Patent Abstract:
Certain embodiments of the present invention relate to arcuate saddles typically used to anchor and suspend insulated or non-insulated pipes. Rounded corners on the saddles facilitate comfortably introducing and placing the saddles into hangers as well as improving use. Certain embodiments of the present invention involve methods of manufacturing arcuate saddles with rounded corners.

Full Description:
This application is a continuation of U.S. patent application Ser. No. 12/759,227, filed Apr. 13, 2010, which claims the benefit of U.S. Provisional Application Ser. No. 61/168,749, filed Apr. 13, 2009, which are hereby incorporated by reference in their entirety. 
    
    
     FIELD OF THE INVENTION 
     Aspects of the present invention relate generally to saddles for anchoring and supporting insulated and uninsulated pipes. 
     BACKGROUND OF THE INVENTION 
     Metal components which are commonly known as “saddles” are typically used in building construction to anchor and support pipes to suspend the pipes from the structure of the building. Saddles typically spread the force of a hanger across a portion of the pipe to minimize the force applied to a particular spot. Arcuate saddles with 90° right angle corners along the edges ( FIG. 1 ) are well known in the art. An improved saddle is desired. 
     SUMMARY 
     Certain embodiments of the present invention relate to arcuate saddles typically used to anchor and suspend insulated or non-insulated pipes. Rounded corners on the saddles facilitate comfortably introducing and placing the saddles into hangers as well as improving use. Certain embodiments of the present invention involve methods of manufacturing arcuate saddles with rounded corners. 
     In one embodiment an arcuate saddle is formed for supporting pipe where the saddle has a length and a width. The saddle defines two parallel length sides and two parallel width sides, wherein the width is formed into an arc defined by a radius. The length sides are substantially perpendicular to the width sides and the intersections of the length sides with the width sides are formed with arcuate curves forming rounded corners. 
     In certain embodiments, a method for forming an arcuate saddle for supporting pipe includes forming a substantially rectangular flat saddle blank having a length and a width with two parallel length sides and two parallel width sides with corners. The length sides are substantially perpendicular to the width sides. Material is removed from the corners along a convex arcuate curve to form rounded corners tapered into the length and width sides; and the saddle blank is formed into an arcuate saddle shape defined by a radius. 
     In certain embodiments, a method for forming an arcuate saddle for supporting pipe includes: advancing a sheet of material; cutting convex arcuate curves into opposing edges of the material to form rounded corner portions; separating a blank with convex rounded corners defined by the rounded corner portions from the material; and forming the blank into an arcuate saddle shape. In certain options, the saddle is then ejected from the forming assembly. 
     In further embodiments, a progressive die assembly is provided for forming arcuate saddles for supporting pipe. The assembly include a bed defining a material path to receive a strip of sheet material advanced by a feeding mechanism. A pair of cutting pieces is aligned with the bed along opposing edges of the material path. The pair of cutting pieces is arranged in a compressive cutting relationship with the bed to cut convex arcuate curves into the material to form rounded corner portions. The bed includes a forward shearing edge. A lower stamping die with an arcuate portion is arranged along the material path forward of the forward shearing edge. An upper stamping die is arranged in a compressive relationship with the lower stamping die. The upper stamping die has a trailing shearing edge arranged adjacent the forward shearing edge of the bed to cut the material, thereby forming a separated saddle blank when the upper stamping die is compressed relative to the lower stamping die. The upper stamping die has an arcuate bending portion complimentary to the lower stamping die to stamp the saddle blank into an arcuate shape. 
     Objects, features and advantages of the present invention shall become apparent from the detailed drawings and descriptions provided herein. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a prior art saddle. 
         FIG. 2  is an example of a hanger assembly usable to suspend saddles according to embodiments of the present invention. 
         FIG. 3  illustrates a hanger assembly and saddle supporting a pipe according to a preferred embodiment of the present invention. 
         FIG. 4  is a perspective view of a saddle without ribs. 
         FIG. 5  is a perspective view of a saddle with 180 degree arcuate ribs. 
         FIG. 6  is a perspective view of a saddle with partial ribs. 
         FIG. 7  is a perspective view of the lower portion of a progressive die arrangement for stamping arcuate saddles according to certain embodiments of the present invention. 
         FIG. 8  is a cross-sectional view of the upper and lower portions of the progressive die arrangement of  FIG. 7 . 
         FIGS. 9-11  are perspective views of one embodiment of a progressive die arrangement according to certain embodiments. 
         FIGS. 12A and 12B  are perspective views of the lower and upper cutting pieces and profiles usable in the embodiments of  FIGS. 9-11 . 
         FIGS. 13-15  are perspective views of the bending assembly of  FIGS. 9-11 . 
         FIGS. 16-19  illustrate operative steps of the arrangement of  FIGS. 9-11 . 
         FIGS. 20-22  illustrate an ejector assembly useable in the embodiments of  FIGS. 9-11 . 
         FIGS. 23 ,  23 A and  23 B illustrate perspective views of a cutting assembly usable in certain embodiments. 
         FIG. 24  is a perspective view of a roll bending arrangement usable in certain embodiments. 
     
    
    
     DESCRIPTION OF PREFERRED EMBODIMENTS 
     For the purposes of promoting an understanding of the principles of the disclosure, reference will now be made to the embodiments illustrated and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope is thereby intended, such alterations, modifications, and further applications of the principles of the disclosure being contemplated as would normally occur to one skilled in the relevant art. 
     Embodiments of the present disclosure relate to arcuate saddles with rounded corners typically used to anchor and suspend insulated or non-insulated pipes. As illustrated in  FIGS. 2 and 3 , in a typical assembly  10  a hanger assembly  20  wraps around a pipe or insulated pipe  15  with a saddle  30  situated between the lower portion of the hanger and the pipe. According to an embodiment of the present invention, saddle  30  includes rounded edge corners  60 , typically four, to facilitate introduction of the saddle into the hanger and to eliminate or minimize the ability of sharp corners of the saddle to catch upon or scratch a user, the hanger, a pipe, insulation, a vapor barrier or other materials during introduction or use. 
     Hanger  20 , for example the clevis hanger illustrated in detail in  FIG. 2 , typically includes an upper portion or bracket  22  which can be suspended from a building structure, a lower bracket  24  for receiving and engaging the saddle and pipe and optionally includes a pivot  26  between the upper and lower brackets to allow some relative movement of the hanger portions, if necessary due to vibration, expansion or contraction. Alternately, the hanger can be one piece or a strap which suspends a pipe and saddle. 
     When putting together assembly  10 , an installer takes saddle  30  and slides it through lower bracket  24  of hanger  20  either independently or with the introduction of pipe  15  into the hanger. The vertical sides of saddle  30  have a width in a close tolerance with the interior of hanger lower bracket  24  to transfer suspension force from the pipe to the hanger once in place. 
     Certain embodiments include: non-ribbed saddles, 180° ribbed saddles or partial ribbed saddles, each with rounded corners as illustrated in  FIGS. 4-6 . In 180° ribbed saddles or partial ribbed saddles, the ribs or partial ribs typically have a higher profile and larger radius than the interior of the hanger particularly on the sides. When ribbed saddles are mounted in place in the hangers, the ribs preferable inhibit or minimize relative sliding movement of the saddle with respect to the hanger. 
       FIG. 4  illustrates a non-ribbed saddle  30  with rounded corners  60  according to one preferred embodiment. Saddle  30  is formed typically from a rectangular blank of sheet metal  32  pressed or rolled into approximately a 180° arcuate bend about a radius R, forming a length L and a width W. Saddle  30  includes two ends  33  and  34  at opposing ends of the saddle length. Ends  33  and  34  are optionally slightly outwardly flared  35  to facilitate introduction of the pipe into the saddle and to minimize any abutment of sharp edges against the pipe or insulation. The exterior face of saddle  30  includes a generally lower portion or lower face  38  and opposing vertical sides  39 . “Vertical” and “lower” references herein refer to arcuate or curved portions of the saddle which may include generally vertical or horizontal tangents and are not intended to imply planar or flat portions. 
     The outer diameter or width W of saddle  30  is preferably sized to closely correspond to the inner diameter or width W C  of the lower bracket  24  of hanger  20  while the saddle inner diameter corresponds to the outer diameter of the pipe and/or insulation. As examples, pipe and/or insulation sizes may range from 0.5 to 24 inches. More typical saddle sizes have diameters of 1.5 to 12 inches, optionally available in half-inch increments, although other diameter sizes can be made as desired. Example lengths are 8 or 12 inches. 
     An interior channel  42  extends through the interior of saddle  30  along a channel axis. In use, the interior diameter of channel  42  is sized to receive and engage an outer diameter of a corresponding pipe or insulated pipe. 
     In an option for certain embodiments, the saddle can be configured to adhere to the pipe or insulation surrounding the pipe to minimize relative movement of the saddle to the pipe or insulation. In one example of this, a double-sided adhesive strip may be mounted to the interior of the saddle longitudinally along interior channel  42 . In one embodiment, the adhesive strip is pre-mounted in the saddles and includes a peel-away cover which is removed to expose an inward facing adhesive face just prior to installation. In an alternate embodiment, an unmounted two-sided strip with two peel-away covers may be supplied with the saddle. In the two-sided version, a first face is first exposed and mounted either to the pipe assembly or the saddle. The second face is then exposed and adhered to the other of the saddle or pipe assembly when they are arranged respectively in a desired location. One or more adhesive strips may extend all or partially along the length of the saddle, and can be mounted between the interior lower portion of the saddle and a pipe assembly or along one or both side portions. 
     In the embodiments of  FIGS. 5 and 6 , 180° ribs  150  or partial ribs  250  are defined on the lower face  138  and  238  of saddles  130  and  230  with rounded corners  160  or  260 . Ribs  150  and  250  typically have an arcuate bend corresponding in shape to the arcuate curve of lower face  138  and  238 . The ribs are generally transverse to the length L of saddle  30  and parallel to the width W. Ribs  150  and  250  preferably extend a sufficient height and width to inhibit saddle  130  or  230  from moving relative to the lower bracket  24  of hanger  20  once installed. When partial ribs are used, the partial ribs  250  are preferably primarily oriented on lower face  238  and do not substantially extend to side portions. In certain preferred embodiments, the arcuate bend of the partial ribs  250  is approximately 60° or less. 
     Ribs  150  and  250  each include a central peak section  152  or  252  and opposing slanted or curved sides extending from face  138  or  238  to peak  152  or  252 . Peak section  152  or  252  may be sharp, blunted or rounded. The ends of the partial ribs  250  may be sharply defined, but preferably are tapered into saddle  230  at each end to form a closed end. Ribs  150  or  250  could be mounted to lower face  38  with an attachment process, but preferably are formed into the metal. 
     In certain preferred embodiments of the present invention, arcuate saddles are made with rounded corners. Non-limiting examples of corner radii which may be used are ¼″, ⅜″ or ½″. Alternately a larger or smaller radius of curvature, or a non-constant radius may be used as desired. Preferably the rounded periphery at each corner is convex and smoothly tapers into the respective length and width edges of the saddle to eliminate sharp corners or discontinuities. 
     In one method of manufacture, rounded corners  60 ,  160  or  260  are individually formed into a piece or “blank” of sheet metal either to be bent or in an already arcuately formed saddle. A blank is typically a flat, rectangular sheet of metal with a length corresponding to the desired length of the saddle and a width corresponding to the desired circumference of the saddle around the desired radius. The length forms two parallel length sides which are perpendicular to two parallel width sides. The corners of the blank or saddle may be individually formed by cutting or grinding. Examples of ways to cut or trim the corners include automated or manual trimmers or using a grinding machine to shape the blank or saddle to remove material and to form the rounded portion. 
     If the corners are cut or trimmed into a flat sheet metal blank, the blank may then be bent into an arcuate shape, for example using a stamping or rolling process. One method of roll bending saddles is to use a two or three roll bending machine, for example, using an Acrotech Model 1618 two roll bending machine. The roll bending machine may form a flat or ribbed blank into a non-ribbed saddle, a 180° ribbed saddle or a partially ribbed saddle, as desired, and may form flares on the edges as desired. 
     Alternate methods of manufacturing include forming the corners with an automated process, such as in a stamping machine which forms the corners by trimming a blank either simultaneously or as a separate step to forming the blank into an arcuate shape. A typical stamping machine compresses the blank between mating portions for bending and/or cutting. 
     In certain embodiments one or more stamping machines may be used with successive stamping steps and positions. In one embodiment, a first stamping position includes substantially flat male and female portions forming a cutting table to support a flat blank piece. Cutting punches extend from the male and/or female portions corresponding to each desired rounded corner. During compression, pressure is preferably applied so that the cutting punches penetrate and cut through the blank to remove material from the blank, forming rounded corners. Upon opening of the stamping machine, a substantially flat blank with rounded corners may be removed. 
     The flat blank with rounded corners is then automatically fed or manually transferred to a second stamping position of the same or a different stamping machine. In the second stamping position, the blank is arranged between a protruding male portion and receiving female portion formed in complementary arcuate shapes. When the stamping machine is compressed, the portions bend the blank into an arcuate saddle shape. Optionally, the stamping machine portions may also include protruding 180 degree or partial ribs which stamp corresponding rib sections into the saddle during the same step. 
     An example embodiment of a stamping machine and process is illustrated in  FIGS. 7 and 8 .  FIGS. 7 and 8  show an example of a progressive die having a lower die portion  300  and an upper die portion  400 . Lower die portion  300  includes a cutting portion  310  and a bending portion  350 . Upper die  400  includes a corresponding cutting portion  410  and bending portion  450 . 
     As illustrated in detail in  FIG. 7 , cutting portion  310  of lower die  300  includes a bed portion  312  with an entry edge  314 , an upper edge  316  and a lower edge  318 . An exit edge  344  of the bed is formed with a replaceable cutting bar  340  mounted along the edge opposite entry edge  314 . 
     Cutting pieces or punches  325  are mounted in bed  312 . Cutting pieces  325  are preferably formed with two concave radius portions extending from each side of the cutting piece inward toward the center of the bed to an inner tip. The tips of the two cutting pieces are preferably aligned along a trim axis T-T. Optionally, cutting pieces  325  are selectively mountable in various locations relative to bed  312  to vary the width distance W 1  between axis T-T and the cutting edge  344  of bar  340  in certain preselected measurements. Optionally, cutting pieces  325  may also be mounted to bed  312  along the upper and lower edges forming side rails  316  and  318  as shown, or each may be moved inward along the length axis L 1  of bed  312  to engage a correspondingly shorter length of material. The length of dimension L 1  is intended to correspond to the desired length of the finished saddle piece, for example saddle lengths of 8 or 12 inches. The length dimension L 1  may correspond to the width measurement from the perspective of a metal strip or ribbon being supplied to die portion  300 , such as from a steel coil. 
     In correspondence with cutting portion  310  of lower die  300 , cutting portion  410  of upper die  400  is arranged with a cutting bed portion arranged to mate with lower bed  312 . Cutting or pierce punch pieces  425  which are complimentary in shape to cutting pieces  325  are mounted to upper portion  412 . As shown, cutting pieces  425  include two convex radius portions extending from outer edges inward towards the center of the bed to meet at a tip. Cutting portions  325  and  425  are preferably substantially equal in complimentary shapes with a slight tolerance difference in size so that upon compression of the die, a lower cutting portion  325  pushes upward on a piece of metal in the die a while upper cutting portion  425  pushes downward on the metal creating a shearing effect to cut a plug of material from the metal, leaving a shape in the metal matching the radius portions where the upper and lower cutting punches pass. 
     In an optional feature, upper bed  412  may include a compression plate  415  mounted on springs. When used, the compression plate typically would be the first portion of the upper cutting portion  412  to contact the metal material in the die and would provide a clamping force on the metal between the plate and lower bed  312  to hold the metal in place while the upper die continues its downward stroke. As the downward stroke continues, the springs compress to resiliently increase the clamping pressure on the metal in the die until the cutting portions have finished a cutting downward stroke. The clamping pressure releases and retracts as the upper die  400  moves in the reverse stroke. 
     Lower die  300  further includes bending portion  350  arranged to receive material exiting cutting portion  310 . Bending portion  350  includes a radiused male portion  360  forming a radius and diameter corresponding to the desired inner arcuate radius and curve of the saddle. The radius may extend for approximately 180°, or optionally may include a slight variation or be slightly oversized to accommodate expected spring back of the metal material being bent. 
     Male radius  360  typically includes a radiused face portion  362  forming a central portion of the bending surface. Optionally arranged on opposing sides of the center of central portion  362  are partial or full ribs  364  to press corresponding partial or 180° ribs into the metal blank being bent. The face of radius  360  preferably includes slightly tapered flared portions  367  at each end to impart a flare to the upper and lower edges of the blank being bent. 
     In certain embodiments, the face of radius  360  includes radiused sections  365  arranged outward along the length L 1  between upper edge  356  and lower edge  358  of bending portion  350 . 
     Optionally, the face of bending portion  350  can be arranged to accommodate a narrower blank corresponding to an arrangement where cutting portions  325  are spaced inward from upper edge  316  and lower edge  318  of bed  312 . For example, this can be used with a strip of metal having a length L 2  such as eight inches. In this arrangement, spacer plates (not shown) are placed over the outward radiused sections  365  so that a centered metal blank is fed between them in the area designated L 2 . The spacer plates optionally include flared portions along their central edges so that a blank bent in the L 2  region receives flared outer edges. The spacer plates preferably include radii to correspondingly fit snugly on radiused portions  365  when in place without interfering with compression of the die. The spacer plates may be mounted by resting in place or may optionally be secured with fasteners. 
     Upper die  400  has an upper bending portion  450  matching and complementary to lower bending portion  350 . As illustrated in a cross-section in  FIG. 8 , bending portion  450  includes a cutting bar  440 , preferably replaceable, which forms a shearing relationship with lower cutting bar  340  to cut material in the die as the die compresses. 
     Bending portion  450  includes a concave female radius  460  complementary to male radius  360 . Female radius  460  may optionally include indentations or grooves allowing for partial or full ribs  364  to press ribs into the metal being bent. In some embodiments, male radius  360  and female radius  460  each include slight vertical wall sections  369  and  469  transitioned from the arcuate radius portions to allow the male and female portions to compress sufficiently to impart a full 180° radius to the metal being bent. 
     Preferably, the center of male bending portion  350  is spaced from the shear or cutting edge  344  of cutting bar  340  at a distance of ½ W 1 . The spacing corresponds to half of the distance W 1  between the punch  325  cutting tips along trim axis T-T and the shear edge  344 . 
     In operation of the illustrated progressive die, a ribbon or strip of metal is fed into bed portion  312  from the direction of intro edge  314 . The strip or ribbon of metal may have a width corresponding to the desired length of the saddle to be made, for example filling length distance L 1  of bed  312 . The thickness of the metal is preferably of a gauge designed to be cut by the height of punch pieces  325  and  425 . Prior to the introduction of the metal, cutting punches  325  and  425  are arranged at a distance W 1  from shearing edge  344  of cutting bar  340  where distance W 1  corresponds to the desired blank to be cut with a width to be formed into the desired circumference measurement of the saddle piece to be produced. 
     In a loading step, the leading edge of the metal with two rounded corners is advanced into bed  312  until the forward edge is adjacent the shear edge of cutting bar  340 . Optionally, the metal may be advanced further or less; however, a scrap portion will need to be cut and discarded in the first cycle or two of the die to create a leading edge with two rounded corners. 
     In a first cycle of operation, the male and female die portions compress to shear off any excess material extending beyond cutting bar  340  and also to punch radiused convex indentations along axis T-T into the metal material. Upon completion of the first compression and release cycle, the metal strip is advanced a distance W 1  through the die. In the next position, the portion of the metal in which the radiused indentations were made along axis T-T is aligned with the shearing edge of cutting bar  340  with the forward portion of the metal extending between the bending portions of the respective dies. Upon the next compression cycle, cutting bars  340  and  440  shear the material along axis T-T leaving a blank to be bent in the bending portions of the dies while also punching the next radiused indentations with punches  325  and  425  into the metal of material. Each compression and cutting cycle by punches  325  and  425  forms two rounded corners on one side of axis T-T and two rounded corners on the opposite side of axis T-T. When the metal is cut along axis T-T, these form rounded trailing corners of a prior blank and rounded leading corners on the edge of the next blank. 
     As the die closes in the second and successive iterations, the upper point of male radius  360  and the lower portions of upper bending portion  450  contact and hold the metal piece between them in a three point contact grasp. As the metal is cut and the dies continue to compress, the metal is bent around male radius  360  until the desired bend arc has been imparted to the blank. Typically the cutting portions and bending portions simultaneously compress and retract the same distance h 1  during a cycle. 
     During compression bending, the outer portions of the blank are pushed downward and slightly drawn inward to wrap around the male radius  360 . The lower edges of the female radius  460  preferably include a slight radius or taper  465  to facilitate the metal being bent rather than scraped as the female radius is forced downward to wrap the metal. 
     Upon completion of the compression cycle, the die portions are separated and the formed arcuate saddle may be removed from lower bending portion  350 . The metal strip or ribbon is then advanced a distance W 1  to provide the next portion of material to be cut off and bent in the bending portions and the next portion of material to be cut with indentations in the cutting portions of the die. The operation may then be repeated as desired to form multiple arcuate saddles with rounded corners. 
     In certain optional embodiments, the female bending portion  450  may include one or more retractable compression pins to contact the metal blank during the compression portion of the cycle. The pin or pins preferably push the saddle out to prevent it from sticking within the female bending portion during the upward stroke. 
     In certain optional embodiments, an embossing die may be arranged in the cutting or bending portions of the arrangement to emboss indicia such as size information or a brand name or logo into the inner or outer faces of the saddle being formed. 
     In one embodiment, the cutting portions and bending portions are mounted in a fixed distance relationship defined so that the distance between shear edge  344  and the center of bending portion  350  is one-half of the distance between the shearing edge  344  and the trim axis T-T. Alternately, the distance between the cutting portions and the bending portions can be varied at predefined intervals to maintain the relationship of W 1  to ½ W 1  as the cutting punches  325  are arranged within bed  312  to accommodate different width measurements W 1 . For example, different width measurements W 1 , would be used to accommodate the differences in circumference measurements between arcuate saddles of differing radii and diameters. In an alternate embodiment, the bending portion can be arranged to receive a cut blank with rounded portions from the cutting portions and to then automatically center the blank over the desired radius portion. 
     A further example embodiment of a stamping machine  500  and process is illustrated in  FIGS. 9 through 22 .  FIGS. 9-22  show an example of a progressive die arrangement having a cutting assembly  510 , a bending assembly  550  and an ejector assembly  590 . 
     As illustrated in detail in  FIGS. 9-11 , cutting assembly  510  includes a lower portion with bed  512 . The top of bed  512  is closed with an upper plate  513 . Bed  512  includes a bed area with side rails which is covered by plate  513  to define a sheet metal path with entrance  514  sized to receive sheet metal material  235  fed, for example from a coil and advanced by a feeding mechanism. The bed ends in forward or shearing edge  544  ( FIG. 13 ). Upper plate  513  defines vertical edge slots  518  arranged along its longitudinal length and optionally a logo stamping slot  519 . 
     Bed  512  includes two cutting profiles  527 , as seen in  FIG. 12A , aligned with edge slots  518 , which are complimentary in shape to and are mated to form a shearing arrangement with the cutting profiles of cutting pieces  525 . In the illustrated embodiment, the cutting profiles  527  within bed  512  have two convex radiused portions  528  extending from each side inward toward the center of the bed to a tip  529 . The tips of the two cutting profiles are preferably aligned along a trim axis T-T. 
     The upper portion of cutting assembly  510  includes an upper carrying plate  520  with cutting pieces or pierce punches  525  extending downward. As seen in  FIG. 12B , cutting pieces  525  are preferably formed with a cutting profile having two concave radiused portions  526  extending from each side of the cutting piece inward toward the center of the bed to a tip  524 . 
     Cutting pieces  525  of the upper portion are aligned with longitudinal edge slots  518  in plate  513  and with the cutting profiles  527  of bed  512 . Cutting pieces  525  and cutting profiles  527  are preferably substantially equal in complimentary shapes with a slight tolerance difference in size so that upon compression of the die, the upper cutting portions push downward on the sheet metal, while the lower cutting profiles resist/push upward, creating a shearing effect to cut a plug of material from the metal, leaving a cutout shape  255  ( FIG. 16 ) in the metal  235  matching the radius portions where the cutting pieces and the cutting profiles pass. 
     Cutting pieces  525  and cutting profiles  527  are preferably selectively mountable in various locations along the length of edge slots  518  to vary the distance between axis T-T and the forward or cutting edge  544  of bed  512 . They optionally may also be mountable along the width of bed  512 . For example, two edge slots  518  are illustrated along one side of plate  513 . The cutting pieces on that side can be arranged in the inner or outer edge slots to accommodate metal widths corresponding to different lengths for example lengths L 1  and L 2  as discussed with respect to  FIG. 7 . 
     If desired, an optional logo stamping piece  520  may be aligned with an optional logo stamping slot  519 . The logo stamping piece may be used to stamp the imprint of graphics or text into the sheet metal to apply a logo, sizing indicia or other information as desired. 
     Progressive die arrangement  500  further includes a bending assembly  550  illustrated in detail in  FIGS. 13-15 . Bending assembly  550  is arranged adjacent the forward edge  544  of cutting assembly  510 , to receive sheet metal  235  advanced through bed  512 . Bending assembly  550  includes a lower die  560  and an upper die  580 . Upper die  580  is mounted on upper carrying plate  520 . Upper die  580  includes a cutting bar  584 , preferably replaceable, which forms a shearing relationship with a lower cutting bar  546  along edge  544  to cut extending sheet metal material into blanks as the die arrangement compresses. 
     Lower die  560  includes a radiused male portion forming a radius and diameter corresponding to the desired inner arcuate radius and curve of the saddle to be formed. The radius may extend for approximately 180°, or optionally may include a slight variation or be slightly oversized to accommodate expected spring back of the metal material being bent. Optionally arranged on lower die  560  are partial or full ribs  564  to press corresponding partial or 180° ribs into the metal blank being bent. Lower die  560  optionally but preferably includes slightly tapered flared portions  567  at each end to impart a flare to the width edges of the blank  230  being bent. Optionally, lower die  560  can be arranged to accommodate blanks of length L 1  or L 2  as discussed with respect to other embodiments herein. 
     Preferably, the center of the male bending portion is spaced from forward edge  544  at a distance corresponding to half of the distance between the cutting tips of the cutting pieces  527  along trim axis T-T and forward edge  544 . 
     Upper die  580  has an upper female radiused bending portion matching and complementary to the male bending portion of lower die  560 . The female bending portion allows, for example with indentations or grooves, for partial or full ribs  564  to press ribs of lower die  560  into the metal being bent. 
     In operation of the illustrated progressive die, shown in  FIGS. 16-18 , a ribbon or strip of metal  235  is fed into bed  512  via entry slot  514 . Prior to the introduction of the metal, cutting pieces  527  and cutting punches  525  are arranged at a distance from shearing edge  544  corresponding to the width of the desired blank  230  to be cut and then formed into the desired circumference measurement of the saddle being produced. Ejector assembly  590  is not illustrated in  FIGS. 16-18  for ease of reference. 
     In a loading step, the leading edge of metal  235  is advanced into bed  512  until the forward edge is adjacent the shear edge of cutting bar  546 . Optionally, the metal may be advanced further or less; however, a scrap portion will typically need to be cut and discarded in the first cycle or two of the die assembly to create a leading edge with two rounded corners. 
     In a first cycle of operation, trimming assembly  510  and bending assembly  550  compress concurrently to shear off any excess material extending beyond cutting bar  546  and also to punch radiused convex indentations as cut-out shapes  255  along axis T-T into the metal material. Upon completion of the first compression and release cycle, the metal strip is advanced a distance through the die. In the next position, illustrated in  FIG. 16 , the forward or leading portion of the metal  235  has rounded corners. Additionally, the next portion in which the radiused indentations  255  were made along an axis T-T is aligned with the forward edge  544  and cutting bar  546 . The forward portion of the metal extends between lower die  560  and upper die  580 . 
     Upon the next compression cycle, carrying plate  520  is lowered to simultaneously lower cutting pieces  525  and upper die  580 . During the compression step, cutting bars  584  and  546  cut the metal material  235  along one axis T-T, leaving a separated blank  230  which is then bent between the upper and low dies  580  and  560 . Simultaneously, cutting pieces  525  are punching the next radiused indentations  255  into the metal of material  235  along the next axis T-T. Each compression and cutting cycle by punches  525  forms two rounded corners  260  on one side of an axis T-T and two rounded corners  260  on the opposite side of the axis T-T. When the metal is advanced and then cut along that axis T-T, these form rounded trailing corners of a prior blank and rounded leading corners on the edge of the next blank. 
     As the die closes in the second and successive iterations as illustrated in  FIGS. 17 and 18 , the upper die  580  and the lower die  560  contact and hold the metal piece between them in a three point contact grasp. As the metal is cut and the dies continue to compress, the metal is bent around the male radius until the desired bend arc has been imparted to the blank. 
     Upon completion of a compression cycle, once the die portions are separated as seen in  FIG. 19 , the formed arcuate saddle  230  may be removed from lower die  560 . The metal material is then advanced a distance to provide the next portion of material to be cut off and bent in bending assembly and the next portion of material to be cut with indentations  255  in the trimming assembly. The timing of compression cycles, removal of finished saddles and advancing material is preferably synchronized. The operation may be repeated as desired to form multiple arcuate saddles with rounded corners. 
     In certain preferred embodiments, an ejector mechanism such as ejector assembly  590  can be used to eject a formed arcuate saddle from lower die  560 , for example onto a gravity slide  599  into a collection area. Details of an example ejector assembly  590  are illustrated in  FIGS. 19-22  among others. In the illustrated embodiment, ejector assembly  590  includes a longitudinal arm  592  extending alongside and parallel to the base of lower die  560 . In its lowered position, arm  592  lies between lower die  560  and bed  512 . Preferably a scraper portion  594  is formed with or attached to arm  592 , although alternately the arm can directly function as the scraper portion. Scraper portion is arranged along selected portions or entirely along the length of lower die  560  and extends closely adjacent the face of lower die  560 . 
     Ejector assembly  590  includes two radial legs  597  having outer ends formed with or attached to opposing ends of arm  592  and inner ends aligned along a longitudinal axis defined by a pair of pivot points. At least one of the inner leg ends is mounted to an axle portion  596  as a crank arm at a fixed angular relationship which allows and causes the radial legs  597 , arm  592  and scraper portion  594  to rotate around the pivot point and lower die  560  when the axle portion  596  is rotated. One end of ejector assembly  590  includes a rotation mechanism  598  operable to rotate axle portion  596  and thus ejector assembly  590  on demand. In one example embodiment, rotation mechanism  598  includes a compressed air powered cylinder which expands and contracts and corresponding rotates a crank arm or gearing inside rotation mechanism  598  to correspondingly rotate the axle and ejector arm  592 . 
     Preferably the closest separation distance between scraper portion  594  and the face of lower die  560  is less than the thickness of the sheet metal material being used. In one embodiment, when ejector assembly  590  is operated, scraper portion  594  impacts the lower edge of the finished saddle and propels the saddle off of the lower die and onto slide  599  directed to a collection point. The pivot axis may be aligned with the axis defined by the radius of die  560 . Alternately, scraper portion  594  may contact the surface or other aspects of the finished saddle and may follow a path not corresponding to the radius of the lower die, such as a radial path eccentric to the die or following a tangential approach path. In certain embodiments, engagement features such as rubber feet or pads may be used to allow the ejector assembly to contact and propel the saddle while not wearing on the lower die. 
     In certain preferred embodiments, compressive die assembly  500  and other arrangements herein include appropriate sensors and PLCs to monitor material within the assembly before, during and after compression cycles. Such sensors may signal operational readiness states. Preferably sensors may be used to detect whether material is within bed  512  and whether material is present and ready to be bent between lower die  560  and upper die  580 . Further a sensor and PLC preferably detects when an arcuate saddle has been formed and, upon sufficient separation of the dies, triggers the ejector assembly  590  to eject the finished saddle from lower die  560 . Completion of a compression cycle and ejection of a finished saddle preferably further is synchronized with a signal to an automated feed mechanism to advance the metal material the next desired distance within arrangement  500  for the next cycle. 
     A further example embodiment of a manufacturing arrangement is illustrated in  FIGS. 23 ,  23 A,  23 B and  24 .  FIGS. 23 ,  23 A and  23 B show a cutting assembly  610  and  FIG. 24  shows a roll bending assembly  650 . 
     Cutting assembly  610  includes a bed  612  carried on a base plate  611 . A sheet metal path sized to receive sheet metal material is formed along bed entry  614  between side rails  616 . Bed  612  further includes two slide rails  618  along the metal path, which slightly raise the metal material as it is fed into the assembly. Bed  612  further defines an inset or lowered area  660  between slide rails  618 . A rib block  662  can be placed within inset area  660 . In certain embodiments, rib block  662  includes upward protruding rib portions  664  along all or a portion of the block length. Rib block  662  preferably can be mounted at selected desired positions within inset area  660  to corresponded to desired placement of rib indentations in the metal material. 
     In the illustrated embodiment, the tops of slide rails  618  are slightly taller than the height of protruding rib portions  664  so that material travelling over the slide rails travels above protruding rib portions  664 . In this arrangement, slide rails  618  are preferably mounted within slots in bed  612 . Specifically, slide rails  618  are resiliently supported by springs within the bed to allow slide rails  618  to depress under pressure during the compression cycle and to be biased to rise upward when the pressure is released. 
     The forward portion of bed  612  defines a lower cutting profile  680 . Lower cutting profile extends lengthwise across the width of bed  612 , and preferably corresponds in length to the width of the metal material to be cut. Lower cutting profile  680  has two convex radiused portions at each end. The radiused portions extend inward from the edges to a longitudinal channel connecting the radiused portions at opposing ends of the profile. An exit slide  699  is arranged along the path forward of cutting profile  680 . 
     The upper portion of assembly includes carrying plate  620  arranged in a compressive arrangement with bed  612 . Carrying plate  620  includes a stamping portion  626  arranged opposite slide rails  618  and ribs  664 . Stamping portions  626  includes clamping rails  628  arranged opposite sliding rails  618 . An upper rib block is mounted between clamping rails  628  and aligned opposite lower rib block  662 . The upper rib block defines rib portions complimentary to the rib portions in the lower rib block, such a grooves corresponding to and aligned with protruding rib portions  664 . 
     The forward portion of carrying plate  620  includes an upper cutting or punch portion  684 . Punch portion  684  is aligned with the placement and length of lower cutting profile  680  across the width of bed  612 , and preferably corresponds in length to the width of the metal material to be cut. Punch portion  684  is complementary in size and shape to lower cutting profile  680 , and defines two concave radiused portions at each end which are connected by a thin punch blade. 
     In operation, a coil or ribbon of metal material is fed into assembly  610  via entry  614 . As the metal is advanced, it slides upward and over sliding rails  618  and thus travels above protruding ribs  664 . In the loading cycle, the forward edge of the metal is advanced at least slightly forward of cutting profile  680 . Carrying plate  620  is then compressed downward. During the downward compression, clamping rails  628  contact the metal material and depress it, correspondingly depressing sliding rails  618 . Depression of sliding rails  618 , allows the metal material to bear against the protruding rib portions  664  which then stamps the metal between the protruding rib portions  664  and the corresponding rib portions in the upper rib block to form rib indentations. Upon upward motion of carrying plate  620 , sliding rails  618  rise, in turn raising the material above the protruding rib portions  664 , enabling the material to travel forward without hindrance by the rib portions. 
     Concurrently, with stamping rib indentations into the material, punch portion  684  engages the metal against lower cutting profile  680  in a shearing arrangement which cuts a piece of material from the metal. The cut shape forms convex rounded corners on the trailing edge of the metal material forward of cutting profile  680  and forms convex rounded portions on the leading edge of the material rearward of cutting profile  680 . Additionally, the blade of punch portion  684  cuts the material along the channel of profile  680 , separating metal material forward of cutting profile  680  from the material rearward of cutting profile  680 . The separated metal can then be removed from assembly  610 , for example by being pushed to fall along slide  699 . 
     After upward movement of carrying plate  620 , the metal material is advanced forward a predetermined distance corresponding to the circumferential width of the saddle to be formed. This places the metal material containing the rib indentations stamped in the prior cycle forward of cutting profile  680 . Upon the next compression cycle, cutting profile  680  and punch portion  684  forms convex rounded corners on the trailing edge of the metal material forward of cutting profile  680  and separate the material as a flat, ribbed blank of material with rounded corners. Currently, rib portions are stamped into the next portion of the metal material. The compression and advancement cycle can be repeated to create additional flat, ribbed saddle blanks. 
     In a separate step, using a manual or automated feed, the separated blank is fed into a roll bending assembly  650  which bends the blank into an arcuate shape. An example roll bending assembly  650  based on an Acrotech model 1618 machine, with a flared die, is illustrated in  FIG. 24 . 
     While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiment has been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected.

Technology Classification (CPC): 5