Abstract:
One aspect is a hydraulic ironworker system having a hydraulic ironworker configured with hydraulic power to deliver controlled force to metal workpieces. An accessory tool is coupled to the hydraulic ironworker via a harness assembly and configured to receive the hydraulic power from the hydraulic ironworker. A remote pushbutton assembly is selectively coupled to the harness assembly and configured to control hydraulic power from the hydraulic ironworker to the accessory tool and further configured with an emergency stop button that, when actuated, disables all power to the hydraulic ironworker system. A safety plug assembly is configured to alternately couple to the harness assembly in place of the remote pushbutton assembly. Power to the hydraulic ironworker system is disabled until one of the remote pushbutton and safety plug assemblies are attached on the harness assembly.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This patent application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application Ser. No. 62/169,841 entitled “EMERGENCY STOP CONFIGURATION FOR IRONWORKER,” having a filing date of Jun. 2, 2015, the contents of which are incorporated herein by reference. 
     
    
     BACKGROUND 
       [0002]    Hydraulic ironworkers are a class of machines that can shear, notch, and punch holes in steel plate and bars. Ironworkers generate force using mechanical advantage or hydraulic systems. Modern systems use hydraulic rams powered by a heavy alternating current electric motor. High strength carbon steel blades and dies of various shapes are used to work the metal. The machine itself is made of very heavy steel to handle the enormous force that can be generated during use. Ironworkers are rated according to the force they can generate in tons. Although ironworkers are tools, just like hammers and wrenches, they also provide many more safety hazards due to the enormous power and force that they generate. For these and other reasons, there is a need for the present invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0003]    The accompanying drawings are included to provide a further understanding of embodiments and are incorporated in and constitute a part of this specification. 
           [0004]    The drawings illustrate embodiments and together with the description serve to explain principles of embodiments. Other embodiments and many of the intended advantages of embodiments will be readily appreciated as they become better understood by reference to the following detailed description. The elements of the drawings are not necessarily to scale relative to each other. Like reference numerals designate corresponding similar parts. 
           [0005]      FIG. 1  illustrates one embodiment of a hydraulic ironworker. 
           [0006]      FIG. 2  illustrates an ironworker system including a hydraulic ironworker coupled to an accessory tool in accordance with one embodiment. 
           [0007]      FIG. 3  illustrates a partial view of an accessory tool, including a remote unit, coupled to a hydraulic ironworker in accordance with one embodiment. 
           [0008]      FIG. 4  is an electrical schematic illustration of a hydraulic ironworker coupled to an accessory tool in accordance with one embodiment. 
       
    
    
     DETAILED DESCRIPTION 
       [0009]    In the following Detailed Description, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. In this regard, directional terminology, such as “top,” “bottom,” “front,” “back,” “leading,” “trailing,” etc., is used with reference to the orientation of the Figure(s) being described. Because components of embodiments can be positioned in a number of different orientations, the directional terminology is used for purposes of illustration and is in no way limiting. It is to be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope of the present invention. The following detailed description, therefore, is not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims. 
         [0010]    It is to be understood that the features of the various exemplary embodiments described herein may be combined with each other, unless specifically noted otherwise. 
         [0011]      FIG. 1  illustrates hydraulic ironworker  10  in accordance with one embodiment. In one example, ironworker  10  is a  55  ton ironworker, such as that manufactured by Edwards Manufacturing Company of Albert Lea, Minn. Ironworker  10  can be any of a variety of hydraulic ironworkers that are rated, for example, anywhere from  20  tons to as high as  150  tons. Ironworker  10  can be used for punching, shearing, notching, bending and other metal fabrication functions. Ironworker  10  uses hydraulic power to deliver controlled force to various work pieces. Ironworker  10  can be used in manufacturing or fabrication shops, maintenance departments, and vocational school to save time, increase productivity, eliminate waste and create clean smooth cuts and holes. 
         [0012]    In one embodiment, hydraulic ironworker  10  includes punch station  12 , flat bar shear station  14 , angle shear station  16 , coper notcher station  18 , control panel  20  and foot pedal  22 . Control panel  20  includes start switch  24 , disconnect switch  26 , emergency stop button  28 , and select switch  30 . Foot pedal  22  is also coupled to control panel  20 . 
         [0013]    In operation, various metal fabrication functions are performed at each of punch station  12 , flat bar shear station  14 , angle shear station  16 , and coper notcher station  18 . The motor of ironworker  10  is engaged with the toggling of start switch  24 . In one embodiment, a work piece is then introduced into one of the stations  12 / 14 / 16 / 18  and then foot pedal  22  is actuated to engage the hydraulics to force blades and/or dies of hydraulic ironworker  10  to complete the action of punching, shearing, notching, bending or similar actions on the workpiece. Select switch  30  can be toggled between three modes of operation: an iron worker mode, an accessory mode and an auto cut mode. When select switch  30  is in the iron worker mode, engaging the hydraulics to force the blades or dies is accomplished by stepping down on foot pedal  22 . Once the user steps off foot pedal  22 , the unit is disengaged after the cylinder retracts. For the shearing function, the auto cut mode can be selected such that the hydraulics are continuously enabled and will engage each time a sensor within flat bar shear station  14  senses that a work piece is in proper position and will “auto cut” each time the piece is sensed. In this auto cut mode, foot pedal  22  is disengaged. Finally, the accessory mode enables an accessory that can optionally be attached to ironworker  10 , as will be discussed in more detail below. 
         [0014]    Because ironworker  10  generates enormous forces when actuated in any of its modes, it also provides an emergency provision for shutting down completely and quickly. Accordingly, emergency stop button  28  is provided on control panel  20 . If something or someone is engaged in a dangerous way with ironworker  10 , pushing emergency stop button  28  cuts off all power to ironworker  10 . Accordingly, once emergency stop  28  is pushed, the motor and hydraulics are disabled and there is no way for any additional force to be output by the machine. In one embodiment, emergency stop button  28  is a twist lock mushroom head that opens a circuit when depressed. 
         [0015]    Disconnect switch  26  on control panel  20  is provided for further safety in the operation and maintenance of ironworker  10 . In order to access the inside of ironworker  10 , a front door panel must be opened. The door will not open, however, unless disconnect switch  26  is in the off position. Once in the off position, all incoming power to the components inside the enclosure is completely cut off. Disconnect switch  26  also has a lock out position that allows electricians or mechanics to lock into the off position with the door closed and prevent the machine from being started during maintenance or if the machine is not working properly.  FIG. 2  illustrates ironworker system  40  in accordance with one embodiment. Ironworker system  40  includes ironworker  10  coupled to accessory tool  50 . Accessory tool  50  can be any one of several available options that can attached to ironworker  10 , such as pipe benders, shop presses, radius rollers, horizontal presses, brake presses, plate shears, plate rollers, slip rollers, welding positioners, power hammers, power shrinker/stretchers, planishing hammers, power bead rollers, automotive lifts and a variety of others. 
         [0016]    In one embodiment, ironworker  10  is coupled to accessory tool  50  via accessory harness  52 . Accessory harness  52  includes first and second hydraulic hoses  54  and  56  and includes electrical cable  58 . Once coupled to ironworker  10 , first and second hydraulic hoses  54  and  56  deliver the hydraulic power of ironworker  10  to accessory tool  50 , such that accessory tool  50  uses the power of ironworker  10 . As such, accessory tool  50  does not require its own internal power system, effectively using ironworker  10  as the power plant, and accordingly, ironworker system  40  is a very cost-effective system. Accessory tool  50  can be specifically tailored to any of a variety of applications. 
         [0017]    Because accessory tool  50  can be located somewhat remotely from ironworker  10 , by virtue of the length of accessory harness  52 , ironworker system  40  also includes remote push button unit  60 . Remote push button unit  60  includes controls for engaging and releasing accessory tool  50 , and includes a means of cutting off all power for the entire ironworker system  40 , as will be more fully discussed below. An operator can use remote push button unit  60  to control the operation of accessory tool  50  without needing to be located proximate to ironworker  10 . In one embodiment, an operator can use remote push button unit  60  to execute the same functionality as available on the control panel  20  of ironworker  10 , such as the iron worker mode, the accessory mode and the auto cut mode. 
         [0018]      FIG. 3  illustrates further detail of remote push button unit  60  for use with accessory tool  50  in accordance with one embodiment. In one embodiment, remote push button unit  60  includes remote cable  62 , extend button  64 , retract button  66 , and emergency stop button  68 . In operation, once connected, remote push button unit  60  controls the functionality of ironworker  10  and accessory tool  50  out at remotely located accessory tool  50 . Pressing the extend button  64  will cause power from ironworker  10  to be delivered to accessory tool  50  causing it to extend and pressing retract button  66  will accordingly cause it to retract. In one embodiment, pressing emergency stop button  68  will not just stop power to accessory tool  50 , but will actually cut off all power to the entire ironworker system  40 , including ironworker  10 . Enabling emergency stop button  68  to cut off power to the entire system  40  provides added safety in cutting off power at the source to ensure complete power loss in the event of an emergency situation. 
         [0019]    Ironworker  10  can be provided by itself, without an accessory tool. When ironworker  10  is configured for use with accessory tool  50 , however, accessory harness  52  is hard-wired into ironworker  10 . As illustrated in  FIG. 3 , accessory harness  52  includes first and second hydraulic hoses  54  and  56 , which are coupled to accessory tool  50  to provide hydraulic power thereto. Accessory harness  52  also includes electrical cable  58 , which also includes female connector  58   a  out at its end intended for connection to accessory tool  50 . Remote cable  62  of remote push button unit  60  also includes male connector  62   a,  which is configured to plug into female connector  58   a  in one embodiment. In this way, remote push button unit  60  is electrically coupled back to ironworker  10  in order to control hydraulic power delivery, and potentially other control functions. 
         [0020]    Because ironworker  10  can be used directly without using accessory tool  50 , even when it is equipped to be used with accessory tool  50 , it is important to ensure that accessory tool  50  is properly assembled even when not in use. Accordingly, ironworker system  40  further includes safety plug assembly  70  in accordance with one embodiment. Safety plug assembly  70  is configured with male connector  70   a,  which is configured to plug into female connector  58   a  of accessory harness  52 . In one embodiment, power is cut off from the entire ironworker system  40  until one of either safety plug assembly  70  or remote cable  62  is plugged into accessory harness  52 . When safety plug assembly  70  is coupled to accessory harness  52 , emergency stop button  28  is functional and its actuation will cut off all power to ironworker system  40 . When remote cable  62  is coupled to accessory harness  52 , both emergency stop button  28  and emergency stop button  68  are functional and actuation of either will cut off all power to ironworker system  40 . This configuration prevents a situation where auxiliary harness  52  is mistakenly left active, but without the ability of an emergency stop function out at the remote control. The design also ensures that emergency stop button  28  is never disabled while the system is active, essentially providing redundant emergency stopping locations. 
         [0021]    In one embodiment, ironworker system  40  can be delivered to a customer with ironworker  10  and without accessory tool  50 , but including auxiliary harness  52 . In this way, the customer can attach an accessory tool  50  it already owns or that it later acquires. In such a case, the customer must attach safety plug assembly  70  in order to operate ironworker  10 , otherwise, system power is disabled. Once the customer adds accessory tool  50 , it can swap out safety plug assembly  70  for remote cable  62 , thereby enabling remote push button unit  60 , including emergency stop button  68 . 
         [0022]      FIG. 4  is a simplified electrical schematic illustrating aspects of ironworker system  40  in accordance with one embodiment. Control circuitry and most connections to various load components are eliminated in order to simplify the figure. In  FIG. 4 , ironworker  10 , accessory harness  52 , safety plug assembly  70  and remote push button unit  60  are illustrated in dotted lines so that some selected portions of the electrical connections within the various components are visible. Power supply  80  is located within ironworker  10 . Power supply  80  provides power to the entire ironworker system  40 , including its motor for the hydraulics and all system controls. The motor and other various loads in the system are represented by system load  81 , also illustrated as within iron worker  10 . In practice, system load  81  is made up of any of various motors, pressure switches, valves, lights and so forth, and they may be located within ironworker  10 , or out on accessory tool  50 , or at another location. For simplification of the figure, however, system load  81  is illustrated within ironworker  10 . 
         [0023]    As illustrated in  FIG. 4 , negative supply line  84  is coupled to the negative terminal of power supply  80  on one side and coupled to a first side of load (L)  81  on its other side. The second side of load (L)  81  is then routed from within ironworker  10  through accessory harness  52  out to first port  86  out at the end of accessory harness  52  in one embodiment. First port  86  is located at an end of accessory harness  52  that is configured to couple to either safety plug assembly  70  or remote push button unit  60 . Positive supply line  82  is coupled to the positive terminal of power supply  80  on one side and coupled to a first side of emergency stop button  28  on its other side. The second side of emergency stop button  28  is coupled to second port  88  of accessory harness  52 . Accordingly, pressing emergency stop button  28  breaks or electrically interrupts positive supply line  82 . Second port  88  is located adjacent first port at the end of accessory harness  52  that is configured to couple to either safety plug assembly  70  or remote push button unit  60 . As also illustrated in  FIG. 4 , safety plug assembly  70  and remote push button unit  60  are each configured with first and second ports  86  and  88 . In operation, either first and second ports  86  and  88  of safety plug assembly  70  or first and second ports  86  and  88  of remote push button unit  60  are coupled to first and second ports  86  and  88  of accessory harness  52 . Within the simplified schematic illustrated, coupling safety plug assembly  70  to accessory harness  52  closes the circuit between positive and negative supply lines  82  and  84 , thereby allowing power supply  80  to drive system load  81 . 
         [0024]    Similarly, coupling remote push button unit  60  to accessory harness  52  also closes the circuit between positive and negative supply lines  82  and  84 , as long as emergency stop button  68  has not been depressed, thereby allowing power supply  80  to drive system load  81 . Circuitry within the simplified version of remote push button unit  60  of  FIG. 4  that couples to extend and retract buttons  64  and  66  is eliminated in the figure for simplification. 
         [0025]    When neither safety plug assembly  70  nor remote push button unit  60  are coupled to accessory harness  52 , there is an open circuit between positive and negative supply lines  82  and  84  such that power supply  80  is disabled, and all system power for ironworker system  40  is cut off, thereby providing an extra measure of safety protection for system  40 . 
         [0026]      FIG. 4  also illustrates that emergency stop buttons  28  and  68  will always function to cut off all power to ironworker system  40 . When remote push button unit  60  is coupled to accessory harness  52 , actuation of either of emergency stop buttons  28  or  68  will create an open circuit in positive supply line  82  disabling the system. Because emergency stop buttons  28  or  68  are in series with each other relative to power supply  80 , pressing either one will create an open circuit condition. When safety plug assembly  70  is coupled to accessory harness  52  actuation of first emergency stop button  28  will create an open circuit in positive supply line  82  disabling the system. Because remote push button unit  60  is not connected in that condition, there is no possibility of operator confusion with respect to using emergency stop button  68 . Requiring connection of safety plug assembly  70  in order to allow the system to operate provides further safety in require purposeful action by the operator even when accessory tool  50  is not intended to be used. 
         [0027]    Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a variety of alternate and/or equivalent implementations may be substituted for the specific embodiments shown and described without departing from the scope of the present invention. This application is intended to cover any adaptations or variations of the specific embodiments discussed herein. Therefore, it is intended that this invention be limited only by the claims and the equivalents thereof.