown along arrow A of FIG. 17, the lower portion  318  is also slid away from the motion converter  302 . The interaction between the ramped surface  324  of the lower portion  318  and the lower surface  334  of the upper portion  320  causes the upper portion  320  to be raised with respect to the walls  322  as shown along arrow B of FIG. 17. The upper surface  348  of the upper portion  320  is thereby raised a predetermined distance.  
         [0108]    It will be understood that the position of the upper surface  348  of the upper portion  320  of the adjustable floor device  304  determines the amount of bending introduced to the part  40  located at forming station  32  as the tool  344  is lowered with the upper die  14  during the stroke of the progressive die machine  10 . The lower surface  346  of the tool  344  is brought into contact with the part  40  located therebeneath and performs the bending of the part  40  by forcing the part  40  between the lower surface  346  of the tool  344  and the upper surface  348  of the upper portion  320  of the adjustable floor device  304 .  
         [0109]    Thus, upon an appropriate signal delivered to the motor  300 , the upper surface  348  of the upper portion  320  can be adjusted to provide a lesser or greater degree of bending depending upon the direction of rotation of the output shaft  308  of the motor  300 . This degree of bending is determined by a quality control signal generated from the measuring apparatus  46 .  
         [0110]    The measuring apparatus  46  is shown in FIG. 18 comprising an upper portion  350  and a lower portion  352 . It will be understood that the measuring apparatus  46  can be manufactured as a separate assembly and retrofitted to an existing progressive die machine. Alternatively, the measuring apparatus  46  can be manufactured as an integral portion of a progressive die machine  10 .  
         [0111]    The upper portion  350  comprises a body  354  having an upper surface  356  and a lower surface  358 . The body  354  is provided with several cylindrical bores  360  which extend through the body  354  between the upper and lower surfaces  356  and  358 , respectively. The upper surface  356  of the body  354  can be provided with a mounting assembly, such as shaft  362  shown in FIG. 18, for mounting the upper portion  350  to the upper die  14  of the progressive die machine. Alternatively, the upper portion  350  can be mounted to a separate lifting assembly (not shown) for raising and lowering the upper portion  350  with respect to the lower portion  352 . The lower surface  358  of the body  354  is provided with a central flange  364  extending outwardly therefrom. The central flange  364  is preferably provided with a downwardly-extending extension  366 .  
         [0112]    Each bore  360  in the upper portion  350  is adapted to receive a transducer  368  therein. Each of the transducers  368  in the upper portion  350  comprise a transformer  370  having a core mounted therein for axial movement with respect thereto. The transducers  368  are preferably mounted within the bores  360  of the upper portion  350  so that each of the cores  372  in the transducers  368  extends beyond the lower surface  358  of the upper portion  350 .  
         [0113]    The lower portion  352  of the measuring apparatus  46  comprises a body  374  having a table  376  mounted for vertical movement with respect to the body  374 . As with the upper portion  350  of the measuring apparatus  46 , the lower portion  352  can either be mounted as a unit to a lower die  12  of a progressive die machine  10  or mounted adjacent the die machine  10  downstream from the forming stations  20 - 36 .  
         [0114]    The body  374  of the lower portion  352  includes an upper surface  378  and a lower surface  380  having several cylindrical bores  382  extending therebetween. In addition, the body  374  of the lower portion  352  is provided with a pair of bearings  384  located adjacent each vertical side of the body  374 . Preferably, the bores  382  are located intermediate the bearings  384 .  
         [0115]    The table  376  comprises a plate  386  having an upper surface  388  and a lower surface  390 . Several apertures  392  extend through the plate  386  between the upper and lower surfaces  388  and  390 , respectively. The apertures  392  are preferably located in a spaced lateral relationship with respect to one another. In addition, the apertures  392  and the plate  386  preferably correspond in vertical concentric alignment with the bores  382  in the body  374  of the lower portion  352 . The lower surface  390  of the plate  386  is provided with at least two depending legs  394  located on adjacent opposite edges of the plate  386  which preferably correspond in vertical concentric alignment with the bearings  384  on the body  374 .  
         [0116]    The table  376  is mounted to the body  374  by journaling the legs  394  within the bearings  384  on the body  374 . Springs  396  are preferably disposed around the legs  394  between the lower surface  390  of the plate  386  and the upper surface  378  of the body  374  so that the table  376  is biased upwardly from the body  374 . Further, transducers  398  having a transformer  400  and a core  402  mounted therein for axial movement with respect to the transformer  400  are provided in the bores  382  of the body  374 . When the transducers  398  are mounted to the body  374 , the cores  402  of each of the transducers  398  preferably extend through the apertures  392  in the plate  386  and beyond the upper surface  388  thereof.  
         [0117]    It will be understood that the transducers  368  and  398  of the upper and lower portions  350  and  352 , respectively, are properly interconnected to the A/D converter  408  through the signal conditioning device  410 .  
         [0118]    It will be further understood that one of the transducers  398  on the lower portion  352  is also designed as a trigger device shown in FIG. 18 by an additional reference numeral  406 . The core  402  of the transducer  406  is preferably in vertical alignment with the extension  366  on the upper portion  350 . The extension  366  and transducer  406  are preferably located either forwardly or rearwardly of a plane containing the remaining transducers  368  and  398  for reasons which will be obvious as explained below.  
         [0119]    The trigger function of transducer  406  is to signal the initiation of the measurement process as well as provide a “zero” reference plane for comparison with the remaining transducer  398 . As the web  18  having a formed part  40  thereon is fed between the upper portion  350  and the lower portion  352  of the measuring apparatus  46 , the extension  366  on the upper portion  350  contacts the core  402  of the trigger transducer  406  which causes the core  402  to be retracted within the transformer  400  thereof. As the upper portion  350  continues to be lowered toward the lower portion  352 , the cores  372  and  402  of the remaining transducers  368  and  398  are urged against upper and lower surfaces of the part  40  located therebetween. The lowering of the upper portion  350  toward the lower portion  352  causes the part  40  to be urged between the table  376  and the upper portion  350  so that the table  376  is urged downwardly against the bias of the springs  396  located between the body  374  and table  376 . This ensures that all of the transducers  368  and  398  obtain contact with the part  40 .  
         [0120]    Once the transducers  368  on the upper portion  350  and the transducers  398  on the lower portion  352  have sufficiently contacted the part  40 , data is sent to a conventional analog-to-digital converter (not shown) which provides data information from the transducers  368  and  398  to the PLC  50  through the connections  440 .  
         [0121]    [0121]FIG. 19 shows a diagram of the process whereby a part  40  is measured by the measuring apparatus  46 . As shown in FIG. 19, the transducers  368  and  398  send a signal through connections  404  to an analog-to-digital converter  408  (A/D converter). It will be understood that a signal conditioning device  410  can be mounted intermediate the transducers  368  and  398  and the A/D converter  408  and is interconnected therebetween by suitable connections  412 .  
         [0122]    The A/D converter  408  converts analog signals from the transducers  368  and  398  into a digital format in a conventional manner which is well known in the art. The A/D converter  408  has an input port  414  and first and second output ports  416  and  418 . The input port  414  and first output port  416  are interconnected by suitable connections  420  and  422 , respectively, to a direct memory access (DMA) controller  426  of a computer  424  DMA which, in turn, is interconnected by suitable connections  428  to a random access memory (RAM) buffer  430 . The RAM  430  is interconnected by a suitable connection  432  to a central processing unit (CPU)  434  of any suitable type. An additional memory portion of the computer  424  contains a main program  436  which has access to the CPU  434  through a suitable connection  438 .  
         [0123]    As data is read by the transducers  368  and  398  regarding the part  40  located between the upper and lower portions  350  and  352 , the data are sent through connection  404  through the signal conditioning device  410  and into the A/D converter  408 . The data is thereby converted to a digital signal and sent through the first output port  416  and through connection  422  into the DMA controller  426  in the computer  424 . The digital signals are thereafter sent through connection  428  and stored in the RAM  430 .  
         [0124]    The RAM  430 , CPU  434  and main program  436  cooperate to determine whether the part  40  conforms with specifications for the part  40  which are preferably suitably stored within the computer  424 . The RAM  430 , CPU  434  and main program  436  cooperate to perform quality control analyses on the digital data stored in the RAM  430 .  
         [0125]    First, the specific measurements of the part  40  located between the upper portion  350  and lower portion  352  of the measuring apparatus  46  are compared with the part specifications stored in the computer  424  to determine whether the part  40  located within the measuring apparatus  46  falls within acceptable tolerance limits specified by the part specifications. If the part  40  located within the measuring apparatus  46  does not fall within acceptable tolerance limits as noted by the part specifications, an error signal, which is generally referred to as “flag  1 ,” is generated and is sent out of the computer  424  to the input port  414  of the A/D converter  408 .  
         [0126]    The RAM  430 , CPU  434  and main program  436  also track the number of consecutive “flag  1 ” error messages which were generated. If “flag  1 ” error messages were generated by the computer  424  for three consecutive parts  40  located in the measuring apparatus  46 , a second error message, identified as “flag  2 ,” is sent out of the computer  424  to the input port  414  of the A/D converter  408 .  
         [0127]    Third, the RAM  430 , CPU  434  and main program  436  cooperate to compute a rolling average and variance of a previous predetermined number of parts  40  which have passed through the measuring apparatus  46 . It has been found that computing a rolling average and variance for the previous ten parts  40  which have passed through the measuring apparatus  46  provides an acceptable measure of the current performance of the progressive die machine  10 . However, a larger or smaller sample of the number of parts  40  passing through the measuring apparatus  46  can be computed without departing from the scope of this invention. If the most recently computed average and variance computations are determined to be too high or too low compared to the preferable values denoted by the part specifications, a third error message, noted here as “flag  3 ,” is sent to the input port  414  of the A/D converter  408 .  
         [0128]    A value for the mean displacement of the transducers  368 ,  398  is calculated. The mean is calculated using the well known equation:  
       μ   =         ∑   l   n          X   i       n                           
 
         [0129]    where:  
         [0130]    X i =the individual reading from each transducer  368 ,  398  on the measuring apparatus  46 ;  
         [0131]    n=the number of readings from the transducers  368 ,  398  which corresponds to the previous n parts passing through the measuring apparatus  46 ; and  
         [0132]    μ=the calculated mean from the readings from transducers  368 ,  398 .  
         [0133]    A difference δ between the calculated mean μ and a target value τ of the parts formed is computed as follows:  
         δ=μ−τ 
         [0134]    where:  
         [0135]    δ=a calculated difference;  
         [0136]    τ=a predefined desired target value.  
         [0137]    A control signal σ is computed per the following formula:  
         σ=|δ|−λ 
         [0138]    where:  
         [0139]    δ=the difference as calculated above;  
         [0140]    λ=a predefined tolerance limit for a formed part.  
         [0141]    If necessary, the control signal is generated by the computer  424  and sent to the PLC  50  through the A/D converter  408  to adjust the bending apparatus  44 .  
         [0142]    The PLC  50  preferably has first, second and third output ports  442 ,  444  and  446 , respectively. The first output port  442  is preferably interconnected to a sorting device  448  by a suitable connection  450 . The sorting device  448  preferably comprises a discharge chute provided with a diverter mechanism (not shown) whereby acceptable parts are deposited into a first bin for accumulation and rejected parts are deposited into a second bin for later disposal or recycling. The sorting device  448  can accomplish this function using any suitable mechanism known in the art as the particular mechanism or device used to accomplish this function should not be interpreted as limiting the scope of this invention.  
         [0143]    The second output port  444  is interconnected to a press control device  452  by a suitable connection  454 . The press control device  452  can preferably, upon receipt of an appropriate signal, halt operation of the progressive die machine  10 . As with the sorting device  448 , the particular device used to accomplish the function of the press control device  452  should not be interpreted as limiting the scope of this invention.  
         [0144]    The third output port  446  is interconnected to the bending apparatus  44  by a suitable connection  456 . It will be understood that the bending apparatus  44  includes a controller (not shown) which is adapted to receive signals from the PLC through the connection  456 .  
         [0145]    Upon receipt of a particular message from the computer  424  through the A/D converter  408 , the PLC  50  can, in turn, send an appropriate signal to the sorting device  448 , the press control device  452  and/or the bending apparatus  44 . For example, if “flag  1 ” is received by the PLC from the A/D converter  408 , the PLC  50  sends a signal through the first output port  442  and connection  450  to the sorting device  448  to discard the particular part  40  which is located in the measuring apparatus  46 . If “flag  1 ” is not received by the PLC  50 , the part  40  is determined to be acceptable and will be deposited in a bin for accumulation.  
         [0146]    If “flag  2 ” is received by the PLC  50  from the computer  424  through the A/D converter  408 , the PLC  50  sends a suitable signal through the second output port  444  and connection  454  to the press control device  452  to halt operation of the progressive die machine  10 . If “flag  2 ” is not received by the PLC  50 , the operation of the progressive die machine  10  will be continued.  
         [0147]    If “flag  3 ” is received by the PLC  50  from the computer  424  through the A/D converter  408 , a suitable signal is sent through the third output port  446  and connection  456  to the bending apparatus  44  that the mean of a recent number of parts  40  passing through the measuring apparatus  46  are unacceptable with respect to the target part specification stored in the computer  424 . A signal is sent to the stepper motor  300  to raise or lower the adjustable floor device  304  with respect to the upper die  14  so that subsequent parts  40  formed in the progressive die machine  10  at forming stations  20 - 36  correspond more closely to the specifications for the parts  40 .  
         [0148]    [0148]FIG. 20 shows a diagram which outlines the events which occur during the stroke of the progressive die machine  10 . The events and the particular angle notation at which the identified events occur should not be interpreted as limiting the scope of this invention. It will be understood that the events shown can occur at other stroke angles without departing from the scope of this invention.  
         [0149]    While particular embodiments of the invention have been shown, it will be understood, of course, that the invention is not limited thereto since modifications may be made by those skilled in the art, particularly in light of the foregoing teachings. Reasonable variation and modification are possible within the scope of the foregoing disclosure of the invention without departing from the spirit of the invention.