CA2154816C - Roll forming apparatus and method - Google Patents

Abstract

A roller die apparatus supporting a plurality of pairs of roller dies in predetermined clearances for processing a web workpiece, and for varying the clearances between the dies to accomodate variations in the thickness of a web workpiece and having first and second roller dies rotatably mounted on respective roller die bearings, one of the first and second roller dies being moveable both transversely to its axis of rotation, and axially along its axis of rotation, thereby achieving adjusting of the die clearance by movement along a generally diagonal axis between the first and second roller dies.
The method of forming a web workpiece by the use of such diagonal adjustment of the dies is also described.

Description

FIELD OF THE INVENTION
The invention relates to roll forming machinery, of the type used for continuously working and/or forming, a continuous strip or web of sheet material, and in particular, to such roll forming machinery in which the spacing between the rolls can be adjusted for variations in the thickness of the web, or the width of the web.
BACKGROUND OF THE INVENTION
Roll forming machinery is well known, for forming web strip materials of a variety of different types and compositions. Typical applications include the roll forming of metal web material. The roll forming machine has a plurality of sets of rolls, usually arranged in upper and lower pairs, and usually spaced apart along the length of the machine on what are known as roller stands.
Typically, the roller dies at one stand will produce a continuous formation in the web, and the roller dies of the next stand will for example increase the angle of the formation which has already been started at the previous stand and so on. Several different formations can be formed, in sequence, in most machines.
A wide variety of commercial and other products are made on such roll forming machines, such as roof decking, siding, and a large number of components for consumer equipment. The shapes may simply be webs with edge formations formed along one edge or both, or may be C sections or U sections, but in many cases consist of relatively complex formations with longitudinal formations being formed along the length of the web, side by side. Such formed web is finally cut off after the formations are complete, into predetermined lengths, and the lengths are then stacked and shipped out to a purchaser.
Generally speaking at each stand of rolls there are two lower dies and two upper dies arranged in pairs, to form folds, indentations, bends, and the like in the web on either side of a central web axis, simultaneously. The lower dies engage the underside of the web and the upper dies engage the upper side of the web. The dies are formed as annular or circular shapes, and are mounted on rotatable axles so that as the web passes between them the dies can rotate at the same speed as the sheet metal.
A gear drive mechanism is coupled to the dies so as to drive them at the speed of the sheet metal.
Each set of such roller dies must be designed to provide a particular formation in the web. In addition, each pair of dies must have a clearance between them which is dete, mined by the thickness of the web.
Thus where it is desired to discontinue working on a web of one thickness, and to then run a web of another thickness through the dies on the roller die stands, each pair of roller dies must be readjusted to a new clearance, to accommodate the new thickness of the new web. This involves costly down time, and skilled machinists are required in order to perform the fine adjustments.
It is not necessary to change the dies themselves, where the formations to be prmi aced in the webs are the same shape as before. However if there is a different thickness of web, which is formed on the same dies, the clearance of the dies must be moved further apart or closer together, to accommodate the new thickness of the web.

A

All of this is very well known in the art and is accepted as the normal operating procedure.
It is however well known that a further problem exists in roll forming. The web of sheet material which provides the basic feed stock for the roller machine should preferably maintain its thickness within very narrow limits, along the entire length of the web. If there is any significant variation in thickness, then the dies, being fixed as to clearance, will produce varying effects on the web as the web passes along the roller stands, or the web may jam causing stoppage of the line.
In practice, it is well known that some web material varies in thickness to a greater extent than is permissible. This results in unusual effects being produced in the final formed web, which may warp or bend or twist, or even jam.
Generally speaking, it is not possible to adjust the clearances of the roller dies, during the actual operation of the machine, and the best that can be done is that in the initial set up, the machinist will set the die clearances to a predetermined average web thickness. The results obtained in this way however are not always entirely satisfactory.
It would in theory be desirable to provide for automatic self adjustment of the spacings or clearances between the pairs of dies in each stand. However, due to the shaping of the dies there are difficulties in such adjustments. Usually the dies will have two surfaces, one of the surfaces being more or less horizontal, or at least parallel to the plane of the web itself, and the other of the surfaces being at a web forming angle.

Any attempt to take into account the clearances between both of these die surraces on both dies in a pair, simultaneously, on a continuous automatic basis, presents serious problems.
Another set of problems arises if it is desired to use the same roller dies, to form a web having a width which is greater, or narrower.
In the past this was possible, with some down time. Each of the stands would have to be moved further apart, or closer together, to take into account the width of the new web to be processed.
However, the re-adjustment of the spacing of the pairs of stands was time corr~uming. Desirably spacer rolls will be provided between dies on opposite stands, to support the web between the pairs of dies. The use of spacer rolls between the die sets on opposite sides of the web was a common practice. However, it was time consuming to dismantle the arrangement of dies for one web width, and then reassemble the dies with spacer rolls between them for a new web width. In addition, this was awkward anti time consuming work.
It is therefore desirable to provide for roller die stands arranged in pairs, in which at least one of each of the stands in each of the pairs, and preferably both, shall be transversely moveable relative to the other. The dies on one stand are driven by gear drives and some form of transmission mechanism is provided between the two stands, so that the dies carried on each of the two stands of each pair, are all positively driven.
Given both die clearance adjustment, and stand width adjustment, it would be possible, using one set of roller die stands and dies, to provide for the processing of 21 5 4~8 1 6 webs both of different thicknesses, and also of different widths. This enables a manufacturer to produce a standard rolled form section such as a C section in a variety of widths, and in a variety of gauges, from a single machine. This would reduce the capital investment in machinery. In addition this would reduce the down time required for change over from one web to another and also reduce the need for skilled labour.
Additional savings would be achieved if the spacer rolls could be introduced between the pairs of dies by some form of powered mechanism, so that the stands could simply be moved to part the spacer rolls placed in position and then the stands moved together again, with the spacer rolls in position. This would further reduce the down time, and enable manufacturers to maintain the quality of the roll forming operations.
A further problem arises with roll forming certain sections, particularly sections which have the shape of a letter C with in turned flanges, or a partially closed-in box section.
In this type of section, the two edges or flanges of the C, or partially closed-in box, are turned inwardly. This is usually done by roll forming the edge flanges first, and then roll forming the C bends lader downstream. Special dies are required to form the last bends, and it is desirable to provides for adjustment of these dies.
Adjustment of such dies in this location however, to accommodate variations in web thickness and to form different sizes of C-section. presents further problems.
BRIEF SUMMARY OF THE INVENTION

The invention provides a roller die apparatus supporting a plurality of pairs of roll: r dies in predetermined clearances, and for varying said clearances between said roller dies to accommodate variations in the thickness of a web workpiece passing there between, said apparatus having first and second roller dies rotatably mounted on respective roller die bearings, said apparatus comprising, means for moving one of said first and second roller dies along a generally diagonal axis , diagonal to its axis of rotation, thereby achieving simultaneous adjusting of the die clearance in two planes.
Preferably one of the dies is fixed, and the other of said dies incorporates both axial adjustment movement means and also transverse adjustment movement means, so as to keep all of the adjustment movement means in a common location where it is readily accessible for servicing and adjustment.
In another form of the invention means may be provided for moving said lower roller die axially, and further means for moving said upper roller die transversely, thereby adjusting each said die separately from the other.
In the latter case the lower die would be movably mounted in fixed support means, and would be movable axially, along its axis of rotation, and there would be lower bearing member movement means for moving said lower bearing member, and the upper die is movable transversely and has means for moving the upper die including an upper bearing member rotatably carried in support means, and defining an axis of rotation, and means for moving the upper bearing member transversely relative to its axis of rotation, towards and away from the lower bearing member.
A further feature of the invention provides movement transmission means coupling all of said movable bearing members together for movement in unisonant power operated means for operating each of said movement transmission means.
A further feature of the invention provides a thickness sensor for sensing the thickness of said web material workpiece, and generating a thickness signal in response thereto, and signal responsive means for generating movement signals for moving said movement transmission means, whereby to procure simultaneous movement of said moveable bearing means in response to said thickness signal.
A further form of the invention provides for an edge forming roller die assembly for ~ olling the edge formations and means for moving said at least some of said roller dies relative to one another, to vary the clearance between them.
A further aspect of the invention provides for a straightening assembly, comprising straightening rolls adapted to engage the workpiece after exiting from the roller dies to prevent warping.
Another aspect of the invention provides for width adjustment of the die stands, and means for inserting or removing spacer rolls between the dies.
This form of the invention includes a movable support table movable upwardly and downwardly between the die stands, with the spacer rolls stored on the table.
The invention also includes a method of forming a web workpiece.

'The various features of novelty which characterize the invention are pointed out with more particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its use, reference should be had to the accompanying drawings and descriptive matter in which there are illustrated and described preferred embodiments of the invention.
IN THE DRAWINGS
Figure 1 is a side elevation of a roller die apparatus for working a web of sheet material partially cut away, and illustrating a plurality of roller die stands at spaced apart intervals along the path of the sheet material and controls shown schematically;
Figure 2 is a top plan of part of Figure 1 in cross section;
Figure 3 is an enlarged s ide elevation of the roller apparatus of Figure 1, partially cut away to illustrate the movable raise table and spacer rolls;
Figure 4 is a top plan schematic view of the two side plates holding the roller stands, and the transverse movement mechanism;
Figure 5 is a cross section of the roller die apparatus of Figure 1 at the line 5-5, in a first position;
Figure 6 is a cross section, corresponding to Figure 5, showing parts in a second position;
_g_ 21 5 4a 1 fi Figure 7 is a cross section corresponding to Figure 5 showing parts in a third position;
Figure 8 is a section of one roller stand, sectioned along the line 8-8 of Figure 2, and showing details of the upper die movement means;
Figure 9 is a section corresponding to a portion of Figure 8 along line 9-9 of Figure 8;
Figure 10 is section along the line 9-9 of Figure 7 and showing movement;
Figure 11 is a section along the line 11-11 of Figure 10, showing upward and downward movement of the upper die;
Figure 12 is a top plan view partially cut away showing the axial movement mechanism for the upper die;
Figure 13 is a section, corresponding to Figure 11, but showing axial movement of ~he upper die relative to the lower die;
Figure 14 is a perspective illustration of the upper die bearing housings, and the upward and downward movement mechanism, and the axial movement mechanism;
Figure 15 is a side elevational view of an alternate embodiment of roll forming machine using certain of the features of the embodiment of Figures 1 through 14;
Figure 16 is a top plan view of the embodiment of Figure 15;
Figure 17 is a greatly enlarged top plan view showing the area marked 17 on fig~.ire 16;

21 5 4g 16 Figure 18 is a top plan view greatly enlarged of the area marked 18 in Figure 16;
Figure 19 is a side elevation of area marked 18 in figure (6) Figure 20 is a section along the line 20-20 of Figure 19;
Figure 21 is a section along the line 21-21 of Figure 19;
Figure 22 is a section along the line 22-22 of Figure 19;
Figure 23 is a section along the line 23-23 of Figure 19;
Figure 24 is a section along the line 24-24 of Figure 19, and, Figure 25 is a section along the line 25-25 of Figure 17.

21 5 48 1 fi DESCRIPTION OF A SPECIFIC EMBODIMENT
Referring first of all to Figure 1 and 2, it will be seen that this illustrates a roll forming apparatus, for use in conjunction with web sheet metal processing lines.
Additional equipment may comprise an uncoiled, a flattener, a cut off die or shear, and a stacker or conveyor, all of which components are essentially well known in the art anti form no part of the present invention and are therefore omitted from this description for the sake of clarity.
The roll forming apparatus comprises a base indicated generally as B, defining an upstream end U, and a downstream end D, and the web sheet metal W passes from the end U, to the other end D, continuously, while being progressively roll formed.
The roll forming of the web W, is performed progressively at a series of pairs of roller die stands indicated generally as 10, 12, 14, 16, 18, 20, 22, 24, 26, 28, 30, 32, 34, 36. The stands are secured to the base B, at spaced apart intervals, along the path of the web W. As shown in Figure 2, each pair of stands is designated as l0a and lOb, 12a and 12b, and so on. The stands are moveable relative to one another, so as to accommodate webs W of different widths. The stands l0a and lOb etc. are supported by continuous upright plates 38 and 40,(Figures 1 and 3) the lower end of which are securcd to the base B.
Each of the stands 10a, l2a,etc. (Figure 5) consist of upper and lower transverse bearing shafts 42 and 44. Upper and lower dies 46 and 48 are adapted to be mounted on the r espective shafts 42 and 44. Complementary bearing sleeves 50 and 52 are supported by stands lOb, 12b, etc and support upper and lower dies 54 and 56.
As is 2~ 5 4a 16 well known in the art, the respective upper and lower roller dies are shaped in such a way that they co-operate together to form the web in a continuous fold or bend, and each set of dies on each stand successively downstream along the roller die apparatus will progressively increase the formation either as to angle or as to depth, or otherwise or may produce different formations, depending upon the design of the dies, and the desired configuration to be formed in the web.
The apparatus may also incorporate means for moving the sides plates 38 and 40 transversely relative to one another where this additional flexibility is desired. This comprises a longitudinal side shaft 58, driven by a suitable motor, and connected in suitable manner to transverse movement means shafts 59 at each end of plates 38 and 40 for moving all of the stands relative to each other, so as to accommodate strips or webs of different widths (described below).
In accordance with the present invention, as explained above, there is provided means for adjusting at least one of the upper and the lower dies relative to the other, so as to adjust the clearance between the dies, to match the thickness or gauge of the web material as closely as possible. Such adjustments in accordance with the invention can be made while the web is actually running through the dies, thus compensating for variations in the thickness of the web along its length, all of which will be described below. The adjustment facility may be provided in all of the dies in a roll forming line.
However in many cases it will be found that the adjustment feature may be requred only in one or two groups of dies in the line. Generally it may be said that the adjustment feature is most often required where the forming angle of the web is greater, than say 45 or 50 degrees, or more . At lesser bending angles the thickness adjustment requirement is not so great, and in some case can simply be ommitted. For the purpouses of this explanation all of the roller stands are described as incorporating the thickness adjustment facility, but it will be understood that , as explained above the adjustment facility may be provided only on a few of the roller stands.
Usually these will be at the downstream end of the machine where the bend angles of the web are at their greatest. In some machines such as those used for forming C sections however whey a two bends are formed along either side of the web, then the adjustment facility may also be incorporated in a group of roller stands mid way along the machine where the first of these bends is reaching its greatest angle, and a further group at the downstream end where the second of the bends is reaching its greatest angle.u Referring to Figure 1 it will be seen that a web thickness sensing unit 60 is provided at the upstream end U of the roll forming apparatus. The thickness sensing unit may typically comprise a pair of rolls 62, and a signal generator (not shown) coo r~ected to a computer control centre 64.
In a manner to be described below, the sensing unit 60 senses the thickness or gauge of the web as it passes through the sensing unit, and before it enters the roller die stands. The signal generator sends a gauge signal to the computer 64, and by mechanism to be described below. The clearances between the dies is adjusted either closer or further apart depending upon the actual thickness or gauge sensed by the sensing unit.

21 5 48 1 fi In each of the roller die stands 10a, 12a, 14a the lower shafts 44, in well-known manner, are driven by a suitable drive train (not shown), and a suitable drive motor and transmission of a type well-known in the art (not shown) will thus drive the lower roll shafts .
The lower roll shafts have drive gears 70 secured thereon, and upper roll shafts 42 have gears 72 secured thereon meshing with gears 70. Thus as lower roll shafts 44 are all driven in the same rotational direction, all of the upper roll shafts are driven in the reverse rotational direction. The shafts connect telescopically with respective sleeWes 50 and 52 and drive them.
This, therefore, causes the dies 46 and 48 and 54, 56 to rotate in opposite directions on opposite sides of the workpiece W, in well-known manner.
The respective lower and upper dies are illustrated only in phantom, since roller diPS axe well-known in the art, and their manner of attachment is also well-known, typically being attached by means of a single groove and spline.
Each of the lower shafts 44 are rotatably mounted in bearings in openings 74 in plate 38.
The upper shafts 42 are carried in bearing housings 76. Each bearing housing 76 is supported in a suitable opening in plate 38. As explained above this adjustment feature is described as being part of each of the stands, simply for sake of clarity, it being understood that these features may be confined to one or two groups of stands, in many cases.

2~ 548 16 Bearing housing 76 is able to rotate in a manner to be described below, and thus cause movement of upper die 46 transverse to their axes. This then enables the clearance between the upper and lower dies to be adjusted by adjusting the upper die in a plane transverse to its axis in a manner described below.
Lower bearing sleeves 52 are mounted in suitable openings in side plate 40.
Upper bearing sleeves 50 are mounted in upper bearing housings 80 and are rotatable in the same way as housings 76. Roller bearings are mounted within the bearing housings 76 and 80.
The side plates 38 and 40 are between 5 and 6 inches in thickness, in this case, and provide strong support for the shafts, sleeves and dies of the roller stands.
The axial adjustment movement of the upper dies 42 and 54 is achieved by means to be described below thus providing adjustment movement in both the transverse plane, and in the axial direction, the resultant direction of adjusting movement being generally diagonal.
As explained above, the plates 38 and 40, incorporating the die stands 10a, lOb, etc. , are movable away from and towards one another, by means of the two transverse movement transmission shafts 59. The upper and lower shafts 42 and 44 are dimensioned and designed so as to make a telescopic sliding fit within the sleeves 50 and ~2. In this way the drive from the die stands 10a, 12a, etc., is transmitted to the die stands lOb, 12b, etc. , as described above.
However, referring to Figure 5, 6 and 7, it will be seen that the transverse movement means can be operated to withdraw the shafts 42 and 44 entirely from the slee;~es, thereby leaving the vacant space between the free ends of the shaft and the sleeves.
This feature enables easy changeover of the dies if the dies must be changed.
More importantly however, this feature permits the insertion of spacer rolls 84, between the free ends of the shafts and the sleeves. This could be achieved manually.
However, in accordance with a feature of the invention, the sets of spacer rolls for each of the pairs of die stands are supported on a length wise support table 86.
The support table 86 is of rectangular tubular construction (Figure 5) and along its upper surface it is provided with a plurality of spacer rolls support brackets 88 spaced apart from one another and defining generally downwardly directed three-sided recesses. Along the length of the brackets 88, there are provided retention springs 90 at spaced intervals.
Each set of spacer rolls 84 is provided with a central axial opening, which is designed to fit on the shaft 44 of the stands 10a, 12a, etc.
As shown in Figure 3 a table raising movement means is indicated generally as 94, located beneath the table 86. Figure 3 shows only the one table movement means.
However there are two such movement means, one at each end of the table, so as to ensure that when the movement means are operated, the table is maintained level while it is raised or lowered.
Movement means comprises a raise shaft 96, and guide shaft 98. Both shafts run through a drive housing 100. A motor 102 drives a drive shaft 104, and a shaft extension 106 connects the drive from the motor 102 to the other of the table raise mov;.ment means (see Figure 1).

A

21 5 48 1 fi Referring again to Figure 5, it will also be appreciated that the table 86 is movable transversely as well as up and down in a vertical plane. The transverse movement is permitted by means of the transverse carriage 108 (Figure 5), in response to movement of side plate 40.
Comparison of Figures 5, 6, and 7 will show that the entire table and raise mechanism has moved substantially to the right to accommodate the simultaneous closing movement of the two side plates 38 and 40, and the roller die stands.
Note that in Figure 7 the transverse carriage 108 is extending substantially to the right in a rectangular portion of the base B.
As has already been explained all of the stands 10a, l Ob, 12a, 12b, etc. , are all formed integrally with one another, as part of respective single continuous side plates 38 and 40 (Figures 1 and 4). At each end of each side plate that is to say at the upst~ eam end and at the downstream end, there is provided a cross bearing tube of substantial diameter indicated as 112. The side plates 38 and 40, for each of the stands 10a, 12a, etc. , and l Ob, 12b, etc. , are provided with bearing sleeves 114, adapted to ride on the tubes 112.
This provides a means for permitting movement of the entire set of stands 10a, etc. an the one side, and l Ob, etc. , on the other side, for moving transversely towards and away from one another in unison. The space between the tube 112 at one end and tube 112 at the other end, is free open space, and permits the raising and lowering of table 86.

y' ,: :''~, It will of course be appreciated that while the illustrations of Figures 5, 6, and 7 illustrate the lower shaft 44 picking up all of the spacer rolls 84, it is perfectly possible that a particular application will not require all of the spacer rolls.
Accordingly, all that is required in this case is simply to insert the shaft 44, (see Figures 6 and 7) part wz;~ into the stack of spacer rolls 84. The table 86 would then be lowered, leaving some of the spacer rolls on the shaft 44, and removing downwardly the rest of the spacer rolls, resting on table 86.
The die stands will then be closed up as in Figure 7 and in fact the die stands would be closer together than they are shown in Figure 7, since there would be fewer spacer rolls between the dies.
These operations can be controlled by the computer 64 so that the changeover from; one width of web to another width of web would simply require a few instructions to be programmed into the computer, after which the die stands would be moved apart, and then moved partially or fully together, depending upon whether they were picking up all of the spacer rolls or only a selection of them.
Removal of the spacer rolls, or changing their number can be effected in the same way.
In this case the table 86 is raised until it is in contact with the spacer rolls 84.
At this point, the side ii~ames are then moved fully open, withdrawing the shaft 44 from the spacer rolls 84. This will then leave the spacer rolls 84 sitting freely on the racks 88 on the table 86. The table 86 will then be lowered, and the die stands can simply be closed up again.

ADJUSTMENT OF DIE CLEARANCE

As generally described above, the adjustment of the die clearances is achieved by moving, in this embodiment, the upper die relative to the lower die. The lower die remains unadjusted. Again it is to be understood that while this description shows that all of the roller stands are provided with the clearance adjustment feature, described below, in many cases it will be sufficient if the adjustment feature is provided in one, or two groups of stands, where the bend angle being formed in the web is most extr cme. Where the bend angle is only slight it may be that no adjustment is required at all, or it may be that the adjustment can be confined to a simple up down adjustment.
The adjustment of the upper die takes place along a generally diagonal axis,diagonal to its axis of rotation .To achieve this in this embodiment the die is moved along the axial direction of the shaft 42, in the axial direction, and secondly, the die is moved on an axis transverse to the axial direction of shaft 42, ie. up and down.
By providing adjustments in both planes,the resultant direction of adjusting movement is generally diagonal and it is possible to adjust for variations in web thickness even while the web is running through the roller dies. The transverse adjustment is best understood with reference to figures 8, 9, 10, 11 and 14.
As explained, the lower die 48 remains unadjusted. It simply rotates on its shaft 44, which runs in bearings mounted directly in opening in plate 38.
The same is also true of die 56, mounted on its sleeve in plate 40.
The two upper dies 46, in stand l0A and 54 in stand lOB however are mounted respectively on shaft 42, in stand 10A, and in sleeve 50 in stand lOB. Both shaft 42 and sleeve 50 are in turn carried in bearing sleeves indicated respectively as 76 and 80.
The bearing sleeves in turn are received in making openings formed in their respective plates 38 and 40, so that they can simply rotate.
In order however to provide for adjustment, by means of rotation of the bearing sleeves, the bearing sleeve 76 is provided with an offset shaft recess 120, containing both bearings, and the shaft 42. The axis of the shaft recess 120 is offset from the central axis of the sleeve 76 (see figure 10). Thus when the sleeve 76 rotates, the axis of the shaft 42 must move relative to the axis of the bearing sleeve 76.
Provided that bearing sleeve 76 is suitably located, so that its thinnest point and its widest point lie on a more or less horizontal axis (figure 10) then rotation of bearing sleeve 76 in one direction will cause shaft 42 to move upwardly and the rotation of the sleeve 76 in the other direction will cause shaft 42 to move downwardly.
Turning to stand IOB, it will be seen that shaft sleeve 50 which is mounted in the hearing sleeve 80, also has the same characteristics. That is to say the recess 122 in bearing sleeve 80 is offset with respect to the central axis of bearing sleeve 80 so that the central axis of the sleeve 50 is offset with respect to the central axis of the bearing housing 80.
Thus if the bearing housing 80 is rotated in one direction the shaft sleeve 50 will move upwardly, and if the bearing housing 80 is rotated in the opposite direction the shafC sleeve 50 will move downwardly.
In order to provide for rotational movement of the bearing housing 76 and 80 in unison, each bearing housing is provided with an annular rack semi gear portion 124, which is welded at a suitable position to the edge of the respective bearing housing 76 and 80.
Two racks 126 are provided in stands l0A and lOB engaging the gear segment 12a (figures 9 and 10). Each of the racks is mounted on to a respective push pull rod 128. The two push pull rods 128 are mounted so as to extend to the upper regions of respective stands 10A, 12A, etc. and IOB, 12B etc. The push pull rods 128 are threaded along their length, for convenience.
Each of the racks 126 is secured to its respective push pull rod by means by locknuts 130. The push pull rods 128 are both operated simultaneously, by means of a transverse drive coupling shaft 132 (figure 2) and a drive motor 134.
Thus, by the operation of motor 134, all of the respective racks 126 can be operated so as to move their respective semi annular gear segments 124, thus moving simultaneously all the bearing housings 76 and 80 in the stands 10A, lOB, etc.
Thus all of the upper dies will move simultaneously either upwardly or downwardly by the same increment.
As mentioned above, adjustment also takes place axially along the axis of the shaft, and shaft sleeves. This axial movement is best understood with reference to figures 8, 12, 13 and 14.
Again, the lower die 48, 56, remains unadjusted, in this embodiment.
The upper dies 46 and 54 are the dies that are adjusted. This is achieved by the same means in both stands l0A and lOB.

The bearing housing 76 and 80 are both rotatable in their openings in their plates 38 and 40, and they are both axially slidable, to a limited extent, to their plates 38 and 40. This axial movement is achieved by means of an annular groove 133, formed in each of bearing housings 76 and 80. A self lubricating anti wear block 135 rides in the groove 133. The block 135 has a central recess (not shown).
A spur gear 138, is secured in a cross member 140 fastened to the top of the respective plates 38 and 40. The spur gear is engaged by a respective rack 140. The plurality of racks 140 are secured to respective push pull rods 142, by means such as locknuts 144.
The spur gears 138 have a downward axial extension 146. At the free end of ex~~nsion 146, there is located an offset stub 148. Stub 148 is received in the recess in wear blocks 135.
It will thus be seen that by the operation of the racks 140, in response to the movement of the push pull rods 142, the spur gears 138 will rotate one way or the other. This will cause an orbital movement of the offset stub 148, the axis of which is offset relative to the central axis of the extension 146 and gear 136.
This orbital movement will thus force the respective bearing housings 76 and 80, to move axially one way or the other relative to their respective plates 38 and 40.
It will be appreciated that as a result of this movement there is a slight lateral displacement of the annular gear segments 124, relative to their respective racks 126.
However, since the degree of movement is relatively slight, this will not cause any problem in operation.

The push pull rods 142 are again operated by a cross shaft 150, and motor 152 (figure 5), so that the push pull rods on all of stands 10A, 12A, and IOB, 12B
etc.
operate simultaneously.
It will thus be seen that during operation of the roll forming line, if the sensor 60 detects a change in the thickness of the web, it will send a signal to computer 64.
Computer 64 will thereupon signal motors 134 and 152 to adjust the die clearances, in two planes simultaneously, to accommodate the different web thickness. This adjustment which will in effect be along a generally diagonal axis, will of course be relatively minor, but will have the effect of maintaining the highest quality of the roll forming action on the web, which would otherwise not occur if the die clearances were not adjusted.
It will of course be appreciated that in the event of a changeover in the operation of the roll forming apparatus from one web to another, the web may have a thickness which is increased or decreased somewhat more, as compared with the previous web that was being processed.
These adjustments pan in the great majority of cases can be taken into account simply by programming the computer, so that it instructs the motors 134 and 152 to adjust the die clearance to suit the new web thickness.
In the event of an extreme change in web it may of course be necessary to readjust the position of the racks on the push pull rods. This can readily be done simply by loosening off the locknut, resetting the positions of the racks and locking up the ~ocknuts to hold the racks in the new position.

a: :;
..~, ~t In accordance with a further embodiment of the invention, illustrated in general in Figures 15 and 16, provision may be made for a somewhat different form of operation than in the Figure 1 through 14 embodiment.
In the Figure 1 through 14 embodiment, the C-section is formed by bending the two outer flanges of the C by the main dies, at the leading end of the machine, and then progressively forming the intermediate bends of the C-section, in downstream sets of rolls.
This however placed certain restrictions on the size and the shape of the C-section that could readily be formed in this way.
In accordance with the embodiment of Figures 15 and 16, the inner bends of the C-section are formed first by the main sets of rolls, and the final in turned flanges of the C-section are formed last, downstream from the main rolls. This has certain advantages. It enables a greater range of flange sizes, and web depths, to be formed on a single machine.
It also provides for easier adjustment. The embodiments of Figure 15 and 16 also provide a finished C-section straightener, all to be described below, which can in fact be used with the embodiment of Figures 1 through 14 or 15 and 16.
Many of the features of Figures 1 through 14 and Figures 15 and 16 are common to both, and will therefore be described in somewhat less detail, since they have already been described in connection with Figures 1 through 14.
Referring now to Figure 15 it will be seen that this embodiment of the invention comprises a roll forming apparatus indicated generally as 200, and having an upstream end 202 and a downstream end 204. A web of material passes from the upstream end to the downstream end during the process of being formed from a flat web into a C-section.
The apparatus 200 will also have an upstream web thickness measurement device similar to that shown in Figure 1, and a computer control similar to that shown in Figure l, for providing for continuous adjustment.
The entire apparatus, as before, is supported on a base made up of a frame work of rectangular beams 206, connected to rectangular cross members 208.
As before, there are a plurality of roller die stands indicated as 210, 212, 214, 216, 218, 220, 222, and 224. As shown in Figure 16, in each case each of the stands comprise respective right and left hand die stands indicated by the suffix a-b.
Also as in the previous embodiment, each of the die stands comprises pairs of upper and lower dies, which mesh with one another to provide the formations desired.
As before, selected ones or groups of the upper dies are moveable relative to the lower dies by means of push pull rods 226 and 228, the two rods being respectively referenced a and b (see Figure 16) on opposite sides of the apparatus.
The operation of the push pull rods to procure the upward and downward movement, and lateral movement, of the upper die is as already described, and consequently the apparatus is not described in detail again for the sake of simplicity.
S imilarly, as in the Figure 1 through 14 embodiment the die stands 210A and 210B, etc. are moveable away from one another and together, to provide for varying spacings between the stands and also, to permit varying numbers of spacer rolls to be _w. 21 5 4 8 1 6 introduced there between. The spacer rolls indicated as 230 are carried on a spacer roll table 232 operated by means of the raise mechanism 234 (see Figure 15). The spacer robs, table and raise mechanism all operate in the same way, as is already described in the embodiment of Figures 1 through 14.
As before the roller die stands are all driven by a common drive motor 236 driving through transmissions 238.
The push pull rods 226 are operated by means of motor 240, and the push pull rods 228 are operated by means of the motor 242.
As mentioned above, this embodiment of the invention provides for the formation of the edge flanges of the C-section downstream from the main roller die stands. The edge flange forming die stands are indicated generally in Figures 15 and 16 as 250 and 252. Each of the edge forming die stands 250 and 252 consists of in this case five pairs of outer and inner edge forming dies on each side indicated as 254 and 256.
As will be seen from Figures 17 through 24, each pair of edge forming dies 254 and 256 consist of outer dies 254 and inner dies 256, the outer dies being of much larger diameter than the inner dies for reasons to be described below.
It will also be seen that each pair of dies is mounted for rotation on spaced apart vertical axes, so that the dies rotate in horizontal planes, again for reasons to be described below.
Each set of dies outer 254, is mounted on respective common mounting frames 258 and each set of inner dies 256 is mounted on sub-frames 260. Sub-frames 260 are 2154816_ rnnunted on mounting frames 258 and are moveable relative thereto as described below.
All of the dies 254, and 256 can be moved as a group towards and away from the other set, to accommodate workpieces of different widths, or to form C-sections of different dimensions by movement of the two mounting frames 258-258.
Thus the two mounting frames 258-258 carrying the two groups of dies 254 and 256 can be moved towards and away from one another by transverse movement means (nol shown) similar to figures 1-14, and moving all of the dies transversely, siriultaneously.
The apparatus also provides for upward and downward adjusting movement of the mounting frames 258-258 holding the two groups of dies 254 and 256. These upward and downward adjustment movements are procured by means of motor 262 operating through shaft 264 and gear drives 266, the lower ends of which are connected directly to the mounting frames 258 and 258 respectively. Guide posts 268 guide such vertical movement.
In this way, the positioning of the two groups of horizontal dies can be adjusted up and down, so as to accommodate the manufacture of C-sections of different shapes, ie., having deeper web sections or shallower sections.
Figure 20 shows that each inner die 254, is mounted on a drive shaft 270, having a driven gear 272, connected by idler gears 272a. One of gears 272 meshes with an elongated drive gear 274. The reason for the elongated drive gear 274 is to permit the upward and downward movement already described, performed by moving the framework 258 upwardly or downwardly, to move all of the pairs of dies in unison.
Gear 274 is mounted on shaft 276 connected to the main drive train 278.
The outer dies 254 are not in themselves adjustable, other than as already exr~lained, when the entire assembly of dies is moved by movement of the mounting frame 258.
The apparatus also provides means for adjusting the clearance between the inner and outer dies in respective pairs, in much the same way as the adjustment of the upper dies relative to the lower dies, in the main part of the apparatus, similar to the embodiment of Figures 1 through 14.
The purpose of the adjustment of the clearance of the horizontal edge forming dies is to solve the same problem, namely to accommodate the variations in the thickness of the workpiece, as it moves along the line.
The adjustment of the outer dies relative to the inner dies, in the pairs of the horizontal dies, is best understood with reference to Figures 21, 22, and 23.
Adjustment of the clearance between the outer dies 254 and the inner dies 256 is achieved by providing for adjusting movement of the outer dies as a group, in a vertical plane, and also in a transverse plane. Sub Frames 260 are mounted on mounting fraxraes 258 in such a way that they can be moved both vertically in such a way that they can be moved both vertically and transversely.
Vertical adjustment for the inner dies comprise shafts 280 on which the sub-frame 260 is mounted at each end. The shafts 280 are provided within sleeves 282.
Jack screws 284, engage threaded members 286. Shafts 280 are operated by means of the push pull rods 226a and 226b, engaging elongated gears 288 on the upper ends of shafts 280. Members 2865 are secured to captive plates 290 secured within either end of sub-frame 260 (Figure 21 and 22). Rotation of shafts 280 will thus raise, or lower, sub-frames 260 relative to frames 258.
The transverse adjustment of the inner die relative to the outer dies for clearance adjustment, is also achieved by means of movement of sub-frames 260 relative to frames 258, transversely.
Shafts 292 have gears 294 which engage push pull rods 228a and 228b. Shafts 292 are connected to eccentric shafts 296 which extend down through sub-frames 260, and into side frames 38. Shafts 296 at their lower ends have bosses 296, coaxial with shafts 292. Thus rotation of shafts 292 will cause eccentric orbital movement of shafts 296 causing sub-frames 260 to move transversely relative to frames 258.
It will thus be seen that it is possible to move the entire assembly of inner and outer dies, on each side of the apparatus, both upwardly and downwardly, as an assembly and also inwardly and outwardly as an assembly.
It will also be seen that it is possible to adjust the inner dies both upwardly and downwardly and also inwardly and outwardly relative to the outer dies, to accomodate variations in the thickness of the web.
The apparatus of Figure 15 and 16 further provides an end finishing operation, by means of two pairs of end finishing roll assemblies 300a and 300b, on opposite sides of the apparatus. The end finishing roll assemblies have lower dies 302 and upper dies 304 and intermediate side dies 306. In this way, it is possible for the three dies to engage all three outer surfaces of the C-section, and provide the final finishing and squaring step.
Inward and outward movement of the two die assemblies is provided by the main transverse movement mechanism already described above (see Figure 1-14).
The lower die 302 in each of the finishing die assemblies 300 will remain fixed as to height, and is not adjustable. The side dies 306 are simply likewise fixed, relative to uhe lower dies 302, so that they simply adjust inwardly and outwardly, with the in°~~~ard or outward movement of the entire finishing die assemblies.
The upper dies 304 of each finishing die assembly are moveable upwardly and downwardly, to take into account different dimensions of different C-sections being formed. This is achieved by means of the jack screws 308 operated through suitable transmissions by motors 310. The lower ends of the jack screws are secured by the bearing housing 312 carrying shaft 314 for the upper dies 304.
Operation of the jack screw will thus cause the entire bearing housing 312 to eitr~er move upwardly or downwardly.
In the finishing dies, there is no separate adjustment for die clearance to accomodate different thicknesses of web material, since the upper and lower and side dies are simply working to finish the exterior of the C-section (Figure 24).
Finally, in this embodiment, provision is made for straightening the C-section as it exits from the finish rolls.

It is well known that when forming C-sections, they may have a tendency to warp, which implies either that the section will bend upwardly or downwardly, or sideways.
In order to overcome this tendency, there are provided straightening assemblies 320a and b, which are located just downstream, at the exit end of the apparatus. This is best understood with reference to Figure 19 and 25. The straightening assembly comprises a fixed lower roll 322, which is located along the pass line of the lowermost web of the C-section. Two, leading and trailing, straightening rolls 324 and 326 are mounted above the lower roll, and spaced apart with respect thereto upstream and downstream.
In addition, a side roll 328 is provided for engaging the side portions of the C-section.
As in the case of all of the rest of the rolls, the straightening rolls are mounted as lift and right hand sets of rolls on opposite sides of the apparatus, and will move towards and away from one another in conjunction with and in unison with the mo ~ ernent towards and away from one another and all of the rest of the dies in the manner described above.
The lower roll 322 is fixed. The two upper rolls are mounted on a generally inverted U-shaped yoke 330, which is pivotally mounted on the axle 332 (Figure 19).
The yoke can thus tilt about the axle, bringing one of rolls downwardly and the oth;,. roll upwardly and vice versa.

Connected to one end of the yoke 330, is a jack screw 334, which is operated by motor 336 (Figure 25).
Operation of the motor will thus cause the one end of the yoke to either tilt upwardly or downwardly.
Thus if the C-section is tending to warp up, the jack screw 334 will be raised thereby causing the trailing die 326 to move downwardly, and thus correcting the upward warp of the C-section.
If the C-section is warping downwardly, then the jack screw 334 is operated in the apposite way to depress the leading die 324.
The side rolls are also operable from side to side in order to correct any sideways warping. This is achieved by means of the jack screws 338, operated by motors 340. Operation of the jack screw 338 in one direction will cause the side roll 328 to move in one direction, and operation of the jack screw in reverse will move the roll in the other direction.
Thus by operation of the motors 340-340 on opposite sides, it is possible to mo ~ a the two side rolls 328, one on each side of the C-section, either to the left or to the right, thus straightening any sideways warping.
Warp sensors, such as optical sensors 342 (Figure 19) and 344 (Figure 25) are connected to computer 64 and would cause appropriate signals to be sent to motors 336 and 340.
The invention also includes the method of forming a web work piece as described The foregoing is a description of a preferred embodiment of the invention which is given here by way of example only. The invention is not to be taken as limited to any of the specific features as described, but comprehends all such variations thereof as come within the scope of the appended claims.

g

Claims (27)

1. A roller die apparatus having a plurality of pairs of roller dies in predetermined axial and transverse clearances for forming a web workpiece sequentially as it passes through said pairs of dies, said web workpiece having variations in the thickness of a web workpiece, said apparatus comprising;
a plurality of pairs of roller die stands mounted at spaced intervals;
a first and a second roller die rotatably mounted in pairs on each roller die stand;
moveable die bearing means on at least some of said roller die stands supporting a moveable one of said first and second roller dies of respective said pairs and being moveable whereby to move said moveable die relative to the other of said first and second roller dies in each said pair on respective said die stands along a diagonal adjustment path, movement of all said moveable die bearing means causing simultaneous adjusting movement of all of said moveable dies of said pairs of said first and second dies, thereby adjusting the clearances between moveable one of said first and second dies and the other of said first and second dies in a said pair;
movement transmission means coupling all of said moveable bearing means on said roller die stands together for adjusting movement in unison; and, power operated means for operating said movement transmission means.

2. A roller die apparatus as claimed in claim 1 and including a thickness sensor for sensing the thickness of said web workpiece, and generating a thickness signal in response thereto, and signal responsive means for generating movement signals for moving said movement transmission means, whereby to procure simultaneous movement of said moveable bearing means in response to said thickness signal.

3. A roller die apparatus as claimed in claim 1 and including edge forming roller die assemblies for rolling edge formations on said web workpiece and means for moving said edge forming assemblies relative to one another.

4. A roller die apparatus as claimed in claim 1 and including straightening rolls adapted to engage the web workpiece after exiting from the roller dies to correct warping of the web workpiece.

5. A roller die apparatus as claimed in claim 1 and including finish die support assemblies, located on opposite sides of sides of said web workpiece;
respective pairs of finish roller dies being supported on respective said finish die support assemblies, said finish dies being rotatable about vertical spaced axes, and said finish dies lying in essentially horizontal planes; and, means for driving at least one of said finish dies of each of said pairs of finish dies.

6. A roller die apparatus as claimed in claim 5 and wherein said finish die assemblies are mounted on moveable carriages, said carriages belong operable to procure movement of said finish die assemblies upwardly or downwardly, and including power operated movement means for moving said finish die assemblies upwardly and downwardly, to accommodate workpieces of varying heights.

7. A roller die apparatus as claimed in claim 1 and including;
finishing die stands, said finishing die stands being moveable towards and away from one another;
lower and upper finishing dies on each of said finishing die stands;
an intermediate side die between said lower and upper finishing dies on each of said finishing die stands, whereby said upper and lower finishing dies and said side dies may engage said web workpiece on three surfaces normal to one another, along each edge of a said workpiece.

8. A roller die apparatus as claimed in claim 7 and including movement means for moving one of said upper and lower dies relative to the other, whereby to accommodate web workpieces of varying height.

9. A roller die apparatus as claimed in claim 8 and including;
fixed lower die means engaging an underside of said web workpiece at a predetermined pass line level for said web workpiece;
leading correcting die means and trailing correcting die means, said leading and trailing correcting die means being mounted on a common mounting yoke;
pivotal mounting means for said yoke, whereby said yoke may swing, so as to raise one of said leading and trailing correcting die means and lower the other;
power operated means for swinging said yoke, whereby to cause either said leading correcting die or said trailing correcting die to engage an upper portion of said web workpiece, said leading and trailing dies being located spaced apart from one another on opposite sides of said lower die, thereby causing either downward bending of said web workpiece or upward bending of said web workpiece, to correct warping and straighten said web workpiece.

10. A roller die apparatus as claimed in claim 9 and including correcting side die means, engageable with opposite sides of said web workpiece, and means for moving said correcting die means from side to side, whereby to cause straightening of said web workpiece from one side to the other.

11. A roller die apparatus as claimed in claim 1 wherein said web workpiece has right and left hand edge and including respective right and left hand die stands for supporting respective pairs of upper and lower dies along opposite edge of said web workpiece;
means interconnecting said right and left hand die stands for movement towards and away from one another;
die drive shafts extending from one of said right and left hand die stands towards the other of said right and left hand die stands in each pair, movement of said right and left hand die stands apart from one another causing separation of said die drive shafts from said other of said die stands, whereby to leave a spacing therebetween; and, a spacer roll support located beneath said right and left hand die stands, and movement means for moving said spacer roll support upwardly and downwardly, and spacer rolls supported on said spacer roll support, whereby when said right and left hand die stands are moved apart, said spacer rolls may be moved upwardly into registration with said die drive shafts, after which said right and left hand die stands may be moved towards one another, said die drive shafts thereby engaging selected ones of said spacer rolls supported therebetween.

12. A roller die apparatus as claimed in claim 11 wherein said die drive shafts are located in first die stands of said right and left hand stands, and wherein second die stands in said right and left hand die stands are provided with die support bearing means, and said die bearing support means defining drive recesses for telescopic interengagement with said drive shafts, whereby when said drive shafts are in telescopic inter-engagement with said recesses, whereby said dies on both said die stands are driven simultaneously.

13. A roller die apparatus as claimed in claim 12 wherein said spacer rolls define axial openings, said die drive shafts being dimensioned to be received in said axial openings when said die stands are moved towards one another.

14. A roller die apparatus as claimed in claim 11 and wherein, said moveable die bearing means are operable to move said moveable ones of said first and second roller dies of respective said pairs relative to the other of said first and second roller dies in said pairs, thereby achieving simultaneous adjusting movement of the die clearance between said first and second roller dies of each said pair.

15. A roller die apparatus as claimed in claim 13 including bearing sleeves having eccentric bearing openings therein for mounting said moveable bearing means, and means for rotating said bearing sleeves, thereby moving the axes of said moveable bearing means transversely thereto.

16. A roller die apparatus as claimed in claim 13 and wherein said moveable bearing means are mounted in respective axially slidable sleeves, and including a groove formed in each said sleeve and a plate member moveable in said groove and means to move said plate member around said groove thereby causing axial movement of said sleeve, and said bearing means supported therein.

17. A roller die apparatus as claimed in claim 15 including an operating rod connecting all said bearing sleeves for causing rotational movement thereof simultaneously.

18. A roller die apparatus as claimed in claim 16 including operating rod means connecting all said plate members in respective grooves in said sleeves, for causing movement thereof in unison.

19. A roller die apparatus as claimed in claim 13 including respective bearing sleeves having respective eccentric bearing openings therein for mounting said moveable bearing means, and means for rotating said bearing sleeves, thereby moving the axes of said bearing means transversely thereto, and said bearing sleeves being axially slidable, and including grooves formed in respective said sleeves and plate members moveable in said grooves and means to move said plate members around said grooves thereby causing axial movement of said sleeves, and said bearing means supported therein, and including operating rod means operable to cause said rotational movement and said axial movement simultaneously, thereby causing a diagonal clearance adjustment movement of said dies.

20. A roller die apparatus as claimed in claim 1 and including side flange corner forming upper dies; and, side flange control rolls engaging the outer surface of said side flanges, said control rolls being movably mounted for tilting inwardly or outwardly, so as to produce a greater or lesser degree of bend between the side flanges and the web workpiece.

21. A method of continuously roll forming a web workpiece in a roll forming line having a roller die apparatus having a plurality of pairs of roller dies located in sequence having predetermined clearances for forming a web workpiece, and comprising the steps of;
passing a web workpiece along said roll forming line having a plurality of pairs of first and second dies, each pair of dies defining a predetermined die clearance;
varying said clearances between at least some of said pairs of roller dies by moving a moveable one of said dies in each pair to accommodate variations in the thickness of a web workpiece passing there between by moving said one of each pair of said dies relative to the other along generally diagonal axes.

22. A method as claimed in claim 21 and including a thickness sensor for sensing the thickness of said web workpiece, and including the step of generating a thickness signal in response thereto, and signal responsive means for generating movement signals, and moving said moveable dies in response to said thickness signal.

23. A method as claimed in claim 21 and including right and left edge forming roller die assemblies and including rolling edge formations on said web workpiece and moving said edge forming assemblies relative to one another to compensate for variations in thickness of said web workpiece.

24. A method as claimed in claim 21 and including straightening rolls adapted to engage the web workpiece after exiting from the roller dies, and engaging said web workpiece and correcting warping of the web workpiece.

25. A method as claimed in claim 21 and including respective right and left hand die stands for supporting respective pairs of upper and lower dies, means interconnecting said die stands for movement towards and away from one another, die drive shafts extending from one of said die stands of each pair towards the other of said die stands of each pair, and including the steps of moving said die stands apart from one another causing separation of said drive shafts on said one of said die stands from said other of said die stands, whereby to leave a spacing there between and moving spacer rolls upwardly on a spacer roll support, into registration with said drive shafts;
and, moving said die stands towards one another, said drive shafts thereby engaging selected ones of said spacer rolls supported there between.

26. A method as claimed in claim 21 and including, fixed lower die means engaging an underside of said web workpiece at a predetermined pass line level for said web workpiece, leading correcting die means and trailing correcting die means, said leading and trailing correcting die means being mounted on a common mounting yoke, pivotal mounting means for said yoke, whereby said yoke may swing, so as to raise one of said leading and trailing correcting die means and lower the other, power operated means for swinging said yoke;
and including the step of causing either said leading correcting die or said trailing correcting die to engage an upper portion of said web workpiece, said leading and trailing dies being located spaced apart from one another on opposite sides of said lower die, thereby causing either downward bending of said web workpiece or upward bending of said web workpiece, to correct warping and straighten said web workpiece.

27. A method as claimed in claim 21 wherein said die bearing means are carried in sleeves which are moveable along axes parallel to the axis of rotation, to move said dies along their axes of rotation and wherein said bearing means are moveable transversely to said axis of rotation to move said dies transverse to their axis of rotation simultaneously, and including moving said sleeves both transversely and axially simultaneously thereby moving said moveable dies along generally diagonalally to said axes of rotation, while said web workpiece is moving, between said dies.