Patent Publication Number: US-2015068265-A1

Title: Rebar Cutting, Bending, and Shaping

Description:
RELATED APPLICATIONS 
     The present application claims priority to U.S. Provisional Patent Application Ser. No. 61/875,949, which was filed on Sep. 10, 2013, the entire disclosure of which is incorporated herein by reference. 
    
    
     TECHNICAL FIELD 
     The present invention relates, generally, to devices and processes for cutting, bending, and shaping rebar; and, more particularly, to field-operable devices and processes for cutting, bending, and shaping rebar wherein an hydraulic pressure source is used in association with a table-like structure to drive rebar cutting, bending, and shaping functions. 
     BACKGROUND 
     As is well-known in the construction industries, rebar (short for reinforcing bar), is a steel bar commonly used as a tensioning means for reinforced concrete and like structures, such as masonry. When rebar is to be used in association with such concrete structures, its function is to hold the concrete in compression—wherein the concrete is strongest. The rebar, then, functions to carry and spread the tensile loads, provide resistance to concentrated and/or bending loads, and add stiffness to the structure. 
     Rebar is sized (in the U.S.) from #2 bar size, corresponding to an approximate nominal diameter of ¼ inch, to #18 bar size, corresponding to an approximate nominal diameter of 2¼ inches; although greater diameter, “jumbo” bars are commonly available for large structures. Rebar is available in a number of different grade designations, and a variety of industry specifications have been established for control of rebar chemical composition, mechanical properties (such as, for example, yield strength, percentage of elongation, tensile strength, ductility, heat treatment, and the like), and surface coatings (such as, for example, zinc/galvanized coatings, epoxy coatings, and the like). 
     In use and application, a rebar structure is typically fabricated on-site and in advance of the concrete pour. A structural engineer or architect will have specified, in advance, the component sizes, lengths, and shapes, as well as the assembly, welding, and/or tying configuration, for each rebar structure. Depending upon the size and nature of the job, these components can be fabricated in-advance and transported to the job site for subsequent assembly, or they can be fabricated on-site using site-stocked materials. 
     For large jobs, rebar elements are cut (most often by shearing) and shaped, in advance, at a rebar fabrication facility using high-capacity hydraulic equipment. For smaller jobs, though, rebar elements are most often cut, bent, and shaped on-site. As will be described below, because power sources, such as electrical lines, are often unavailable on the job site during this phase of construction, on-site rebar cutting, bending, and shaping operations are typically performed by-hand. One form of manual rebar bender, known as a Hickey, is often used. The Hickey operates through manually applied leverage, and bending operations can be inaccurate, time consuming, and physically demanding. 
     Of course, it should be readily apparent that the force required to complete each cutting, bending, and shaping operation is dependent upon, for example, the size of the rebar, its grade, and its associated chemical and mechanical properties, such as were described above. Accordingly, only smaller sizes of rebar—typically no larger than #6 (¾ inch nominal diameter)—can be manually processed on-site. 
     Because electrical power often is not yet available on-site during grading and foundation pouring phases of construction, electrically powered rebar cutting, bending, and shaping tools may not be convenient or usable. Any powered tool would, accordingly, require a different and conveniently available power source for its operation and use. Additionally, in order to most efficiently and safely process rebar component parts, workers should have access to a processing station that can be conveniently placed near on-site rebar material staging areas, and subsequently relocated as-required. Such a processing station should be capable of accurately and safely cutting, bending, and shaping rebar component parts; it should be effective, convenient, and simple to operate; it should be adjustable to accommodate its operator; and it should be capable of processing a variety of sizes and grades of rebar. 
     Accordingly, it is to the disclosure of such devices and related processes that this disclosure is directed. 
     SUMMARY 
     In general, the present disclosure is directed to embodiments of a rebar processing station meeting the aforedescribed requirements, and taking the form of an hydraulically powered rebar cutting, bending, and shaping table. Specifically, and pursuant to a preferred embodiment of the hydraulically powered rebar cutting, bending, and shaping table of the present disclosure, a table, preferably formed from durable, structural steel component parts, is configured with a rebar cutting assembly and with a rebar grasping, bending, and shaping assembly. 
     In some embodiments, the rebar cutting assembly comprises a pair of hardened shearing plates or dies, one of which is preferably stationary and one of which articulates about a pivot center. Each shearing plate or die comprises one or more peripheral, U-shaped slot or channel, configured to align with a respective, corresponding U-shaped slot or channel in the other adjacent shearing plate or die. Each U-shaped slot or channel is appropriately sized to receive a rebar therewithin, and when operating thereupon, cuts the rebar by shearing force at the interface between the adjacent shearing plates. In some embodiments, left and right-hand U-shaped slots or channels may be provided within each shearing plate or die for the convenience of the operator. 
     In some embodiments, a rebar grasping, bending, and shaping assembly comprises rebar grasping means, a shaping plate or die, and a movable former, such as a roller. The rebar grasping means may comprise a clamp formed by cooperative interaction between a first, fixed-position, tapered clamp portion and a second, slidable, cooperatively-tapered clamp portion. In operation, one side of a rebar is placed adjacent a fixed-position shaping die, and the slideable, tapered clamp portion is engaged against the opposite side of the rebar; thereby, clamping or grasping the rebar between the fixed-position shaping plate or die and the clamp in a stable and stationary position. Provided that the distal portion of the rebar is of sufficient length to be engaged by the movable former, which in some embodiments takes the form of a hardened steel roller operating within an arcuate field of travel, the rebar may be bent and shaped by operation of the movable former against the rebar, bending the rebar about the adjacent, fixed-position shaping plate or die. Provided, of course, that the applied bending forces are sufficient to exceed the yield strength of the rebar, the bending operation is permanent; and the rebar, accordingly, is shaped to the desired configuration. 
     Because these rebar cutting, bending, and shaping processes often occur contemporaneously with site preparation activities, such as site excavation, grading, and compaction; and, because construction materials must be staged and moved about the construction site, hydraulically-equipped loaders, excavators, tractors, ancillary hydraulic motors and/or power packs, and similar machines, are typically available on-site. Accordingly, hydraulic power out-takes and/or outputs typically associated with such hydraulically-equipped machines are often available for use in association with the hydraulically powered rebar cutting, bending, and shaping table of the present disclosure. 
     Similarly, because the hydraulically powered rebar cutting, bending, and shaping table of the present disclosure can be placed nearly anywhere on-site, the aforedescribed hydraulically-equipped loaders, excavators, tractors, and similar machines can be enlisted to transport and relocate the table about the site, as required. Accordingly, the table may be provided with appropriate features allowing cooperative engagement of the table with appropriate attachments and/or implements associated with such machines. 
     The hydraulically powered rebar cutting, bending, and shaping table of the present disclosure can be treated against weathering and rusting. Table legs can be made extensible, as with cooperating pin and hole arrangements. Shields and/or covers may be provided for worker safety during table operation, and to protect moving components of the table against impact and damage when not in operation. 
     In use and operation, a rebar is placed within the U-shaped slot or channel of the cutting assembly, the preferred cut-point is aligned along the shear interface between the adjacent shearing plates, and the cutting assembly is actuated so as to cut the rebar to its preferred length. One side of the rebar is then placed adjacent the fixed-position shaping die, and the slideable, tapered clamp portion is engaged against the opposite side of the rebar; thereby, clamping or grasping the rebar between the fixed-position shaping plate or die and the clamp in a stable and stationary position. The movable former is actuated; whereby, provided that the distal portion of the rebar is of sufficient length to be engaged by the movable former, the rebar is be bent and shaped by operation of the movable former against the rebar, bending the rebar about the adjacent, fixed-position shaping plate or die. Provided, of course, that the applied bending forces are sufficient to exceed the yield strength of the rebar, the bending operation is permanent; and the rebar, accordingly, is shaped to the desired configuration. The aforedescribed process, or subprocesses thereof, may be repeated as-required to bring each rebar into conformance with its corresponding specification. 
     These and other features and advantages of the various embodiments of devices and related systems comprising , as set forth within the present disclosure, will become more apparent to those of ordinary skill in the art after reading the following Detailed Description of Illustrative Embodiments and the Claims in light of the accompanying drawing Figures. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Accordingly, the within disclosure will be best understood through consideration of, and with reference to, the following drawing Figures, viewed in conjunction with the Detailed Description of Illustrative Embodiments referring thereto, in which like reference numbers throughout the various Figures designate like structure, and in which: 
         FIG. 1  illustrates a rear perspective view of an embodiment of a hydraulically powered rebar cutting, bending, and shaping table according to the present disclosure; 
         FIG. 2  illustrates a top plan view of the hydraulically powered rebar cutting, bending, and shaping table illustrated in  FIG. 1 ; 
         FIG. 3  illustrates a front elevation view of the hydraulically powered rebar cutting, bending, and shaping table illustrated in  FIG. 1 ; 
         FIG. 4  illustrates a right side elevation view of the hydraulically powered rebar cutting, bending, and shaping table illustrated in  FIG. 1 ; 
         FIG. 5  illustrates a rear elevation view of the hydraulically powered rebar cutting, bending, and shaping table illustrated in  FIG. 1 ; 
         FIG. 6  illustrates a top plan view of a portion of the hydraulically powered rebar cutting, bending, and shaping table illustrated in  FIG. 1  in association with a pre-placed rebar, and in a configuration prior to actuation of rebar bending and shaping operations; and, further, depicting means for grasping, bending, and shaping a rebar, said rebar grasping means in an open configuration; 
         FIG. 7  illustrates a top plan view of a portion of the hydraulically powered rebar cutting, bending, and shaping table illustrated in  FIGS. 1 and 6  in association with a pre-placed rebar, and in a configuration following actuation of rebar bending and shaping operations; and, further, depicting means for grasping, bending, and shaping a rebar, said rebar grasping means in a closed configuration; 
         FIG. 8  illustrates a perspective side view of a portion of the hydraulically powered rebar cutting, bending, and shaping table illustrated in  FIG. 1 , depicting an embodiment of a rebar cutting assembly thereof in an aligned configuration prior to activation; 
         FIG. 9  illustrates a perspective side view of a portion of the hydraulically powered rebar cutting, bending, and shaping table illustrated in  FIGS. 1 and 8 , depicting an embodiment of a rebar cutting assembly thereof in a configuration following activation; and 
         FIG. 10  illustrates a bottom perspective view of a portion of the hydraulically powered rebar cutting, bending, and shaping table illustrated in  FIG. 1 . 
     
    
    
     It is to be noted that the drawings presented are intended solely for the purpose of illustration and that they are, therefore, neither desired nor intended to limit the invention to any or all of the exact details of construction shown, except insofar as they may be deemed essential to the claimed invention. 
     DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS 
     In describing the several embodiments illustrated in the Figures, specific terminology is employed for the sake of clarity. The invention, however, is not intended to be limited to the specific terminology so selected, and it is to be understood that each specific element includes all technical equivalents that operate in a similar manner to accomplish a similar purpose. Additionally, in the Figures, like reference numerals shall be used to designate corresponding parts throughout the several Figures. 
     Illustrated in  FIGS. 1-10  is an embodiment of a rebar processing station according to the present disclosure, and taking the form of an hydraulically powered rebar cutting, bending, and shaping table  100 . Table  100  is preferably formed from durable, structural steel component parts, each of which may be treated, as appropriate, against weathering, rusting, and/or the like. 
     As may be seen with reference to  FIG. 1 , table  100  is configured with rebar cutting assembly  200 , and with rebar grasping, bending, and shaping assembly  300 . Preferably, at the rear of table  100  is transport assembly  400 , allowing for cooperative engagement with appropriate attachments and/or implements associated with on-site construction equipment, as described elsewhere herein. Hydraulic power system  500  is provided for actuation of rebar cutting assembly  200  and rebar grasping, bending, and shaping assembly  300 . 
     In some embodiments, rebar cutting assembly  200  comprises a pair of hardened shearing plates or dies  202 ,  204 . In the embodiment shown, shearing plate  202  is preferably stationary and firmly affixed to table  100 , while shearing plate  204  preferably articulates about pivot center  206 . Pivot center  206  may take the form of a hardened steel pin or bolt and cooperating hole. 
     Each shearing plate or die  202 ,  204  comprises one or more peripheral, U-shaped slot or channel  208 , configured to align with a respective, corresponding U-shaped slot or channel  208  in the other adjacent shearing plate or die. Each U-shaped slot or channel  208  is appropriately sized to receive rebar R therewithin, and when operating thereupon, cuts rebar R by shearing force at the interface I between the adjacent shearing plates. In some embodiments, left and right-hand U-shaped slots or channels  208  may be provided within each shearing plate or die  202 ,  204  for the convenience of the operator. 
     In some embodiments, rebar grasping, bending, and shaping assembly  300  comprises rebar grasping means  302 , fixed-position shaping plate or die  304 , and a movable former  306 , such as a bearing-mounted roller. Rebar grasping means  302  may comprise a clamp formed by cooperative interaction between a first, fixed-position, tapered clamp portion  308  and a second, slidable, cooperatively-tapered clamp portion  310 . 
     Best seen with reference to  FIGS. 2 ,  6 , and  7 , second, slidable, cooperatively-tapered clamp portion  310  may be engaged with table  100  via slot  316  and screw and washer assembly  318 . Fixed-position shaping plate or die  304  may be affixed to table  100  via steel weldment  320 . 
     With continuing reference to  FIGS. 6 and 7 , in operation, one side of rebar R is placed adjacent fixed-position shaping die  304 , and slideable, tapered clamp portion  310  is engaged via handle  312  against the opposite side of rebar R; thereby, clamping or grasping rebar R between fixed-position shaping plate or die  304  and grasping means  302  clamp in a stable and stationary position. 
     Provided that the distal portion of the rebar is of sufficient length to be engaged by movable former  306 , which in some embodiments takes the form of a hardened steel, bearing-mounted roller operating within an arcuate field of travel defined by slot  314 , rebar R may be bent and shaped by operation of movable former  306  against rebar R, bending rebar R about adjacent, fixed-position shaping plate or die  304 . Provided, of course, that the applied bending forces are sufficient to exceed the yield strength of rebar R, the bending operation is permanent; and rebar R, accordingly, is shaped to the desired configuration. 
     Because these rebar cutting, bending, and shaping processes often occur contemporaneously with site preparation activities, such as site excavation, grading, and compaction; and, because construction materials must be staged and moved about the construction site, hydraulically-equipped loaders, excavators, tractors, ancillary hydraulic motors and/or power packs, and similar machines, are typically available on-site, and can be enlisted to transport and relocate table  100  about the site, as required. Accordingly, table  100  may be provided with appropriate features, such as transport assembly  400 , allowing cooperative engagement of table  100  with appropriate attachments and/or implements associated with such machines. 
     Returning to  FIGS. 1 and 5 , transport assembly  400  may provide opening  402 , which may cooperatively interface with a protruding portion of a stepped plate or other attachment (not shown) associated with a piece of lifting and transport equipment. Lateral support rails  404 , upper support rail  406 , and facing plate or plates  408  may be provided to cooperatively interface with an outer portion of the stepped plate or other attachment (not shown) associated with the piece of lifting and transport equipment. Each facing plate  408  may be configured at a lower distal portion with angled portion  410 . Angled portion(s)  410  may assist in guiding the stepped plate or other attachment (not shown) associated with the piece of lifting and transport equipment into proper alignment and position with transport assembly  400 ; thereby, ensuring stability and effective securement of table  100  to the lifting and transport equipment. 
     Once the hydraulically powered rebar cutting, bending, and shaping table  100  of the present disclosure has been placed in a desired on-site location, the aforedescribed hydraulically-equipped loaders, excavators, tractors, ancillary hydraulic motors and/or power packs, and similar machines can be conveniently utilized to power table  100  through use of such hydraulic power out-takes and/or outputs typically available on such hydraulically-equipped machines. With continuing reference to  FIG. 1 , hydraulic lines  502 ,  504  may be provided for interconnecting with such available hydraulic power out-takes and/or outputs in typical hydraulic feed-and-return loop configuration. Hydraulic lines  502 ,  504  may be supported by and affixed to table  100  via clamp  506  and post  508 . Clamp  506  and post  508  may be provided with spring  510 , which may bear against washer  512  at an end thereof, to provide cushion for hydraulic lines  502 ,  504  against impact and flexing forces. 
     Best seen with reference to  FIGS. 3 ,  4 , and  10 , hydraulic lines  502 ,  504  are operably connected to hydraulic actuation cylinders  514 ,  516 . In the embodiment shown, hydraulic actuation cylinders  514 ,  516  are arranged in series, with a common, single actuation control system. In such embodiment, rebar cutting assembly  200  and rebar grasping, bending, and shaping assembly  300  are configured to operate essentially simultaneously. It will be apparent, however, that hydraulic actuation cylinders  514 ,  516  may be part of separate hydraulic loops, each loop having an independent actuation control system. In such alternate embodiments, rebar cutting assembly  200  and rebar grasping, bending, and shaping assembly  300  may be configured to operate independently. 
     As may be seen in  FIGS. 8-10 , hydraulic actuation cylinder  514  is affixed at one end to stationary mount  518 . In order to facilitate operation of rebar cutting assembly  200 , ram  520  of hydraulic actuation cylinder  514  is affixed at the other end to a lower distal end of articulating shearing plate  204  via clevis  522  and pin or bolt  524 . As force is applied via hydraulic actuation cylinder  514 , articulating shearing plate  204  pivots about pivot center  206 , and thereby provides shearing force to cut rebar R. 
     Similarly, and with continuing reference to  FIG. 10 , hydraulic actuation cylinder  516  is affixed at one end to stationary mount  526 . In order to facilitate operation of rebar grasping, bending, and shaping assembly  300 , ram  528  of hydraulic actuation cylinder  516  is affixed at the other end to a distal end of articulating cam plate  530  via clevis  532  and pin or bolt  534 . As articulating cam plate  530  is rotated by operation of hydraulic actuation cylinder  516  about pin or bolt  536  in stationary support  538 , movable former  306  travels within an arcuate field of travel defined by slot  314 , as best shown in  FIGS. 6-7 . Accordingly, in use and operation, rebar R may be bent and shaped by operation of movable former  306  against rebar R, bending rebar R about adjacent, fixed-position shaping plate or die  304 . 
     In use and operation, and with continuing reference to  FIGS. 8-9 , rebar R is placed within U-shaped slots or channels  208  of cutting assembly  200 , the preferred cut-point is aligned along shear interface I between adjacent shearing plates  202 ,  204 , and cutting assembly  200  is actuated so as to cut rebar R to its preferred length. Best seen with continuing reference to  FIGS. 6-7 , one side of rebar R is then placed adjacent fixed-position shaping die  304 , and slideable, tapered clamp portion  310  is engaged against the opposite side of rebar R; thereby, clamping or grasping rebar R between fixed-position shaping plate or die  304  and clamp  302 ,  308 ,  310  in a stable and stationary position. Movable former  306  is actuated; whereby, provided that the distal portion of rebar R is of sufficient length to be engaged by movable former  306 , rebar R is bent and shaped by operation of movable former  306  against rebar R, bending rebar R about adjacent, fixed-position shaping plate or die  304 . Provided, of course, that the applied bending forces are sufficient to exceed the yield strength of rebar R, the bending operation is permanent; and rebar R, accordingly, is shaped to the desired configuration. The aforedescribed process, or subprocesses thereof, may be repeated as-required to bring each rebar R into conformance with its corresponding specification. Through use of the aforedescribed process(es), compound bends may be achieved by reorienting rebar R at the desired location of, and in accordance with, the required bend, and repeating the bending operation. 
     In some embodiments, table legs  102  can be made extensible, as with cooperating pin and hole arrangements associated with multi-part legs. In some embodiments, table legs  102  may be provided with plate cleats  104  to provide stability and leveling capabilities. 
     In some embodiments, shields and/or covers  106  may be provided for worker safety during table operation, and to protect moving components of table  100  against impact and damage when table  100  is not in operation. In some embodiments, shields and/or covers  106  may be affixed to table  100  via tether  108 . In some embodiments, set-aside shields and/or covers  106  may be supported, when not in use, by hangers  110  upon table  100 , best seen with reference to  FIG. 2 . 
     It will be apparent that rebar of any of a variety of sizes, shapes, and/or materials may be used in association with table  100 , so long as appropriate to the configuration and power profile of the table. 
     It will also be apparent that, in other embodiments, fixed-position shaping plate or die  304  may be provided in an alternative shape and/or size than has been described and depicted herein, in order to accommodate other, different, and/or further bend specifications. Specifically, in some embodiments, a fixed-position shaping plate or die  304  having a length of approximately 9-10 inches from front radius to heel may be preferred for projects in which rebar bending specifications call for compact, multiple (or consecutive) bends, such as those that might be found, for example, within rectangular-shaped rebar sections used within footings. It will be apparent that such length of fixed-position shaping plate or die  304  will allow one to form, for example, a 12 inch rectangular rebar footing section, without interference or obstruction by fixed-position shaping plate or die  304 . Of course, it will be further apparent that appropriate adjustments may be necessary in the design and/or configuration of table  100 , and associated elements, in order to accommodate other or alternative forms of fixed-position shaping plate or die  304 . 
     It will be further apparent that, in some appropriately configured embodiments, table  100  may be pneumatically and/or electrically powered, in lieu of, in association with, or in addition to, the use of hydraulic power systems of the type that have been described herein. 
     Having thus described exemplary embodiments of the subject matter of the present disclosure, it is noted that the within disclosures are exemplary only and that various other alternatives, adaptations, and modifications may be made within the scope and spirit of the present invention. For example, while the disclosure set forth hereinabove has been provided with reference to materials such as construction rebar, the subject matter could be extended to use in association with many other relatively slender, cylindrical, solid or tubular, bendable materials which preferably may be cut by shearing without performance-degrading deformation adjacent the shear plane. 
     Accordingly, the present subject matter is not limited to the specific embodiments as illustrated herein, but is only limited by the following claims.