Patent GB-1040532-A (GB)
Title: Method and apparatus for fabricating honeycomb core
IPC: B23K11/00
Filed: 1964-02-05
Abstract: 1,040,532. Making honeycomb cores; punching; corrugating; welding by pressure. ROHR CORPORATION. Feb. 5, 1964 [Feb. 12, 1963], No. 4846/64. Headings B3A, B3E, B3R and B3W. In a machine for fabricating honeycomb core layer by layer from a continuous length of corrugated ribbon, the core is shuttled back and forth along its length, the ribbon is assembled in successive layers with opposite corrugations aligned, the abutting corrugations are bonded, e.g., by resistance welding, and the ribbon is automatically doubled back upon itself when the last corrugation of a layer has been bonded. The machine first described with reference to Figs. 2, 3, 4 and 5 has manual lowering of the core and manual looping back of the ribbon. The manner in which these operations can be performed automatically is later described with reference to Figs. 4b and 12. Stainless steel strip e.g. 0.001 inch thick is fed from a reel 239, Fig. 4, by a reciprocating gripper 233 driven on its feed stroke by a spring 236 and returned by a cam 235 on a press head 228 carrying perforating punches 229 and corrugating tools 225, 226, 227. The tools 226, 227 progressively form the corrugations while the tool 225 locates the corrugated strip. The preformed strip 20A is fed over a guide 214 movable by hand to either side of the machine. The strip 20A and the core 19 are supported during welding on sets of internesting pins, Figs. 2, 3 and 5, the lower set comprising a dozen copper electrode pins 22 and the upper set being thirteen steel indexing pins 23. The pins are pointed and have grooves 407 which provide clearance as for the projections created by punching. The welds are effected by six copper electrode wheels 25 which weld alternate nodes on their forward stroke and intervening nodes on the return stroke. Adjacent pairs of wheels are connected in series across secondary windings of a transformer and the welding circuits are completed through the associated electrode pins which are all electrically interconnected. The wheels 25 are mounted on individual rods 32 slidable vertically in a block 53 by common inflatable hoses 54, 55. The block 53 is supported in a horizontal slideway 57 on a frame 59 reciprocable during welding by a fluid motor 75. As the frame 59 moves forward at the start of the welding stroke, rubber-tipped fingers 24 are moved by linkage 88 down and across the unwelded strip to hold it against one of a pair of stripper plates 107, 111 between which the core 19 is located. Cams control the lowering of the wheels 25 and the connection of welding current to the wheels. Near the end of the forward stroke the wheels 25 are lifted and the block 53 is transversely moved by a cam and aligned with the unwelded nodes. After the wheels 25 have been raised near the end of the return stroke the block 53 is cam actuated to make a return transverse movement, and the electrode pins 22 are retracted by a fluid motor 141. The indexing pins 23 are mounted on compound slides 151, 164 moved by fluid motors 155, 179. Motor 179 reciprocates the indexing pins 23 to the side of the machine opposite to a manually positioned stop 285. The indexing pins 23 move the core 19 to locate unwelded nodes adjacent the electrode pins 22 which are reinserted into the core. The indexing pins 23 are retracted, returned to welding position and reinserted in the core 19 over the electrode pins 22. The welding cycle is repeated until the end of the core 19 is reached. The core 19 is supported by pins 191, 192 passed through cells of the core and resting on bars 186, 187 extending outwards from the machine. The electrode and indexing pins are retracted and the pins 191, 192 are readjusted to lower and to return the core by half a cell in each case. The guide 214 and the stop 285 are transferred to the other side of the machine and the electrode and indexing pins are inserted and welding is commenced in the return direction. Initially the first few layers of core are supported on a profiled wooden block which is held on the bars 186, 187 by pins 191, 192. In a modification, pairs of pins 191, 192, Fig. 4b, are mounted on rocking blocks 195 carried by sliders 197 sliding on flanges of the bars 186, 187. When the core reaches the end of its travel a switch 212 or 213 is actuated and at the end of the welding cycle the lower pin say 191 of each pair is extracted by a solenoid and the weight of the core on the pins 192 rocks the blocks 195 to lower and reverse the core 19 by half a cell in each case. The pins 191 are then inserted in the row of cells above the pins 192. The stop 285 may also be replaced by automatically actuated stops. In a further modification, Fig. 12 and Fig. 17 (not shown), the machine is fully automatic and the successive layers of the strip are looped on to the core by a guide having intergeared wheels 392, 393 having profiles corresponding to the strip corrugations, the strip passes between the wheels 392, 393 which are reciprocated across the core and which loop the strip at each end of the core. All the automatic operations are controlled by an electro-mechanical system having a master sequence switch. When the reel of strip is exhausted, another strip is fed either to a hand welder or into the machine wherein the overlapped ends are welded during the formation of the honeycomb. Honeycomb core consisting of strips of different thickness, e.g., a single layer comprising different thicknesses of strips at its edges and in its centre, can be formed by an automatic programmed machine in which a plurality of different strips are fed. sheared and spliced by a welding unit to produce the required pattern of strip thicknesses in the core.