| Center shifted roll forming -> Monitor Keywords |
|
|
 
Center shifted roll formingRelated Patent Categories: Metal Deforming, With Use Of Control Means Energized In Response To Activator Stimulated By Condition Sensor, Metal Deforming By Use Of Roller Or Roller-like Tool Element, Including Use Of Sensor Responsive To Information Carried By Removable Auxiliary Record (e.g., Recording Disk, Tape, Or Card)Center shifted roll forming description/claimsThe Patent Description & Claims data below is from USPTO Patent Application 20070125143, Center shifted roll forming. Brief Patent Description - Full Patent Description - Patent Application Claims
CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This is a continuation-in-part of application Ser. No. 10/896,257, filed Jul. 21, 2004, now abandoned. BACKGROUND OF THE INVENTION [0002] This invention relates generally to an improved roll forming mechanism. And, more particularly, this invention relates to the forming of malleable materials, such as tubes, strips, sheets, webbing, and similar materials into a curvilinear profile, using a roll form machine known to industry, wherein two parallel cylinders selectively act as both a forming mandrel and a forming tool. [0003] As designs in numerous industries become more organic and irregular, having non-repeating patterns and complex shapes (designed to increase strength, increase beauty, maximize performance, or provide clearance), devices are required to form these complex shapes and underlying frameworks. Industries employing these complex design profiles include the aerospace, construction, process industries, and many others. [0004] Current roll form devices, utilizing parallel cylinders, tend to focus on forming repeating or regular patterns in the material, wherein the forming mandrel diameter determines primarily the diameter of the corrugation pattern and the bend angle being primarily determined by the angular displacement of the forming tool around the forming mandrel. These devices are limited in the shapes that can be produced. More complex shapes required in modern industry are not possible with current roll forming means [0005] For instance, in the aerospace industry, it is common to utilize I-beam like structural members having a curvilinear web extending normally between a top and bottom flange. The generally curvilinear profile of the web provides increased strength to weight performance, improved stiffness, and decreased volume. Additionally, in order to accommodate the aircraft wiring harness, hydraulic and fuel lines, as well as immediate strength and volume requirements, the geometry of the web may greatly vary in profile from one point to another down the beam, creating a potentially non-repeating, complex web corrugation pattern. [0006] Currently, structural members are generally constructed from metal or composite materials. With either choice of material, the construction of a structural member with a curvilinear web is a challenge, in maintaining quality, tolerances, and minimizing costs. With the high cost of manufacturing composite structural members, due to the labor intensive techniques utilized, it is often more economical and practical to use metals, such as titanium and aluminum, to construct curvilinear structural members, when the design allows for it. [0007] What is needed is a device that can quickly and economically produce complex curvilinear patterns in malleable materials, especially in metals. What is further needed is a device that can produce a bending radius that is approximately equal to or greater than the forming mandrel. What is additionally needed is a device that can be programmed to bend a complex series of radii or planar sections along a material. SUMMARY OF THE INVENTION [0008] In accordance of the present invention, a roll forming machine capable of quickly and economically producing complex curvilinear patterns in malleable materials is provided. The present invention further provides a device that can produce a bending radius that is approximately equal to or greater than the forming mandrel. The present invention again further provides a device that can be programmed to bend a complex series of radii or planar sections along a material. [0009] The present invention provides a bending machine for strip, webbing, or rod material comprising: [0010] an electronic control means, the electronic control means storing and executing a set of instructions, the set of instructions directing a material feed rate, the set of instructions also directing an angular displacement; [0011] a first cylinder; and a second cylinder, the second cylinder positioned parallel to the first cylinder, the first cylinder and the second cylinder each acting selectively as a forming mandrel or a forming tool, the forming mandrel being held stationary, the forming tool revolving about the forming mandrel with the angular displacement; [0012] an angular displacement means, the angular displacement means being coupled with the forming tool and the forming mandrel, the angular displacement means variably affecting the angular displacement of the selected forming tool continuously, the angular displacement means being responsive to the electronic control means; [0013] a feeding means, the feeding means variably controlling the feed rate of the material continuously, the feeding means being responsive to the electronic control means; [0014] wherein a curvilinear profile of a varying radii is formed in at least a portion of the material by varying the feed rate and the angular displacement, from zero to a maximum, each formed radius of the curvilinear profile being equal to or greater than a forming mandrel radius. [0015] The present invention can form complex curvilinear profiles in materials by adjusting the feed rate of the material and the angular displacement of the forming tool. For example, if a formed radius that is larger than the forming mandrel is required, the angular displacement can be held constant while the material is advanced. Or, if a complex curve (second, third, or nth order equation) is required, the feed rate and the angular displacement can be adjusted simultaneously. For a small radius with a sharp bend angle, it may be necessary to slow the feed rate while increasing the angular displacement. Along the length of the material, the radius and bend angle can be varied, the present invention transitioning easily from one portion of a complex curve to another. Many complex shapes are possible with the present invention, through controlled variations in material feed rate and angular displacement. [0016] Numerous common designs for the roll form machine utilizing the selectively alternating cylinders are well known in industry and need not be described further in detail, the particular mechanism being shown in the proceeding description being for illustrative purposes only. The unique combination and usage of the components of the present invention provide the unexpected and unique result of a complex curvilinear profile in a formed material, with varying radii and bending angles. [0017] The angular displacement means can be any number of mechanisms that serve to selectively hold the forming mandrel stationary while rotating the forming tool in an orbit around the forming mandrel. For instance, the angular displacement means can be a mechanical device such as a geared mechanism, a pneumatic device, an actuated device, or a similar mechanism. The exact mechanism to affect the degree of orbit of the selected forming tool is not central to the present invention, and is compatible with any such mechanism that can receive a command from the electronic control means of the present invention and adjust the angular displacement accordingly. The angular displacement, sector of the orbit over which the forming tool is rotated, can be held at any degree between zero and the maximum degree of orbit. Additionally, the angular displacement can be continuously adjusted throughout the forming process, to create varying bend angles and radii. [0018] The electronic control means can be any device (such as a computing means or similar) that can store a set of instructions, then communicate a signal, correlating to those instructions, to the angular displacement means and the feeding means, the set of instructions determining the feed rate of the material and the angular displacement of the forming tool. The set of instructions are developed to create a series of radii in a material. This set of instructions can be entered into the computing means manually by an operator; or the set of instructions can be imported from a CAD/CAM system, wherein a solid model or other compatible technology is translated into the afore mentioned set of instructions. [0019] The feeding means can be any number of devices known to industry and designed to advance a material into the bending machine, such as a roller mechanism. The present invention is compatible with any feeding mechanism that can receive a command from the electronic control means of the present invention and adjust the feed rate accordingly. [0020] The present invention can operate in several modes, depending on the shape being formed, the properties of the material be formed, or other design demands. The angular displacement and the feed rate can be varied simultaneously; the angular displacement can be held constant and the feed rate varied; and the angular displacement can be varied and the feed rate held constant. Through a combination of these modes, complex formed shapes can be achieved. [0021] Additionally, the roll form machine of the present invention can be used in conjunction with an inspection means. Upon completion of the roll form process, the formed section of the material can be inspected with known inspection techniques. If the curvilinear shape is found to be out of compliance or approaching this limit, adjustments can be made to the forming process, either manually or automatically (through proportional control or similar), to correct the error. [0022] A method for the manufacture of curvilinear profile strip, webbing, or rod material using a bending machine of the present invention is provided comprising the steps of: [0023] a) receiving a set of instructions from an electronic control means, the electronic control means storing and executing the set of instructions, the set of instructions commanding an angular displacement for each instant and a feed rate for each instant of the bending process; [0024] b) inserting the material between a first cylinder and a second cylinder being in parallel orientation, the first cylinder and the second cylinder each acting selectively as a forming mandrel or a forming tool, the forming mandrel being held stationary, the forming tool be capable of revolving about the forming mandrel at the angular displacement; and [0025] c) advancing the material at the feed rate and revolving the forming mandrel at the angular displacement. [0026] In the case of the manufacture of a titanium webbing for application in aerospace, the design of the webbing is created, taking into account the strength requirements of the structural member and interferences with nearby structures and components. The final webbing design, in this exemplified case, is a complex series of curves of varying radii and planar sections, forming a curvilinear profile. This complex curvilinear profile can be created accurately by the roll form device of the present invention. [0027] For each radius defined in the design, there is a corresponding material feed rate and angular displacement of the forming tool. The angular displacement of the forming tool can vary from zero to a maximum; and the feed rate can vary continuously from a reverse maximum to a forward maximum. This feed rate and angular displacement data can be entered into the electronic control means as a set of instructions, such as a computer, CNC device, or the like. The set of instructions consists of an instantaneous feed rate (the feed rate required at each point along the length of the webbing) and an instantaneous angular displacement (the angular displacement required at each point along the length of the webbing) correlating to each said radius of the curvilinear profile. The electronic control means produces a signal or series of signals correlating to the set of instructions, received in turn by the feeding means and angular displacement means, the feeding means altering feed rate according to instructions and the angular displacement means altering the angular displacement according to instructions. [0028] A sheet of titanium material is fed into the roll form machine, being advanced by the feeding means and inserted between the forming mandrel and the forming tool. Several options are available to create a complex webbing profile, depending on the instant radius, the instant bend angle, and how the instant bend transitions to and from contiguous bends, the instant bend being defined as the bend presently being formed. [0029] The first option is to maintain a constant feed rate while varying the angle. In other words, the forming tool is transitioning from one angular position to another, in rotation about the forming mandrel, while the material is being advanced forward at a constant feed rate. One resultant shape of this method could be a curvilinear profile whose curvature varies along the material. Continue reading about Center shifted roll forming... Full patent description for Center shifted roll forming Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Center shifted roll forming patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. Start now! - Receive info on patent apps like Center shifted roll forming or other areas of interest. ### Previous Patent Application: Method of improving the properties of urea granules Next Patent Application: Rolling mill Industry Class: Metal deforming ### FreshPatents.com Support Thank you for viewing the Center shifted roll forming patent info. IP-related news and info Results in 0.13089 seconds Other interesting Feshpatents.com categories: Tyco , Unilever , Warner-lambert , 3m 174 |
 * Protect your Inventions * US Patent Office filing 
PATENT INFO |
|
