AU2005204265B2 - An apparatus and method for angled perforation of sheet metal roof decking - Google Patents

Description

12511AU

ORIGINAL

Complete Specification Applicant: Fielders Australia Pty Ltd Title: An apparatus and method for angled perforation of sheet metal roof decking LESICAR PERRIN, 49 Wright Street, Adelaide, South Australia 5000, Australia Address for Service: The following statement is a full description of this invention, including the best method of performing it known to me/us: An apparatus and method for angled perforation of sheet metal roof decking The present invention relates to the production of sheet metal roof decking. In particular, the invention relates to an apparatus including a variable-angle punching assembly adapted to produce a perforated line in sheet metal at a pre-determined angle, and a method for using such an apparatus and the so produced sheet metal.

BACKGROUND OF THE INVENTION The present invention is primarily directed toward the manufacture of sheet metal decking for use in roofing, however, it is to be understood that this is by way of example only and the apparatus may equally well be used to produce alternately profiled panels for use in other applications such as walling or fencing.

Profiled sheet metal roofing is typically formed by way of roll-forming. Typically, sheet metal is fed from a coil supply through to an automated cutting assembly that serves to cut substantially rectangular panels from the sheet metal. Located further along the production line is a roll-forming assembly which includes a series of spaced apart rollers. The production line generally ends in a conveyer or stacking assembly used to stack the panels so that they may be easily stored and/or transported away.

The current applicant is the owner of a co-pending application entitled "An apparatus and method for the manufacture of roof cladding elements" which allows for corrugated sheet metal to be cut after the roll-forming process at pre-determined angles thereby overcoming the need for roof installers to cut the panels to their required shape whilst on the roof. This same problem extends to roof decking panels which are generally installed in the same way.

However, roof decking panels are generally made up of a series of disposed longitudinal flat portions separated by tapered portions and it would therefore not be practical to manufacture a blade capable of cutting such panels. For this reason, the apparatus of the co-pending application is not suited to cutting roof decking panels profiled in this manner. There is therefore a requirement in the industry for roof decking panels to be able to be cut to their required shape prior to installation, including those requiring angled edges.

Furthermore, a drawback is envisaged when using the apparatus of the co-pending application in that the panels produced are no longer large rectangular panels which are easily stacked and transported, but rather panels of various size and shape ranging from small corner panels to larger rectangular panels. Those skilled in the art would realise the difficulty in stacking and transporting such panels. Thus, as well as the requirement for roof decking panels to be manufactured off-site, there is the additional need for such panels to be easily bundled and more precisely ordered for ease of installation.

It is therefore an object of the present invention to overcome at least some of the aforementioned problems or to provide the public with a useful alternative.

SUMMARY OF THE INVENTION Therefore in one form of the invention there is proposed a punching assembly for use on a longitudinal strip of material, said punching assembly including: a support means adapted to support a punching means in a position to receive the longitudinal strip of material, said punching means being rotatable about a vertical axis of rotation relative to said support means and thereby adapted to produce a perforated line across said material along a pre-determined angle.

Preferably said punching means includes a plurality of upper punching members, and a base including a plurality of apertures correspondingly shaped and positioned to receive said upper punching members.

In preference when said upper punching members are made to engage corresponding base apertures, any portion of the strip of material in the path of the punching members is removed, thereby resulting in a plurality of spaced apart apertures across the strip of material whose shape is governed by the cross-sectional shape of each punching member.

In preference said perforated line includes a plurality of said spaced apart apertures.

In preference said strip of material is frangible along each perforated line by simple manual manipulation thereof.

Preferably said punching assembly includes a cutting means adapted to cut said strip of material along a pre-determined angle.

In preference said punching assembly includes a roll-forming means adapted to profile the strip in a longitudinal direction subsequent to the punching means.

Preferably the motion of the punching means and roll-forming means is controllable via a control means.

Advantageously said material is sheet-metal.

In a further form of the invention there is proposed an apparatus for manufacturing longitudinally profiled roof decking panels, said apparatus including: a coil supply for feeding a longitudinal sheet-metal strip; a punching assembly adapted to form a perforated line transversely across said strip along a pre-determined angle; and a roll-forming assembly for profiling the punched strip in the longitudinal direction.

In preference said apparatus includes a cutting means adapted to cut transversely across said strip at a pre-determined angle.

Advantageously a plurality of sheet-metal portions are cut using the cutting means, said portions including one or more roof-decking panels which are separated by the perforated lines formed by said punching assembly.

In preference said portions are frangible along each perforated line.

Preferably the plurality of sheet-metal portions are of substantially the same size so as to be easily stacked and transported.

In preference said apparatus includes a control means for controlling a range of operations including rate of coil supply, engagement of the punching assembly, and operation of the roll-forming assembly.

Preferably said apparatus includes a computing means including software capable of sending data to the control means, said data corresponding with information entered into the computing means.

In preference said data includes information relating to the leading edge angle, longitudinal length and trailing edge angle of each panel required to cover said roof.

Advantageously said apparatus includes a printing means for labelling each manufactured panel in accordance with its position on the roof.

In a still further form of the invention there is proposed a method of manufacturing longitudinally profiled panels, said method comprising the steps of: feeding a strip of material from a supply means; cutting a leading edge of a first panel using a cutting assembly; forming at least one perforated line across said strip, said lines defining the leading or trailing edge of at least one further panel; cutting a trailing edge of a final panel using said cutting assembly; and longitudinally profiling said portion of material through a roll-forming means.

In a yet further form of the invention there is proposed a sheet metal portion produced using the above claimed method, said sheet metal portion including: a leading edge; a trailing edge; a longitudinal profile; and at least one perforated line extending across said sheet metal portion at a pre-determined angle, said perforated line serving to define either the leading or trailing edge of individual panels forming part of said sheet metal portion.

BRIEF DESCRIPTION OF THE DRAWINGS The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate several implementations of the invention and, together with the description, serve to explain the advantages and principles of the invention. In the drawings, Figure 1 illustrates a perspective view of an apparatus for the manufacture of angle cut decking in accordance with the present invention, including a coil supply, a variable-angle punching assembly, and a roll-forming assembly; Figure 2 illustrates a top view of the variable-angle punching assembly of Figure 1 after having punched a perforated line at approximately 45 degrees into the longitudinal sheet metal; Figure 3 illustrates a partial perspective view of the punching components of the variable-angle punching assembly of Figures 1 and 2; Figure 4 illustrates a perspective view of the metal strip of Figure 2 having an angled perforated line extending across the strip; Figure 5 illustrates an enlarged partial perspective view of the perforations formed on the punched metal strip of Figure 4; Figure 6 illustrates a perspective view of the punched metal strip of Figures following longitudinal profiling through the roll-forming assembly of Figure 1; Figure 7 illustrates an enlarged partial perspective view of some of the perforations formed on the punched and longitudinally profiled metal strip of Figure 6; Figure 8 illustrates a perspective view of the punched and longitudinally profiled strip of Figures 6-7 after having been separated along its perforation(s); and Figure 9 illustrates an enlarged partial perspective view of the cut metal strip of Figure 8.

DESCRIPTION OF THE PREFERRED EMBODIMENTS The following detailed description of the invention refers to the accompanying drawings. Although the description includes exemplary embodiments, other embodiments are possible, and changes may be made to the embodiments described without departing from the spirit and scope of the invention. Wherever possible, the same reference numbers will be used throughout the drawings and the following description to refer to the same and like parts.

The present invention is related to an apparatus 10 for the manufacture of roof decking panels for a house or other like structure, including panels having angled edges and straight edges. A coiled strip of sheet metal 12 is fed through a production line from a coil supply 14 to a variable-angle punching assembly 16, and further to a roll-forming assembly 18. Each punching sequence undertaken by the variable-angle punching assembly 16 produces a single perforated line across the width of the sheet metal 12 along a predetermined angle. When rotation of the punching assembly 16 and the feed of sheet metal 12 through the production line are controlled, perforated lines may be produced on the metal which define the leading and trailing edge of decking panels to be installed onto a roof. The roll-forming assembly 18 is then used to profile the sheet metal into the style of roof decking required and individual roof decking panels may then be detached from the profiled metal by simple manual manipulation across the perforations. Those skilled in the art would realise the advantages that such an apparatus may offer in that an easily transportable bundle of punched and profiled sheet metal portions may be formed. Each portion will include one or more decking panels whose edges are defined by perforated lines, each panel being separated prior to installation.

Although not shown, the production line should also include a means to cut the metal strip 12 into the portions mentioned above. Also, at the end of the production line there may be a conveyer or other transportation means for transporting the resulting portions away from the production line. It is to be further understood that the present invention may equally well be used in the manufacture of a range of alternately profiled sheet metal panels by simple modification to the roll-forming assembly.

The variable-angle punching assembly 16 can be seen clearly in Figures 1 and 2. The assembly 16 is positioned directly following the coil supply 14 and is mounted above a support 20. The assembly 16 includes a substantially rectangular housing or frame 22 mounted above a mechanical turntable 24 rotatable about a fixed centre of rotation 26. A drive motor 28 causes a first cog 30 to rotate which in turn causes the turntable 24 to rotate, the first cog 30 and turntable 24 being in communication with one another through a chain or belt 32. Two further spaced apart cogs 34 and 36 are used as guides for the chain 32 to ensure that it is maintained on its required path.

It is to be understood that when the turntable 24 is made to rotate, the entire housing 22 rotates with it, and thus the punching angle depends on the extent of rotation of the turntable 24. Further, the drive motor 28 is configured such that turntable 24 may rotate both clockwise and anti-clockwise depending on the desired punching angle. For the purposes of this invention, when the variable-angle punching assembly is aligned perpendicularly to the direction of the production line, that is, to produce a rectangular panel, for the purposes of this invention this angle is defined as 0 degrees. Thus, the assembly 16 as shown in Figure 1 is positioned to punch a straight edge along 0 degrees whilst in Figure 2, the assembly 16 is positioned to punch an angled edge of approximately 45 degrees.

The rectangular frame 22 generally surrounds the metal strip 12 as it moves through the production line. Obviously, the width of the frame is enough to ensure that the frame 22 is capable of rotating about the centre of rotation 26 to an appropriate angle without contacting the sides of the metal strip 12. The extent of rotation of the turntable 24 is preferably controlled so that this does not occur. Generally, roof decking panels do not require angled edges of greater than 45 degrees and so a maximum rotation of the frame of degrees is typically sufficient. Of course, the apparatus may punch at larger angles if required.

The variable-angle punching assembly 16 also includes a roller 38 to support and guide the metal strip 12 through the assembly 16. Although not shown, the apparatus 10 may well include further guiding means at various points along the production line, such as conveyers.

The components and mechanisms for punching the metal will now be described with particular reference to Figures 1-3.

Housed within the upper portion of the frame 22 is a punch mounting plate 40 which is moveable in a vertical direction, this movement governed by the movement of three hydraulic pistons 42, 44 and 46 mounted above the frame 22. Extending from the underside of the punch mounting plate 40 is a series of spaced apart punching members 48. Each of the punching members 48 need to be capable of cutting into the metal and therefore may include bevelled edges. Housed within the lower portion of the frame 22 is a punch base plate including a series of apertures 52 which are correspondingly shaped with the punching members 48 for insertion therethrough upon downward movement of the punch mounting plate 40. It is to be understood that the number of pistons, and number and configuration of punching members 48 and corresponding apertures 52 may well vary in accordance with specific user requirements.

Activation of the punching assembly 16 is quite simple in that when a required length of sheet metal 12 has been fed through the frame 22, the pistons 42, 44 and 46 are activated to thereby punch through the sheet 12 as is well known to those skilled in the art. The resulting pattern in the sheet metal 12 is a line of apertures or perforations 54 whose size and shape is governed by the cross-section of the punching members 48. The size of the perforations 54 and the distance between them should be measured to ensure that the roll-forming process would not force the perforations apart, but also that it is not too difficult to then manually separate the panels. It is envisaged that for a typical width of sheet metal, perforations of approximately 2-3 mm in length which are separated by approximately 1mm are appropriate.

Also, although not shown there is preferably a collection tray positioned appropriately underneath the punch base plate 50 for collection of the metal pieces that have been punched out of the sheet metal strip 12.

The required length of sheet metal fed through the frame 22 may be determined either by manually measuring the length of metal required, or in the case of automated production lines, this length as well as other information would simply be entered into a processor or like device which then activates the coil supply 14 and various conveyers (not shown) in the production line to feed through the required length, as is discussed further below. Illustrated in Figures 4-5 is a portion 56 of sheet metal 12 including an angled perforated line 58 produced by the variable-angle punching assembly 16.

As those skilled in the art would no doubt realise, in their rest positions, the pistons 42, 44 and 46 are in a position such that the punching members 48 and apertures 52 are not engaged, that is, the punch mounting plate 40 is maintained in its upper position.

It is to be understood that the apparatus 10 may well include two or more such punching assemblies, one variable-angle punching assembly 16 and a punching assembly (not shown) that is fixed perpendicularly to the direction of the production line. In a production line of this sort, efficiency is crucial and having one assembly for straight punches and another for angled punches would prevent a single assembly from having to continuously rotate to accommodate for different angles.

As previously mentioned, following the variable-angle punching assembly is a rollforming assembly 18 where the now perforated metal strip 12 is profiled in the longitudinal direction. Roll-forming assemblies 18 are typically made up of an arrangement of rollers 60 in between which the strip 12 is made to travel. It is the contour of the roller wheels 62 which gives the metal strip 12 its longitudinal profile. This is typically a progressive process in that the first rollers significantly profile only the inner part of the strip 12 while the rollers further in the production line extend the total width of the strip 12 so that at the end of the rollforming process, a uniformly profiled strip emerges. Those skilled in the art would realise that if the entire profile were applied across the entire width of the strip 12 at once, then the corrugations would not be formed correctly.

In the case of roof-decking panels, the profile typically comprises a series of longitudinal flat portions 64 separated and disposed by longitudinal tapered portions 66. This can perhaps best be appreciated in Figures 6-7 which illustrates a portion 68 of sheet metal including a perforated line 70 produced by the variable-angle punching assembly 16, as well as the profiled portions described resulting from the roll-forming process.

The benefits of using the apparatus 10 of the present invention should now be realised. Not only does the apparatus 10 allow for roof decking panels requiring angled edges to be manufactured off-site, it also allows for a plurality of perforated and profiled sheet metal portions, such as portion 68 described above, to be bundled and transported to a home where the portion may then be separated into individual roof decking panels. For example, portion 68 may well include three or even four roof decking panels separable along individual perforated lines.

Each panel may be separated by manual manipulation or by some other form of separating means. Figures 8-9 illustrate portion 68 having been cut along the perforated line into individual portions 68a and 68b. Those skilled in the art would realise that the apertures 54 formed in each perforated line are separated by only a short distance, thereby making portion 68b easily separable from portion 68a. For example, they may be separated by simply lifting portion 68b whilst portion 68a is maintained flat. The metal which was once linking portions 68a and 68b leave a somewhat coarse edge which may then be filed down to produce a straight edge, or alternatively left alone. Roof decking panels having coarse angled edges will not adversely affect roof performance.

As mentioned, in order to create such portions, the sheet metal needs to be cut and the apparatus 10 therefore requires some form of cutting means. A further embodiment of the invention (not shown) may include a variable-angle punching assembly in combination with a cutting assembly. For example, as well as being rotatable, the frame 22 may also be slideable to thereby shift between a punching and cutting assembly.

Further, in producing portions of perforated and profiled sheet metal, it would be advantageous to an installer for each panel to be labelled in accordance with its position on the roof. A printer may be located along the production line before or after the roll-forming assembly 18 to perform this task. Another advantage that the present invention provides is that roof decking panels adapted to be mounted adjacent one another on a roof may be manufactured, labelled and bundled accordingly in order to make the job of the installer easier.

In fact, an entire process of punching, cutting and forming all roof decking panels necessary for a home, including angled panels, may be achieved using the apparatus 10 of the present invention. It is envisaged that the apparatus 10 will include an appropriate processor (not shown) and control means (not shown) whereby relevant information relating to the leading edge angle, longitudinal length, and trailing edge angle of each panel may be entered, processed and performed. For example, the processor may include software that communicates with the control means for controlling each and every step of the process including feed of sheet metal, rotation of the turntable 24, activation of various pistons for punching the metal 12, activation of the rollers 60, and various other actions required of the apparatus 10. Those skilled in the art would realise that the processor and control panel and associated equipment may be used to make the cutting, punching and forming procedure completely automated.

Thus for example, one may input a roof pitch angle into the processor, and preferably, the processor will automatically determine the number and configuration of panels that are required and further instruct the various assemblies in the production line to produce sheet metal portions having perforations corresponding with the shape and configuration of panels required. Those skilled in the art would realise the immense advantage this provides in that each perforated and profiled portion may then be bundled according to their position, transported to a work site, and separated into individual panels to be mounted directly onto the roof.

The present invention thus provides for a more effective way of manufacturing and installing roof decking panels. It is to be understood that each component in the apparatus comprises numerous bolts, grub screws and other like means of connection, these not being explicitly referred to or described herein.

Further advantages and improvements may very well be made to the present invention without deviating from its scope. Although the invention has been shown and described in what is conceived to be the most practical and preferred embodiment, it is recognized that departures may be made therefrom within the scope and spirit of the invention, which is not to be limited to the details disclosed herein but is to be accorded the full scope of the claims so as to embrace any and all equivalent devices and apparatus.

Dated this 26 August 2005 Fielders Australia Pty Ltd By their Patent Attorneys LESICAR PERRIN

Claims (18)

1. A punching assembly for use on a longitudinal strip of material, said punching assembly including: a support means adapted to support a punching means in a position to receive the longitudinal strip of material, said punching means being rotatable about a vertical axis of rotation relative to said support means and thereby adapted to produce a perforated line across said material along a pre-determined angle.

2. A punching assembly as in claim 1 further including a plurality of upper punching members, and a base including a plurality of apertures correspondingly shaped and positioned to receive said upper punching members.

3. A punching assembly as in claim 2 wherein when said upper punching members are made to engage corresponding base apertures, any portion of the strip of material in the path of the punching members is removed, thereby resulting in a plurality of spaced apart apertures across the strip of material whose shape is governed by the cross-sectional shape of each punching member.

4. A punching assembly as in any one of the above claims wherein said perforated line includes a plurality of said spaced apart apertures. A punching assembly as in claim 1 wherein said strip of material is frangible along each perforated line by simple manual manipulation thereof.

6. A punching assembly as in any one of the above claims wherein said punching assembly includes a cutting means adapted to cut said strip of material along a pre- determined angle.

7. A punching assembly as in any one of the above claims wherein said punching assembly includes a roll-forming means adapted to profile the strip in a longitudinal direction subsequent to the punching means.

8. A punching assembly as in any one of the above claims wherein the motion of the punching means and roll-forming means is controllable via a control means.

9. A punching assembly as in any one of the above claims wherein said material is sheet-metal. An apparatus for manufacturing longitudinally profiled roof decking panels, said apparatus including: (-i a coil supply for feeding a longitudinal sheet-metal strip; ;a punching assembly adapted to form a perforated line transversely across said strip along a pre-determined angle; and a roll-forming assembly for profiling the punched strip in the longitudinal direction. t 11. An apparatus as in claim 10 including a cutting means adapted to cut transversely ID across said strip at a pre-determined angle.

12. An apparatus as in claim 11 wherein a plurality of sheet-metal portions are cut using t 10 the cutting means, said portions including one or more roof-decking panels which are Sseparated by the perforated lines formed by said punching assembly. (-i

13. An apparatus as in claim 11 or 12 wherein said portions are frangible along each perforated line.

14. An apparatus as in any one of claims 11 to 13 wherein the plurality of sheet-metal portions are of substantially the same size so as to be easily stacked and transported An apparatus as in claim 10 wherein said apparatus includes a control means for controlling a range of operations including rate of coil supply, engagement of the punching assembly, and operation of the roll-forming assembly.

16. An apparatus as in claim 10 further including a computing means including software capable of sending data to the control means, said data corresponding with information entered into the computing means.

17. An apparatus as in claim 15 wherein said data includes information relating to the leading edge angle, longitudinal length and trailing edge angle of each panel required to cover said roof.

18. An apparatus as in claim 10 further including a printing means for labelling each manufactured panel in accordance with its position on the roof.

19. A method of manufacturing longitudinally profiled panels, said method comprising the steps of: a) feeding a strip of material from a supply means; b) cutting a leading edge of a first panel using a cutting assembly; 14 c) forming at least one perforated line across said strip, said lines defining the leading or trailing edge of at least one further panel; d) cutting a trailing edge of a final panel using said cutting assembly; and e) longitudinally profiling said portion of material through a roll-forming means. A sheet metal portion produced using the above claimed method, said sheet metal portion including: a leading edge; a trailing edge; a longitudinal profile; and at least one perforated line extending across said sheet metal portion at a pre- determined angle, said perforated line serving to define either the leading or trailing edge of individual panels forming part of said sheet metal portion.

21. An apparatus substantially as hereinbefore described with reference to the accompanying drawings.

22. A sheet metal portion substantially as hereinbefore described with reference to the accompanying drawings.

23. A method of manufacturing a longitudinal sheet metal portion substantially as hereinbefore described with reference to the accompanying drawings.