Patent Publication Number: US-11045854-B2

Title: Automated method and machine for fabricating metal fence pickets

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates to fabricating metal fence pickets. More particularly, the invention relates to an automated process and machine for progressively and continuously rolling and folding material to fabricate metal fence pickets in one operation. 
     SUMMARY OF THE INVENTION 
     This invention relates to an automated method and roll forming machine for fabricating multiple metal fence pickets, a technology of progressively and continuously folding material by means of successive pairs of profiled rolls, the rolls in each pair being described as roll segments. The roll segments are also known as stages, stands or passes. In use, raw material is automatically fed form a de-coiler into the roll forming machine at one end between the pairs of roll segments, and is progressively folded by the successive pairs of roll segments in a series of discrete steps to emerge at the other end of the machine formed about the feed axis. The roll segments in the pairs may both form and drive the raw material through the machine. The material most commonly formed is metal, but non-ferrous metals and other materials are also considerably formed by this method. 
     In a preferred embodiment of the present invention, the method comprises the steps of inserting raw material from a de-coiler to an embossing machine to emboss wooden or other decorative textures on the raw material, transferring the embossed raw material to a first cutting station which includes a hydraulic-driven unit capable of cutting the raw material, cutting upper portion for each metal fence picket, transferring the cut raw material to a punching hole station which includes a hydraulic-driven unit capable of punching multiple holes on the raw material, punching multiple holes on the raw material, transferring the punched raw material to a roll forming station for folding edges of the raw material for each metal fence picket, engraving at least one set or one pair of vertical lines on the raw material for each metal fence picket, transferring the formed raw material to a second cutting station which includes a hydraulic-driven unit capable of cutting the raw material, cutting the length of the raw material for each metal fence picket. 
     In another preferred embodiment, the present invention provides an automated machine for fabricating metal fence pickets. The machine comprises an automated programmable de-coiler for inserting the raw material into the embossing station, automated programmable means for embossing the raw material, automated programmable table run-out and multiple slideable roll segments that are mounted on a shaft carrying the roll segments for transferring the raw material, an automated programmable first cutting station for cutting the upper portion of each metal fence picket, automated programmable means for cutting the raw material, an automated programmable punching station for punching multiple holes on the raw material for each metal fence picket, automated programmable means for punching holes on the raw material, automated programmable table run-out and multiple slideable roll segments that are mounted on a shaft carrying the roll segments for transferring the raw material and fold double edges vertically on the raw material for each metal fence picket, automated programmable means for folding double edges on the raw material, automated programmable means for engraving lines vertically on the raw material for reinforcement rips for each metal fence picket, automated programmable table run-out conveyor for conveying the raw material to the second cutting station, an automated programmable second cutting station for cutting the length of the raw material for each metal fence picket. 
     In another preferred embodiment, the present invention utilizes a table run-out conveyor to automatedly transfer the raw material. 
     In another preferred embodiment, the present invention utilizes the table run-out conveyor and double roll segments that are mounted on a shaft carrying the double roll segments fold double edges along x-axis on the raw material for each metal fence picket. 
     In another preferred embodiment, the present invention utilizes the table run-out conveyor and slideable roll segments that are mounted on a shaft carrying the slideable roll segments to automatedly transfer the raw material and engrave vertical lines on the raw material for reinforcement ribs for each metal fence picket, 
     In another preferred embodiment of the invention, the roll segments can be adjusted to fabricate different sizes of the metal fence pickets preferably 4″, 5″ and 6″ in width. 
     In another preferred embodiment of the invention, the punching and cutting stations of the top of picket include at least one limit switch sensor to guide precise hole and cutting position. 
     In another preferred embodiment of the invention, the roll segments engrave the multiple vertical lines for reinforcement ribs to add strength to the metal on the vertical plan. 
     In another preferred embodiment of the invention, an encoder is attached to the roll forming machine and operatively connected to the computer console to receive predetermined parameters of number of pickets to be produced, length, position of screw holes. 
     In another preferred embodiment of the invention, the roll forming machine is operated by a servo motor that can optimize speed and precision as well as automatically adjust speed to synchronize with the de-coiler and embossing station individual motors. 
     In another preferred embodiment of the invention, the automated machine includes a control unit programmable to set dimensional parameters and process signals from the sensors. 
     Further objects and advantages of the present invention will become apparent from a description of the several embodiments as set forth in the following description and drawings. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
       Referring now to the drawings in which like reference numbers represent corresponding parts throughout. 
         FIG. 1  is an assembled side view of the automated machine for fabricating metal fence pickets according to a preferred embodiment of the present invention. 
         FIG. 2A  is a perspective view of table run-out conveyor and slideable roll segments. 
         FIG. 2B  is a perspective view of table run-out conveyor and metal folding roll segments. 
         FIG. 3  is a diagram of the method for fabricating metal fence pickets according to a preferred embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The following description includes the best mode presently contemplated for carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of describing the general principles of the invention. The scope of the invention should be determined with reference to the claims. References are made to  FIGS. 1-3 , the method and automate machinery system for fabricating metal fence pickets according to a preferred embodiment of the present invention. 
     The machine  100  comprises a de-coiler  130  having a rotary wheel  80  for the raw material and a speed sensor  70  for sensing the speed of the de-coiler  130 , wherein the sensor  70  is connected to computer console  140  to adjust feeding raw material to embossing station  40  as shown in  FIG. 1 . 
     Referred to  FIGS. 1-2A , the table run-out conveyor  110  is mounted on a main frame  150  which has slideable roll segments  60  to transfer embossed raw material first cutting station  30 , wherein the first cutting station  30  is actuated by hydraulic power  180  and has a cutting guide sensor  160  connected to computer console  140  to position the cutting mechanism along the x-axis of the cutting area on the raw material for the upper portion of the metal fence pickets. The main frame  150  is operated by motor  50 , wherein the motor  50  is a servo motor which is automatically adjustable to synch with the embossing station and de-coiler speeds. 
     As shown best in  FIGS. 1-2B , the punching station  20  is actuated by hydraulic power  180  having a punching guide sensor  170  connected to computer console  140  to position the punching mechanism along the x-axis of the punching area on the raw material for the screw holes. Roll forming station  120  is attached to the end of the linear table run-out conveyor to continue transferring the raw material to the roll forming station  120  which includes double roll segments  90 , wherein the double roll segments  90  fold double edges and engrave lines along x-axis on the raw material for each metal fence picket. 
     The guide sensor  190  is attached to the second cutting station  10  and connected to the computer console  140  to position the cutting mechanism on the cutting area on the raw material which runs the length of the each metal fence picket. 
     The computer console  140  is used to display and set operational parameters for operating the cutting and punching mechanisms, wherein the computer console  140  is any type of industrial computer with processor and hard drive to include a programmable logic controller or personal computer. The computer console  140  processes software that controls the feeding, cutting, and punching processes and interfaces to a typical laptop or other portable computer to receive programming instructions. The laptop or other portable computer also includes a wireless card to receive programming software via a wireless network. 
     Referring to  FIG. 3 , and with reference to the machine  100  in  FIG. 1 , the present method  200  begins with step  210 , wherein a first machine operation is begin to perform. At step  210 , at step  210 , raw material is fed into the machine by the de-coiler  130  for processing. Once the embossing station  40  receives the raw material, the method  200  proceeds step  220  to emboss the raw material. 
     At step  230  reference to  FIG. 2A , the embossed raw material is transferred to the first cutting station  30  by the table run-out conveyor  110  and slideable roll segments  60 , wherein the embossed raw material is cut for the upper portion of the metal fence pickets. 
     At step  240 , the punching station  20  is operable to punch screw holes positioned by the punching guide sensor  170  on the raw material. 
     At steps  250  and  260  reference in  FIG. 2B , the raw material is transferred to the folding station  120  for double edges fold and enforcement ribs. 
     At step  270  reference to the machine  100  in  FIG. 1 , the raw material is transferred to the second cutting station  10  for cutting length for each metal fence picket. 
     The embodiments were chosen and described to best explain the principles of the invention and its practical application to persons who are skilled in the art. As various modifications could be made to the exemplary embodiments, as described above with reference to the corresponding illustrations, without departing from the scope of the invention, it is intended that all matter contained in the foregoing description and shown in the accompanying drawings shall be interpreted as illustrative rather than limiting. Thus, the breadth and scope of the present invention should not be limited by any of the above described exemplary embodiments, but should be defined only in accordance with the following claims appended hereto and their equivalents. 
     Having illustrated and described the principles of the present invention in a preferred embodiment, it will be apparent to those skilled in the art that the embodiment can be modified in arrangement and detail without departing from such principles. Any and all such embodiments are intended to be included within the scope of the following claims.