Patent Publication Number: US-10328470-B2

Title: Roll dimpler apparatus and method for preparing metal blanks

Description:
This Application claims the benefit of U.S. Provisional Application Ser. No. 62/139,177 filed on Mar. 27, 2015. 
    
    
     SUMMARY 
     The need for the roll dimpler came about because of the increased use of aluminum stamped panels in automotive and other industries. Currently one line makes the blanks, stacks them, then sends them to the final stamping line. The blanks are stacked in specific pallets for transport. The pallets allow pneumatic suction cups to vertically lift then horizontally feed the blanks into the press. Steel blanks are usually separated by a device called a fanner magnet. This device magnetically lifts the top sheet and slides it sideways off the sheets below so that the vacuum cups can pick it up easily. The non-magnetic nature of aluminum created significant new problems in blank separation. Air knives and other traditional technologies were not sufficient to accomplish blank separation. Separation is important in the blanking process because double feeding a blank can severely damage the die and shut down a manufacturing line. 
     We produced an in-line dimpling device that would run right after the decoiler straightener before the blanks were cut in the blanking press die. The device would need to handle aluminum of different thicknesses and produce small dimples, for example, less than 10% of the material thickness. The dimples need only be sufficient in size and density to accomplish blank separation, usually 0.007″ or less. In order to achieve this goal, we devised a system having two rollers under continuous but variable pressure with compliance to insure the dimpling members would continue to roll concentrically. Our initial device is powered by an air cylinder, but it could also be powered by a gas spring or coil spring. The pairs of rollers or “dimpling heads” are movable to accommodate different widths of coils. 
     Without the dimples, a stack of aluminum blanks are nearly impossible for a man to separate. With the dimples a man can move the top blank with only two fingers. In one test, the addition of 0.006″ tall dimples with two inch spacing makes this dramatic change. 
     Our device used coordinated, opposed, male and female dimpling wheels derived from roll marking technology. The compliant features that allows the wheels to continue to roll concentrically are new. The use of filled teflon Gib sets in the compliance guide absorbs the very short linear travel without fretting or lubrication. The depth of the dimple is controlled by the pressure on the air cylinder combined with the height of the male dimple so that multiple aluminum metal thicknesses can be dimpled with the same unit. The dimpler also works on other nonferrous metals and steel blanks. 
     Once the device is set, one method of operation is as follows: 
     Retract the air cylinders to separate the dimpling wheels; 
     Feed new coil through opening in “dimpling head;” 
     Close dimpling head wheels; 
     Stamp at least 3 blanks and measure dimple height; 
     Adjust air pressure to achieve desired dimple height; and 
     Run blanks as normal. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate various example systems, methods, and so on that illustrate various example embodiments of aspects of the invention. It will be appreciated that the illustrated element boundaries (e.g., boxes, groups of boxes, or other shapes) in the figures represent one example of the boundaries. One of ordinary skill in the art will appreciate that one element may be designed as multiple elements or that multiple elements may be designed as one element. An element shown as an internal component of another element may be implemented as an external component and vice versa. Furthermore, elements may not be drawn to scale. 
         FIG. 1  is a perspective view of an exemplary roll dimpler. 
         FIG. 2  is a rear, plan view of the exemplary roll dimpler of  FIG. 1 . 
         FIG. 3  is a side, plan view of the exemplary roll dimpler of  FIG. 1 . 
         FIGS. 4A-A  and  4 B-B illustrate cross-sectional views taken along the lines shown in  FIG. 4 . 
         FIG. 5  is an enlarged view of an exemplary dimpling head. 
         FIG. 6  is a cross-sectional view taken along line C-C in  FIG. 5 . 
         FIG. 7  is a further enlarged and partial view illustrating the dimpling wheels. 
         FIG. 8  is a further enlarged and partial view illustrating the male dimpling wheel insert or punch. 
         FIG. 9  is a top elevational view of an exemplary dimpler head mechanism. 
         FIG. 10  is a front elevational view of the exemplary dimpler head mechanism of  FIG. 9 . 
         FIG. 11  is a cross-sectional view of the exemplary dimpler head mechanism of  FIG. 9  taken along line A-A. 
         FIG. 12  is a cross-sectional view of the exemplary dimpler head mechanism of  FIG. 10  taken along line B-B. 
         FIG. 13  is an enlarged detail of the wheels of  FIG. 11  area Z showing the replaceable male dimple punch. 
         FIG. 14  is a perspective cross-sectional view of the dimpler head mechanism of  FIG. 9 . 
         FIG. 15  is a diagram of a metal blank forming system. 
     
    
    
     DETAILED DESCRIPTION 
     With reference to  FIGS. 1-8 , an exemplary roll dimpler  100  is shown. The exemplary roll dimpler  100  as shown includes three sets of opposed dimpler head mechanisms  104   a ,  104   b ,  104   c . Each mechanism  104 , in turn comprises a male dimpling roller wheel  108  and an opposed female dimpling roller wheel  110 . A compliant pressure source  112  supplies at least one of the male or female dimpling wheel  108 ,  110 . The compliant pressure source  112  provides continuous engagement of both male and female rollers  108 ,  110  with stock material (not shown) being pushed into the dimpler  100 , for example as fed out of a decoiler/straightener (not shown). In an embodiment, the female dimpling wheel  110  acts as a bolster or bed securing the feed stock (not shown) against the male dimpling wheel  108  while the wheels rotate and stamp the dimple into the feed stock. Examples of compliant pressure sources include air cylinders, pneumatic systems, coil or air springs and the like to apply the pressure. 
     One or more of the dimpler head mechanisms  104  may be adjustable linearly along the device, for example, using adjustment wheels and lead screws  114  or alternately the mechanisms may be positioned manually. The position of the mechanisms  104  in the frame  120  are selected to correspond to the desired location of the dimples on feed stock in use at any particular time. In the illustrated example, each adjustment wheel  114  controls positioning of one mechanism  104 . 
     With reference to  FIGS. 9-14  illustrate views of a dimpler mechanism  104  including compliant pressure source  112 , male dimpling wheel  108  and female dimpling wheel  110 . As illustrated, the compliant pressure source  112  applies pressure to female dimpling wheel  110  where female head  110  acts as a bolster or bed securing the feed stock (not shown) against the male dimpling wheel  108 . 
     With reference to  FIG. 15  a simplified system  1500  is illustrated. A roll  1504  of metal stock, for example aluminum, is fed into a decoiler/straightener  1508 . Decoiled/straightened stock  1512  is fed out of the decoiler/straightener  1508  into a roll dimpler apparatus  1516 . The feed pressure of the decoiled/straightened stock  1512  from the decoiler/straightener  1508  eliminates the need for a separate feed mechanism. As the decoiled/straightened stock  1512  enters the dimpler apparatus  1516 , the stock  1512  encounters the dimpler mechanisms  104  ( FIGS. 1-8, 10 ). Compliant pressure source  112  ( FIGS. 2, 5, 10 ) holds opposed dimpler wheels together while the decoiled/straightened stock  1512  is pushed through. Friction of the decoiled/straightened stock  1512  on the dimpler heads  108 ,  110  ( FIGS. 1-8, 10 ) induces rotation of the wheels. The combination of continuous contact and compliant pressure on the wheels induces rotation of the wheels and produces a dimpled pattern on the stock as it is fed through the dimpler apparatus  1516 . We have found that non-compliant hard-shimmed and hydraulic pressure designs to be ineffective. Further, the use of elastomer female dimpler wheels is ineffective. Dimpled stock  1520  is fed out of the dimpler apparatus  1516  into a cutter or blanking press  1524  which produces dimpled, metal blanks  1528  of a determined shape and size. The dimpled, metal blanks  1528  may be fed directly into a stamping press or stacked  1532  for storage, movement or later use. 
     While the systems, methods, and so on have been illustrated by describing examples, and while the examples have been described in considerable detail, it is not the intention of the applicants to restrict or in any way limit the scope of the appended claims to such detail. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the systems, methods, and so on provided herein. Additional advantages and modifications will readily appear to those skilled in the art. Therefore, the invention, in its broader aspects, is not limited to the specific details, the representative apparatus, and illustrative examples. shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the applicants&#39; general inventive concept. Thus, this application is intended to embrace alterations, modifications, and variations that fall within the scope of the appended claims. Furthermore, the preceding description is not meant to limit the scope of the invention. Rather, the scope of the invention is to be determined by the appended claims and their equivalents. 
     As used herein, “connection” or “connected” means both directly, that is, without other intervening elements or components, and indirectly, that is, with another component or components arranged between the items identified or described as being connected. To the extent that the term “includes” or “including” is employed in the detailed description or the claims, it is intended to be inclusive in a manner similar to the term “comprising” as that term is interpreted when employed as a transitional word in a claim. Furthermore, to the extent that the term “or” is employed in the claims (e.g., A or B) it is intended to mean “A or B or both.” When the applicants intend to indicate “only A or B but not both” then the term “only A or B but not both” will be employed. Similarly, when the applicants intend to indicate “one and only one” of A, B or C, the applicants will employ the phrase “one and only one.” Thus, use of the term “or” herein is the inclusive, and not the exclusive use. See, Bryan A. Garner, A Dictionary of Modern Legal Usage 624 (2d. Ed. 1995). To the extent that the phrase “one or more of A, B and C” is employed herein, (e.g., a data store configured to store one or more of A, Band C) it is intended to convey the set of possibilities A, B, C, AB, AC, BC, and/or ABC (e.g., the data store may store only A, only B, only C, A&amp;B, A&amp;C, B&amp;C, and/or A&amp;B&amp;C). It is not intended to require one of A, one of B, and one of C. When the applicants intend to indicate “at least one of A, at least one of B, and at least one of C,” then the phrasing “at least one of A, at least one of B, and at least one of C” will be employed.