Patent Publication Number: US-9427883-B2

Title: Device and method for manufacturing profile combination

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation-in-part of International Patent Application No. PCT/CN2011/002041 with an international filing date of Dec. 7, 2011, designating the United States, now pending, and further claims priority benefits to Chinese Patent Application No. 201110044389.6 filed Feb. 22, 2011. The contents of all of the aforementioned applications, including any intervening amendments thereto, are incorporated herein by reference. Inquiries from the public to applicants or assignees concerning this document or the related applications should be directed to: Matthias Scholl P.C., Attn.: Dr. Matthias Scholl Esq., 14781 Memorial Drive, Suite 1319, Houston, Tex. 77079. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The invention relates to a device and a method for manufacturing a load-bearing member, and more particularly to a nesting device and a nesting method for manufacturing a nested profile combination. 
     2. Description of the Related Art 
     A typical nested profile combination composed of a first profile member and a second profile member is designed to decrease the consumption of the raw material in the production process and lower the production cost. The nested profile combination is formed by rotating the first profile member for 180° and nesting the first profile member and the second profile member together. The first profile member and the second profile member are strip members having cross sections of the same shapes and sizes. 
     However, the nesting of the first profile member and the second profile member are manually performed. The manual nesting has low production efficiency and low processing speed, and the geometric precision and form and position tolerance are difficult to control. Thus, the automatic production line cannot be realized, thereby resulting in low yield and low utilization of materials. 
     SUMMARY OF THE INVENTION 
     In view of the above-described problems, it is one objective of the invention to provide a nesting device for manufacturing a profile combination that is able to ensure continuous operation of a production line and the coherence of different procedures, and significantly improve the production efficiency. 
     It is another objective of the invention to provide a method for manufacturing a profile combination using the nesting device. 
     To achieve the above objective, in accordance with one embodiment of the invention, there is provided a nesting device for manufacturing a profile combination, the nesting device comprising: a nesting bed; a nesting base; and a rotating positioning device, the rotating positioning device comprising a saddle, a first gas cylinder, two steady rests, and two rotators. The nesting bed is fixed on the ground. The nesting base is disposed and is horizontally movable on the nesting bed. The saddle is disposed and is horizontally movable on the nesting base; the saddle is connected to the first gas cylinder, and the first gas cylinder drives the rotating positioning device to move on the nesting base. The two steady rests are oppositely fixed on the saddle at a certain interval. The rotator is arranged inside each steady rest and is rotatable in relation to the steady rest. Each rotator comprises: a square hole, and a plurality of clamps; the square hole passes through the rotator in a direction of a length of the rotator and matches with a profile. The clamps are arranged on an end face of the rotator surrounding the square hole. Each clamp comprises: a guide rail, and a chuck. The guide rail is fixed on the end face of the rotator, and the chuck is movable on the guide rail and leans against a first profile member. Thus, the clamps tightly lean against the profile for ensuring the nesting between the first profile member and the second profile member. 
     In a class of this embodiment, to ensure the first profile member to rotate within 180° and to prevent inaccurate rotation that affects the nesting and compositing process, a plurality of tooth spaces are arranged on a circumferential face of the rotator at a certain interval between each other. Two first positioning pins are inserted into two opposite tooth spaces at an angle of circumference of 180° for limiting a rotating direction of the rotator. When the rotator rotates for 180°, the first positioning pins are inserted into the corresponding tooth spaces to limit the position of the rotator on the steady rest, and to prevent the rotator from deviating from the steady rest, so that the accuracy and reliability of the nesting and compositing process is ensured. 
     In accordance with another embodiment of the invention, there is provided a method for manufacturing a profile combination by using the nesting device. The method comprises the following steps:
         a) transporting the profile after cross section shaping to the rotating positioning device; allowing the cutting device and the profile to move synchronously when the profile touches a first detecting contact, and cutting the profile by the cutting device to yield the first profile member;   b) allowing the rotating positioning device to move on a nesting base of the nesting device, leaving a required interval between the rotating positioning device and the profile being transported;   c) rotating the first profile member for 180° by the rotating positioning device when the first profile member moves along with the rotating positioning device and touches the second detecting contact, positioning the first profile member; and resetting the cutting device and the rotating positioning device;   d) during the resetting of the rotating positioning device, transporting the profile to the rotating positioning device, and nesting and compositing the first profile member and the profile;   e) allowing the cutting device and the profile to move synchronously when the profile touches the first detecting contact again, and cutting the profile by the cutting device to yield the second profile member; continuing transporting the profile whereby pushing the second profile member and continuing nesting and compositing the second profile member and the first profile member; and   f) completely nesting and compositing the first profile member and the second profile member to form the profile combination; continuing transporting the profile whereby pushing the profile combination for a subsequent process; repeating step a) for another nesting and compositing process when the profile touches the first detecting contact.       

     In a class of this embodiment, to achieve the linkage between the cutting device and the nesting device and to ensure the coherence between the cutting process and the nesting and compositing process, the cutting device comprises: a cutting base, and a cutter. The cutting base is disposed and is horizontally movable on the nesting bed. The cutting base is in rigid connection with the nesting base. The cutting base is connected to a second gas cylinder for driving the cutting base to move on the nesting bed. The cutter is disposed on the cutting base. The nesting base is provided with a cutting stopper and a positioning stopper in a direction of a length of the nesting base. The cutting stopper is used to control the cutting. The positioning stopper is used to control the rotation of the rotating positioning device. A resetting stopper is arranged on one side of the nesting bed close to the cutting base for limiting a movement of the cutting base. Because the cutting base and the nesting base are in rigid connection, once the cutting device is reset, the nesting base is synchronously reset. Besides, the second profile member and the first profile member are ensured to have the same positioning reference and the same cutting length. 
     In a class of this embodiment, to prevent the stopper from interfering with the metal strip thereby successively transporting the metal strip and the profile on the production line, the cutting stopper and the positioning stopper are upwardly and downwardly stretchable stoppers. The cutting stopper and the positioning stopper are used to detect positions of the metal strip or the cut profile member on the production line, as well as control the motion of the cutter and the rotator. The stretch of the cutting stopper and the positioning stopper is controlled by corresponding gas cylinders. To detect the positions of the metal strip or the cut profile member, piston rods of the gas cylinders push the stoppers upwards; after the detection of the positions, the piston rods of the gas cylinders retracts to allow the stoppers move downwardly. 
     Advantages of the invention are summarized as follows: 
     The nesting device is capable of automatically nesting the first profile member and the second profile member, thereby realizing the automatic manufacture of the profile combination. Compared with the manually nesting, the device of the invention highly improves the work efficiency. Furthermore, the mechanical structure of the nesting device improves the quality of the nesting and compositing process, and prevents the profile combination from deformation. Finally, the nesting device is provided with the clamps that are able to lean against the profile combination, thereby ensuring the reliable nesting of the first profile member and the second profile member, and improving the intensity and the quality of the nesting. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention is described hereinbelow with reference to the accompanying drawings, in which: 
         FIG. 1  is a structure diagram of a nesting device (connected to a cutting device) in accordance with one embodiment of the invention; 
         FIG. 2  is a structure diagram of a nesting device in an axial direction of a production line of  FIG. 1  in accordance with one embodiment of the invention; 
         FIG. 3  is a structure diagram of part A-A of a nesting device of  FIG. 1  in accordance with one embodiment of the invention; 
         FIG. 4  is a structure diagram of a transmission structure of a nesting device of  FIG. 3  in accordance with one embodiment of the invention; 
         FIG. 5  is a structure diagram of a production line for manufacturing a nested profile combination in accordance with one embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
     For further illustrating the invention, experiments detailing a device and a method for manufacturing a profile combination are described below. It should be noted that the following examples are intended to describe and not to limit the invention. 
     As shown in  FIGS. 1-4 , a nesting device  6  comprises: a nesting bed  61 ; a nesting base  62 ; and a rotating positioning device, the rotating positioning device comprising a saddle  63 , a first gas cylinder T 1 , two steady rests  64 , and two rotators  65 . The nesting bed  61  is fixed on the ground  9 . The nesting base  62  is disposed and is horizontally movable on the nesting bed  61 . The saddle  63  is disposed and is horizontally movable on the nesting base  62 . The saddle  63  is connected to the first gas cylinder T 1 , and the first gas cylinder T 1  drives the rotating positioning device to move on the nesting base  62 . The two steady rests  64  are oppositely fixed on the saddle  63  at a certain interval. The rotator  65  is arranged inside each steady rest  64  and is rotatable in relation to the steady rest  64 . 
     A plurality of tooth spaces  651  are arranged on a circumferential face of the rotator  65  at a certain interval between each other. Two first positioning pins  68  are inserted into two opposite tooth spaces  651  at an angle of circumference of 180° for limiting a rotating direction of the rotator  65 . When the rotator  65  rotates for 180°, the first positioning pins  68  are inserted into the corresponding tooth spaces to limit the position of the rotator on the steady rest, and to prevent the rotator from deviating from the steady rest, so that the accuracy and reliability of the nesting and compositing process is ensured. Each rotator  65  comprises a square hole  652  and a plurality of clamps. The square hole  652  passes through the rotator  65  in a direction of a length of the rotator  65  and matches with a profile B. Each clamp comprises: a guide rail  66 , and a chuck  67 . The guide rail  66  is fixed on the end face of the rotator  65 , and the chuck  67  is movable on the guide rail  66  and leans against a first profile member. The clamps are arranged on an end face of the rotator surrounding the square hole  652 . The rotator  65  is capable of clamping profiles of different sizes and shapes by adjusting the position of the chuck in relation to the guide rail  66 . 
     A cutting device  5  comprises: a cutting base  51 , and a cutter  52 . The cutting base  51  is disposed and is horizontally movable on the nesting bed  61 . The cutting base  51  is in rigid connection with the nesting base  62 . The cutting base  51  is connected to a second gas cylinder T 2  for driving the cutting base  51  to move on the nesting bed  61 . The cutter  52  is disposed on the cutting base  51 . The nesting base  62  is provided with a cutting stopper  621  and a positioning stopper  622  in a direction of a length of the nesting base  62 . The cutting stopper  621  is used as a first detecting contact to detect a position of the profile B and control the motion of the cutter  52 . The positioning stopper  622  is used as a second detecting contact to detect a position of the first profile member and to control the rotation of the rotating positioning device. A resetting stopper  611  is arranged on one side of the nesting bed  61  close to the cutting base  51  for limiting a movement of the cutting base  51 . Because the cutting base and the nesting base are in rigid connection, once the cutting device is reset, the nesting base is ensured to synchronously reset. Besides, the second profile member and the first profile member are ensured to have the same position reference and the same cutting length. 
     The cutting stopper  621  and the positioning stopper  622  are upwardly and downwardly stretchable stoppers. The cutting stopper  621  is connected to a piston rod of a third gas cylinder T 3 , and the positioning stopper  622  is connected to a piston rod of a fourth cylinder T 4 . The cutting stopper  621  and the positioning stopper  622  are used to detect positions of the metal strip or the cut profile member on the production line, as well as control the motion of the cutter and the rotator. To detect the positions of the metal strip or the cut profile member, piston rods of the gas cylinders push the stoppers upwards; after the detection of the positions, the piston rods of the gas cylinders retracts to allow the stoppers move downwardly. 
     The profile B is cut by the cutter  5  to yield a first profile member and a second profile member. The first profile member and the second profile member are nested by the nesting device to form the profile combination. The nesting and compositing process comprises the following steps:
         a) transporting the profile B after cross section shaping to the rotating positioning device in a direction of the production line; allowing the cutting device  5  and the profile B to move synchronously when the profile B touches the first detecting contact, and cutting the profile B by the cutting device  5  to yield the first profile member;   b) allowing the rotating positioning device to move on the nesting base  62  of the nesting device  6 , leaving a required interval between the rotating positioning device and the profile B being transported;   c) rotating the first profile member for 180° by the rotating positioning device when the first profile member moves along with the rotating positioning device and touches the second detecting contact; and resetting the cutting device  5  and the rotating positioning device;   d) during the resetting of the rotating positioning device, transporting the profile B to the rotating positioning device, and nesting and compositing the first profile member and the profile B;   e) allowing the cutting device  5  and the profile B to move synchronously when the profile B touches the first detecting contact again, and cutting the profile B by the cutting device  5  to yield the second profile member; continuing transporting the profile B whereby pushing the second profile member to allow the second profile member and the first profile member to be continued nesting and compositing; and   f) completely nesting and compositing the first profile member and the second profile member to form the profile combination C; continuing transporting the profile B whereby pushing the profile combination C for a subsequent process; repeating step a) for another nesting and compositing process when the profile B touches the first detecting contact.       

     As shown in  FIGS. 5 , a system for manufacturing a nested profile combination is an automatic production line comprising a plurality of procedures. The metal strip A transported into a feeder is employed as a raw material. The metal strip A is automatically transported to subsequent procedures along the production line. The system comprises the following devices in an order of arrangement thereof on the production line: 
     A profile planisher  1 , the profile planisher  1  is used to planish the metal strip A transported to the production line. 
     A first rolling die set  2 , the first rolling die set  2  is fixed on the ground  9  and comprises a plurality of first rolling sets for forming a required stiffener. 
     A punching device  3 , the punching device  3  comprises: a punching bed  31  fixed on the ground  9 ; a punching machine being horizontally movable on the punching bed  31 ; a fifth gas cylinder T 5  fixed on the punching bed  31  and driving the punching machine to move on the punching bed  31 ; and a pressing device  8 . The pressing device  8  comprises: a pressing plate  81 , an oil cylinder  83 , and a pressing base  84 . The oil cylinder  83  drives the pressing plate  81  to move upwardly and downwardly. The pressing base  84  drives the pressing plate  81  to move horizontally on the punching bed  31  and is in rigid connection with the punching machine. A piston rod of the fifth gas cylinder T 5  is in rigid connection with the pressing base  84 . A second positioning pin  82  is arranged on a bottom of the pressing plate  81 . The second positioning pin  82  is capable of passing through shaped through holes of the metal strip A during the punching process. During the punching process, the punching machine moves along with the metal strip. When the punching process is completed, the second positioning pin  82  is inserted into the through hole for positioning, and the punching machine is reset by the fifth gas cylinder T 5  after the punching process. 
     A second rolling die set  4 , the second rolling die set  4  is fixed on the ground  9  and comprises a plurality of second rolling sets to form a required cross section of the profile B. The required cross section of the profile B comprises: a transverse side, a lateral side, an embedded flanging, an encircling flanging, and a bent part. 
     The cutting device  5  that is used to cut the profile to yield the first profile member and the second profile member. 
     The nesting device  6  that is used to rotate the first profile member for 180°, position the first profile member, and nest the first profile member and the second profile member to form the profile combination C. 
     A third rolling die set  7 . The third rolling die set  7  comprises a third rolling set. The third rolling set is used to shape the encircling flangings into fixing flangings. 
     A method for manufacturing the nested profile combination, the method comprises the following steps:
         1) planishing process: transporting the metal strip A to the profile planisher  1  for planishing, and transporting the metal strip A automatically to a subsequent process of the production line;   2) stiffener forming process: transporting the metal strip A to the first rolling die set  2 , rolling the metal strip A to form the stiffener;   3) punching process: transporting the metal strip A comprising the stiffener to the punching device  3  to form through holes on the metal strip A;   4) cross section shaping process: transporting the metal strip A after being punched to the second rolling die set  4 , rolling the metal strip A to yield the profile B having a cross section in a required shape, the profile B comprising the transverse side, the lateral side, the embedded flanging, the encircling flanging, and the bent part;   5) nesting and compositing process: cutting the profile B to yield the first profile member and the second profile member, nesting the first profile member and the second profile member to form the profile combination C;   6) fastening process: transporting the profile combination C to the third rolling die set  7 , shaping the encircling flangings of the first profile member and the second profile member into fixing flangings for fastening corresponding lateral sides, respectively, whereby yielding the nested profile combination D; and discharging the nested profile combination D from the production line.       

     While particular embodiments of the invention have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from the invention in its broader aspects, and therefore, the aim in the appended claims is to cover all such changes and modifications as fall within the true spirit and scope of the invention.