Abstract:
A bending device for forming a product from a workpiece includes a shaft driven to rotate by a motor, an actuator including an extendable end configured to secure a portion of the workpiece, and a die coupled to the shaft and driven about an axis. The die includes a peripheral portion including a channel configured to receive the workpiece. The channel includes a first end and a second end offset from the first end in a direction parallel to the axis. Rotation of the die about the axis causes the workpiece to bend along the channel.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims the benefit of prior-filed, co-pending U.S. Provisional Patent Application No. 62/343,391, filed May 31, 2016, the entire contents of which are incorporated by reference. 
     
    
     FIELD 
       [0002]    The present disclosure relates to bending tools, and particularly to a channel bender. 
       SUMMARY 
       [0003]    Fiber cable, such as all-dielectric self-supporting (ADSS) cable, is typically used for building and/or connecting fiber optic networks. An ADSS cable provides simple installation for distribution and transmission environments, since no support or messenger wire is required. Since it is not conductive, the ADSS cable may be used above ground neutral. A bracket may be provided for aerially storing and protecting an additional or reserve length of the cable and any associated splice points. 
         [0004]    In one aspect, a bending device for forming a product from a workpiece includes a shaft driven to rotate by a motor, an actuator including an extendable end configured to secure a portion of the workpiece, and a die coupled to the shaft and driven about an axis. The die includes a peripheral portion including a channel configured to receive the workpiece. The channel includes a first end and a second end offset from the first end in a direction parallel to the axis. Rotation of the die about the axis causes the workpiece to bend along the channel. 
         [0005]    In another aspect, a bending device for bending a workpiece includes a motor, a shaft coupled to the motor and driven to rotate by the motor, a block, a ram configured to secure a portion of the workpiece against the block, a die coupled to the shaft and driven about an axis, and a roller. The ram includes an extendable end. The die includes a peripheral portion including a channel configured to receive the workpiece. The channel includes a first end and a second end offset from the first end in a direction parallel to the axis. The roller is positioned adjacent a portion of the channel, and the roller is configured to bias the workpiece against a wall of the channel as the die rotates. 
         [0006]    In yet another aspect, a method for forming a cable storage bracket includes: positioning a portion of a workpiece within a channel of a die; securing a portion of the workpiece against movement; positioning a biasing member against the workpiece to bias the workpiece against a wall of the channel; and rotating the die about an axis to bend the workpiece to a configuration in which one end of the workpiece is bent about the axis beyond the other end of the workpiece, the one end being offset from the other end in a direction parallel to the axis. 
         [0007]    Other aspects of the application will become apparent by consideration of the detailed description and accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]      FIG. 1  is a perspective view of a bending device. 
           [0009]      FIG. 2  is a perspective view of the bending device of  FIG. 1 . 
           [0010]      FIG. 3  is a perspective view of a portion of a bending device. 
           [0011]      FIG. 4  is a perspective view of a die for the bending device of  FIG. 3 . 
           [0012]      FIG. 5  is a perspective view of a workpiece formed by the bending device of  FIG. 1 . 
           [0013]      FIG. 6  is a plan view of a cable storage bracket. 
           [0014]      FIG. 7  is a perspective view of a die according to another embodiment. 
           [0015]      FIG. 8  is a plan view of the die of  FIG. 7 . 
           [0016]      FIG. 9  is a side elevation view of the anvil of  FIG. 7 . 
           [0017]      FIG. 10  is a perspective view of the anvil of  FIG. 7  with an internal gear removed. 
       
    
    
     DETAILED DESCRIPTION 
       [0018]    Before any embodiments are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The disclosure is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. The terms “mounted,” “connected” and “coupled” are used broadly and encompass both direct and indirect mounting, connecting and coupling. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings, and can include electrical or hydraulic connections or couplings, whether direct or indirect. Also, electronic communications and notifications may be performed using any known means including direct connections, wireless connections, etc. 
         [0019]      FIGS. 1 and 2  illustrate a bending device  10  for bending a workpiece  12  to form, e.g., a bracket  14  ( FIG. 6 ) for storing a length of wire or cable, e.g., fiber optic cable (not shown). The device  10  includes a shaft  18 , a motor  22  coupled to the shaft  18 , a block  26 , a ram  30 , and a mandrel or die  34 . The shaft  18  defines an axis of rotation  38  and is rotated about the axis  38  by the motor  22 . The block  26  is positioned adjacent an end of the die  34 , and the ram  30  includes an end  42  that is extendable to engage the block  26 . In the illustrated embodiment, the ram  30  is a linear actuator (e.g., a hydraulic cylinder). 
         [0020]    As shown in  FIGS. 3 and 4 , the die  34  has a round profile and includes a channel  50  extending along an outer periphery. The channel  50  extends in a generally helical shape around the axis of rotation  38  and includes a first end  54  and a second end  58 . In the illustrated embodiment of  FIGS. 3 and 4 , the channel  50  extends through one full revolution around the axis  38 , and the first end  54  is positioned adjacent the second end  58 , although the first end  54  and the second end  58  are offset from one another in a direction parallel to the axis  38 . In some embodiments ( FIGS. 1 and 2 ), the channel may not form a closed profile and the first end and second end may not be positioned adjacent one another. 
         [0021]    As shown in  FIGS. 1 and 2 , the helical shape of the channel  50  creates an axial offset between the ends of a workpiece  12 , permitting the ends of the workpiece  12  to be over bent, or bent beyond the point at which the two ends will be positioned adjacent one another. In the illustrated embodiment, the channel  50  is positioned between an upper flange  62  and a lower flange  66 . The flanges  62 ,  66  can control swedging or movement of the workpiece  12  during bending to ensure that the workpiece  12  is bent along the desired profile. In the illustrated embodiment, a roller  70  ( FIGS. 1 and 3 ) is positioned adjacent the die  34 , and the workpiece is positioned between the roller  70  and the die  34 . The roller  70  biases the workpiece  12  against the die  34  as the die  34  rotates. 
         [0022]    To form the bracket  14 , an end of an elongated workpiece  12  ( FIG. 1 ) is positioned within the channel  50  on the outer surface of the die  34 . In one embodiment, the workpiece  12  is formed from aluminum. The ram  30  is extended to retain a portion of the workpiece  12  against the block  26 . Then, the motor  22  is actuated to rotate the shaft  18 , thereby driving the die  34  about the axis  38 . In the illustrated embodiment, the ram  30  and die  34  are secured to the same support member  72  ( FIG. 1 ), and both the ram  30  and the die  34  are rotated by the shaft  18  about the axis  38  (for example, as shown in  FIG. 1 , the ram  30  and die  34  may rotate in a clockwise direction as viewed from the top of the axis  38 ). In the illustrated embodiment, the roller  70  and the associated biasing structure remain stationary as the die  34  rotates. As the die  34  rotates, the workpiece  12  is bent or wrapped around the outer periphery of the die  34  (e.g., by the roller  70 ). The workpiece  12 ′ ( FIG. 1 ) is bent such that one end is positioned adjacent an opposite end of the workpiece  12 ′, but is bent or rotated beyond the opposite end. 
         [0023]    When the ram  30  is retracted away from the block  26 , the ends of the workpiece  12  may spring back such that the ends do not overlap one another to the extent shown in  FIGS. 1 and 2 . As shown in  FIG. 5 , the workpiece  12  is removed from the die  34 . Referring now to  FIG. 6 , braces or cross-members  74  are positioned across the workpiece  12  to extend between the sides of the workpiece  12 . The end of each cross-member  74  is joined (e.g., by welding) to one side of the workpiece  12 , forming the bracket  14  as shown in  FIG. 6 . The cross-members  74  provide reinforcement and increase the rigidity and strength of the bracket  14 . 
         [0024]    The storage bracket  14  includes a first end where the two ends of the workpiece  12  are brought together and a second end opposite the first end. In the illustrated embodiment, the storage bracket  14  forms a teardrop shape, with the first end forming a wedge portion  82  and the second end forming a round portion  86 . The diameter of the round portion  86  is dependent on, among other things, the stiffness of the workpiece material and the workpiece&#39;s moment of inertia. The amount of spring back of the workpiece  12  can be controlled, and the bracket  14  may be formed without the need to weld the ends of the workpiece  12  together. The overbending of the workpiece  12  also reduces or eliminates weld cracking on the cross-members  74 . 
         [0025]      FIGS. 7-10  illustrate a die  434  according to another embodiment. The die  434  of  FIGS. 7-10  is similar to the die  34  of  FIG. 4 , and similar features are identified with similar reference numbers, plus  400 . In particular, the die  434  includes a channel  450  only including a lower flange  466  without an upper flange. In addition, the die  434  includes an internal gear surface or spline  490  that meshes with a pinion gear  494  coupled to the shaft  418 . In other embodiments, the die  434  may be coupled to the shaft  418  in a different manner. 
         [0026]    As shown in  FIG. 9 , the helical shape is defined by the channel  450 . For example, the pitch of the bent workpiece  12  is determined by the web height and the axial offset between the first end  454  and the second end  458  of the channel  450 . 
         [0027]    Although certain aspects have been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of one or more independent aspects as described. Various advantages and features are set forth in the following claims.