WO2009061637A2

WO2009061637A2 - Adapter-based forming tool system for press brakes

Info

Publication number: WO2009061637A2
Application number: PCT/US2008/081444
Authority: WO
Inventors: Bryan L. Rogers; Brian J. Lee; Jon M. Shimota
Original assignee: Wilson Tool International Inc.
Priority date: 2007-11-09
Filing date: 2008-10-28
Publication date: 2009-05-14
Also published as: WO2009061637A3

Abstract

The invention provides adapter-based forming tool systems for press brakes. Some embodiments provide a modular forming-insert assembly for press brakes. Also provided are methods of using an adapter-based forming tool system on a press brake.

Description

ADAPTER-BASED FORMING TOOL SYSTEM FOR PRESS BRAKES

TECHNICAL FIELD

This disclosure is related to press brakes and, more particularly, to forming tool systems for press brakes.

BACKGROUND

Press brakes are commonly used to bend sheet-like workpieces, such as sheet metal. A conventional press brake has an upper beam and a lower beam, at least one of which is movable toward and away from the other. Typically, the upper beam is movable vertically while the lower beam is fixed in a stationary position. It is common for upper and lower tools to be mounted respectively on the upper and lower beams of a press brake. Thus, when the beams are brought together, a workpiece between the two is pressed between the upper and lower tools to give the workpiece a desired deformation.

SUMMARY OF THE INVENTION

Some embodiments of the invention provide a press brake in combination with an adapter-based forming tool system. The press brake is elongated along a longitudinal axis, and the press brake has an upper beam and a lower beam. In the present embodiments, the adapter-based forming tool system includes an upper adapter, a lower adapter, an upper forming insert, and a lower forming insert. The upper adapter is carried by the upper beam and has a first side with a tang and a second side with a downwardly-facing channel. The lower adapter is carried by the lower beam and has a first side with a tang and a second side with an upwardly-facing channel. The upper forming insert is mounted removably in the downwardly-facing channel and has a forming surface configured to contact an upper surface of a workpiece during pressing operations. The lower forming insert is mounted removably in the upwardly- facing channel and has a forming surface configured to contact a lower surface of the workpiece during pressing operations. Preferably, the forming inserts are mechanical forming tools configured to create a complex form in the workpiece, wherein at least part of the complex form comprises a bend arranged so as to be oblique to the press brake's longitudinal axis. And the adapters preferably are configured to release the forming inserts and to receive different forming inserts configured to create a different type of form.

In certain embodiments, the invention provides an adapter-based forming tool system that includes an upper adapter, a lower adapter, an upper forming insert, and a lower forming insert. The upper adapter is configured to be carried by an upper beam of a press brake that is elongated along a longitudinal axis. The upper adapter has a first side with a tang and a second side with a channel. The lower adapter is configured to be carried by a lower beam of the press brake. The lower adapter has a first side with a tang and a second side with a channel. The upper forming insert is adapted to be mounted removably in the channel of the upper adapter and has a forming surface configured to contact an upper surface of a workpiece during pressing operations. The lower forming insert is adapted to be mounted removably in the channel of the lower adapter and has a forming surface configured to contact a lower surface of the workpiece during pressing operations. Preferably, the forming inserts are mechanical forming tools configured to create a complex form in the workpiece, wherein at least part of the complex form comprises a bend arranged so as to be oblique to the press brake's longitudinal axis.

Further, certain embodiments of the invention provide a modular forming-insert assembly for a press brake that is elongated along a longitudinal axis. The modular forming-insert assembly includes at least two insert modules. Each insert module is configured to be mounted removably in a channel having a generally rectangular cross section. Each insert module has an interfacing surface configured to interface removably with the channel and a face comprising a forming surface opposite the interfacing surface. The forming surface is configured to contact a surface of a workpiece during pressing operations. The insert modules are configured to be secured in an end-to-end arrangement longitudinally to collectively define a mechanical forming tool configured to create a complex form in the workpiece, wherein at least part of the complex form comprises a bend arranged so as to be oblique to the press brake's longitudinal axis. BRIEF DESCRIPTION OF THE DRAWINGS

The following drawings are illustrative of particular embodiments of the present invention and therefore do not limit the scope of the invention. The drawings are not to scale (unless so stated) and are intended for use in conjunction with the explanations in the following detailed description. Embodiments of the present invention will hereinafter be described in conjunction with the appended drawings, wherein like numerals denote like elements.

Figure i is a perspective view of a press brake in combination with an adapter-based forming tool system, according to some embodiments of the present invention.

Figure 2 is a more detailed view of a portion (Detail A) of Figure l.

Figure 3 is an exploded view of an adapter-based forming tool system, according to some embodiments of the present invention. Figure 4 is an assembled view of the adapter-based forming tool system of

Figure 3.

Figure 5 is a schematic end view of an adapter-based forming tool system, according to some embodiments of the present invention.

DETAILED DESCRIPTION The following detailed description is exemplary in nature and is not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the following description provides practical illustrations for implementing exemplary embodiments of the present invention. Examples of constructions, materials, dimensions, and manufacturing processes are provided for selected elements, and all other elements employ that which is known to those of skill in the field of the invention. Those skilled in the art will recognize that many of the examples provided have suitable alternatives that can be utilized.

Figures 1, 2, and 5 show a press brake 5 in combination with an adapter- based forming tool system 7. As is shown, the press brake 5 can be elongated along a longitudinal axis (L). Many press brakes 5 include an upper beam 9 that translates toward and away from a lower beam 11 during pressing operations. In other cases, the lower beam moves toward and away from the upper beam. In still other cases, both beams may be moveable. The upper and lower beams 9, 11 can both carry (directly or indirectly) equipment that creates forms in workpieces (e.g., sheet-like workpieces, such as sheet metal) during pressing operations. As discussed in the following paragraphs, embodiments of the adapter-based forming tool system 7 can include upper and lower adapters 13, 15 and upper and lower forming inserts 17, 19.

Unlike conventional mechanical forming operations, embodiments of the present invention include adapters 13, 15 and removable forming inserts 17, 19, rather than large, single-piece mechanical forming tools. Thus, in some embodiments of the present invention, an upper adapter 13 and at least one upper forming insert 17 replace a single-piece upper mechanical forming tool used in a conventional mechanical forming operations.

The upper adapter 13 can be configured to be carried by the upper beam 9 of the press brake 5 (either directly or indirectly). As can be seen most clearly in Figures 3-4, the upper adapter 13 can have a first side 21 with a tang 23 and a second side 25 with a channel 26. In some embodiments, the channel 26 has a generally rectangular (or substantially rectangular) configuration in a cross section perpendicular to the longitudinal axis (L). In other embodiments, the channel is replaced with a plurality of mount openings each adapted to receive a forming insert. In embodiments of this nature, each mount opening can have a circular cross section, a polygonal cross section, etc. And each insert can have a correspondingly shaped base portion (optionally a "neck portion"). In such cases, the base portions of adjacent forming inserts can be mounted in respective mount openings, such that head portions (or "face portions") of the adjacent forming inserts are arranged side-by-side so as to collectively define a forming tool. Many variants of this nature will be apparent to skilled artisans given the present disclosure as a guide.

The upper adapter 13 can include a main body 27. In some such embodiments, the upper adapter tang 23 projects from the upper adapter main body 27 and has a smaller width than the upper adapter main body 27. The width referred to here is the lateral width (i.e., parallel to the lateral axis LA, shown in Figure 5). Referring to Figures 1-4, in some embodiments of the present invention, a lower adapter 15 and at least one lower forming insert 19 replace a single-piece lower mechanical forming tool used in a conventional mechanical forming operation. The lower adapter 15 can be configured to be carried by the lower beam 11 of the press brake 5 (directly or indirectly). As can be seen most clearly in Figures 3-4, the lower adapter 15 can have a first side 29 with a tang 31 and a second side 33 with a channel 34. In some embodiments, the channel 34 has a generally rectangular (or substantially rectangular) configuration in a cross section perpendicular to the longitudinal axis (L). If desired, the channel can be replaced with a series of mount openings, as described above in connection with the upper forming insert.

The lower adapter 15 can include a main body 35. In some such embodiments, the lower adapter tang 31 projects from the lower adapter main body 35 and has a smaller width than the lower adapter main body 35. Here again, the noted width is the lateral width.

Figure 5 shows a schematic end view of an adapter-based forming tool system 107 carried by upper and lower beams 109, 111 of a press brake 5. The upper and lower forming inserts 117, 119 can be positioned relative to the upper and lower adapters 113, 115 to create a form in a workpiece 140 during pressing operations. The upper forming insert 117 can include a forming surface 150 that is configured to contact an upper surface 142 of the workpiece 140 during pressing operations. In many embodiments, the upper forming insert 117 is mounted removably in the downwardly-facing channel 126 of the upper adapter 113. In many embodiments, the upper forming insert 117 has an interfacing surface 152 opposite its forming surface 150 that is interfaced removably with the downwardly-facing channel 126. The interfacing surface 152 of the upper forming insert 117 can have a width that is substantially equal to a width of the face (and/or substantially equal to a maximum width) of the upper forming insert 117. The upper adapter 113 can optionally include a safety key 160 configured to mate with a corresponding surface on the upper beam 109 to prevent the upper adapter 113 from inadvertently falling from the upper beam 109 during loading and unloading. The safety key 160, when provided, can optionally be a moveable safety key that is moveable laterally (i.e., along the lateral axis LA) into and out of engagement with a slot or channel of the press brake's upper beam 109 (or of an adaptor or tool holder on the upper beam). The safety key 160 can be adapted to project from the tang 23 of the upper adaptor 13, as shown in Figure 5. The safety key could be adapted to move in response to an operator pressing a button on the tool, or it could simply be resiliently biased toward its extended position.

The lower forming insert 119 can include a forming surface 170 that is configured to contact a lower surface 144 of the workpiece 140 during pressing operations. In many embodiments, the lower forming insert 119 is mounted removably in the upwardly-facing channel 134 of the lower adapter 115. In many embodiments, the lower forming insert 119 has an interfacing surface 172 opposite its forming surface 170 that is interfaced removably with the upwardly- facing channel 134. The interfacing surface 172 of the lower forming insert 119 can have a width that is substantially equal to a width of the face (and/or substantially equal to a maximum width) of the lower forming insert 119.

The forming inserts 117, 119 can optionally be secured to the adapters 113, 115 by male projections 180 and female receptacles 182. As shown in Figure 5, the upper forming insert 117 includes laterally extending male projections 180, and the upper adapter 113 includes complementary female receptacles 182. In such embodiments, the projections 180 can be configured to be inserted into the receptacles 182 to secure the upper forming insert 117 to the upper adapter 113. In some embodiments, the lower forming insert 119 includes male projections and the lower adapter 115 includes complementary female receptacles. In other embodiments, the adapters 113, 115 include male projections and the forming inserts 117, 119 include complementary female receptacles. As shown in Figure 3, such projections 48 can optionally pass through holes (or "bores") in the adapters 13, 15 to mate with such complementary female grooves 49 in the forming inserts 17, 19. Thus, some embodiments involve a plurality of moveable projections 48 carried by the adaptor 13, and these projections are adapted to be moved selectively into or out of engagement with forming inserts 17 received in the adapter's channel 26. In such cases, when the projections 48 engage the forming inserts 17, the inserts are prevented from falling downwardly out of the adapter's channel. If desired, the projections 48 can be pins, shafts, or the like that are moveable axially toward and away from the adapter's channel 26. In the embodiment of Figure 3, the projections 48 can be pins that are externally threaded and engaged with internally threaded bores formed in the adapter. To move such a pin toward or away from the adapter's channel (and into or out of engagement with the side of a forming insert in that channel), one could use an Allen wrench or the like to rotate the pin along the internally threaded bore in which it is received. These details, however, are merely exemplary. And more generally, a variety of combinations of projections and receptacles can be used in embodiments of the present invention. Referring again to Figure 5, the adapter-based forming tool system 107 can function like a mechanical forming tool. In such embodiments, the forming inserts 117, 119 are mechanical forming tools. Thus, they are configured to bend on multiple planes, e.g., so as to create a complex form in a workpiece. Fore example, at least part of the complex form may comprise a bend arranged so as to be oblique to the press brake's longitudinal axis. Examples of such forms include card guides (see the completed workpiece 40 in Figures 2-4), louvers, bridges, lance and forms, embosses, and electrical knock-outs. In some embodiments, the forming surfaces 150, 170 of the upper and lower forming inserts 117, 119 are the only surfaces of the adapter-based forming tool system that contact the upper and lower surfaces 142, 144 of the workpiece 140 during pressing operations (in such embodiments, the adapter does not act on the workpiece during pressing).

The adapter-based forming tool system 107 can have self-stripping functionality. In some embodiments, the upper forming insert 117 has a main body 127 adapted to remain substantially stationary relative to the upper adapter 113 during pressing operations. In some embodiments, the lower forming insert 119 has a main body 135 adapted to remain substantially stationary relative to the lower adapter 115 during pressing operations. In some embodiments, at least one of the upper and lower forming inserts 117, 119 is a self-stripping forming insert. In such embodiments, the self-stripping insert can have at least one resiliently-biased part configured to contact the workpiece 140 during pressing operations. In some embodiments, the adapters 113, 115 are configured to release the forming inserts 117, 119 and to receive different forming inserts. The different forming inserts can be configured to create a different type of form. Thus, the adapter-based insert system allows manufacturers to quickly change-out one set of forming inserts in favor of another set of forming inserts.

Embodiments of the present invention include a modular forming-insert assembly for a press brake. The modular forming-insert assembly includes at least two insert modules. In some embodiments, the assembly comprises at least three insert modules, including two end-piece modules and at least one middle-piece module. The modular forming-insert assembly can be used to create forms in workpieces during pressing operations in any of the ways discussed above or in any of the ways that follow.

The insert modules can be arranged so that they collectively make a form (e.g., a single form) in a workpiece during a pressing operation. In some embodiments, each insert module is configured to be mounted removably in a channel (such as a channel of an adapter like those discussed above) having a generally rectangular cross section. Each insert module can have an interfacing surface configured to interface removably with the channel. Each interface module can have a forming surface that is opposite its interfacing surface and that is configured to contact a surface of a workpiece during pressing operations. In some embodiments, the interfacing surface of each insert modules has a width that is substantially equal to a width of the face (and/or substantially equal to the maximum width) of such insert module. In some such embodiments, each insert module includes laterally extending male projections configured to be inserted into complementary female receptacles in the adapter or other tool holder to secure the insert module to the adapter or other tool holder. As already explained, the inserts may alternatively have female recesses (e.g., grooves), rather than male projections.

When assembled, the modular forming-insert assembly can function like a mechanical forming tool. The insert modules can be configured to be secured in an end-to-end arrangement longitudinally to collectively define a mechanical forming tool. Here, all the insert modules when operatively mounted can optionally have side surfaces that abut (i.e., touch) one another. Thus, each two adjacent insert modules can share at least one contiguous interface. This can be seen, for example, in Figure 4. In some embodiments, at least one (optionally each of a plurality, or each) of the insert modules has a main body adapted to remain substantially stationary relative to the adapter or other tool holder during pressing operations. In some such embodiments, at least one (optionally each of a plurality, or each) of the insert modules is a self-stripping insert module that has at least one resiliently-biased part configured to contact the workpiece during pressing operations.

In certain embodiments, a forming tool alignment mechanism is provided. The alignment mechanism, for example, can be provided to help secure the forming inserts in their operative positions during pressing operations. As one example, in embodiments involving a modular lower insert assembly, the alignment mechanism can comprise a lower alignment mechanism securing the lower insert modules in an end-to-end arrangement. Here, the alignment mechanism can optionally comprise first and second stops located on opposed ends of the arranged lower insert modules so as to hold those insert modules snuggly against one another. Figure 4 shows an exemplary stop 800 on one side of a series of lower insert modules. If desired, the alignment mechanism can comprise a resiliently-biased squeezer type system. Or, it can comprise rigid bodies that function somewhat like bookends to hold the modules in their operative arrangement. Many variants of this nature will be apparent to skilled artisans given the present teaching as a guide.

In the foregoing detailed description, the invention has been described with reference to specific embodiments. However, it may be appreciated that various modifications and changes can be made without departing from the scope of the invention as set forth in the appended claims. Thus, some of the features of preferred embodiments described herein are not necessarily included in preferred embodiments of the invention which are intended for alternative uses.

Claims

What is claimed is:

1. A press brake in combination with an adapter-based forming tool system, wherein:

(a) the press brake is elongated along a longitudinal axis, the press brake having an upper beam and a lower beam; and

(b) the adapter-based forming tool system includes:

(i) an upper adapter carried by the upper beam and having a first side with a tang and a second side with a downwardly-facing channel,

(ii) a lower adapter carried by the lower beam and having a first side with a tang and a second side with an upwardly-facing channel,

(iii) an upper forming insert mounted removably in the downwardly- facing channel and having a forming surface configured to contact an upper surface of a workpiece during pressing operations, and

(iv) a lower forming insert mounted removably in the upwardly-facing channel and having a forming surface configured to contact a lower surface of the workpiece during pressing operations, wherein (A) the forming inserts are mechanical forming tools configured to create a complex form in the workpiece, at least part of the complex form comprising a bend arranged so as to be oblique to the press brake's longitudinal axis, and (B) the adapters are configured to release the forming inserts and to receive different forming inserts configured to create a different type of form.

2. The combination of claim l, wherein the downwardly-facing channel and the upwardly-facing channel each have a generally rectangular configuration in a cross section perpendicular to the longitudinal axis.

3. The combination of claim 1, wherein the upper forming insert has a main body adapted to remain substantially stationary relative to the upper adapter during pressing operations, and the lower forming insert has a main body adapted to remain substantially stationary relative to the lower adapter during pressing operations.

4- The combination of claim 3, wherein at least one of the upper and lower forming inserts is a self-stripping forming insert having at least one resiliently-biased part configured to contact the workpiece during pressing operations.

5. The combination of claim 1, wherein the upper adapter includes a main body, the upper adapter tang projecting upwardly from the upper adapter main body and having a smaller width than the upper adapter main body, and wherein the lower adapter includes a main body, the lower adapter tang projecting downwardly from the lower adapter main body and having a smaller width than the lower adapter main body.

6. The combination of claim 1, wherein the upper forming insert is a modular forming-insert assembly comprising at least two upper insert modules secured in an end-to-end arrangement longitudinally, and wherein the lower forming insert is a modular forming-insert assembly comprising at least two lower insert modules secured in an end-to-end arrangement longitudinally.

7. The combination of claim 6 comprising an upper alignment mechanism securing the upper insert modules in said end-to-end arrangement, the upper alignment mechanism comprising first and second upper stops located on opposed ends of the arranged upper insert modules so as to hold the arranged upper insert modules snuggly against one another, and comprising a lower alignment mechanism securing the lower insert modules in said end-to-end arrangement, the lower alignment mechanism comprising first and second lower stops located on opposed ends of the arranged lower insert modules so as to hold the arranged lower insert modules snuggly against one another.

8. The combination of claim 1, wherein the forming surface of the upper insert defines at least part of a face of the upper insert, the upper forming insert having an interfacing surface opposite its forming surface that is interfaced removably with the downwardly-facing channel, the interfacing surface of the upper forming insert having a width that is substantially equal to a width of the face of the upper forming insert, and wherein the forming surface of the lower insert defines at least part of a face of the lower insert, the lower forming insert having an interfacing surface opposite its forming surface that is interfaced removably with the upwardly-facing channel, the interfacing surface of the lower forming insert having a width that is substantially equal to a width of the face of the lower forming insert.

9. The combination of claim 1, wherein the upper forming insert includes a female receptacle, adapted to receive a male projection of the upper adapter, the male projection being configured to be inserted into the receptacle to secure the upper forming insert to the upper adapter.

10. The combination of claim 1 wherein the forming inserts are configured such that the complex form comprises a form selected from the group consisting of card guides, louvers, bridges, lance and forms, embosses, and electrical knock-outs.

11. An adapter-based forming tool system comprising: (a) an upper adapter configured to be carried by an upper beam of a press brake that is elongated along a longitudinal axis, the upper adapter having a first side with a tang and a second side with a channel;

(b) a lower adapter configured to be carried by a lower beam of the press brake, the lower adapter having a first side with a tang and a second side with a channel;

(c) an upper forming insert adapted to be mounted removably in the channel of the upper adapter and having a forming surface configured to contact an upper surface of a workpiece during pressing operations; and (d) a lower forming insert adapted to be mounted removably in the channel of the lower adapter and having a forming surface configured to contact a lower surface of the workpiece during pressing operations, wherein (i) the forming inserts are mechanical forming tools configured to create a complex form in the workpiece, at least part of the complex form comprising a bend arranged so as to be oblique to the press brake's longitudinal axis.

12. The adapter-based forming tool system of claim li, wherein the upper adapter's channel and the lower adapter's channel each have a generally rectangular configuration in a cross section perpendicular to the longitudinal axis.

13. The adapter-based forming tool system of claim 11, wherein the upper forming insert has a main body adapted to remain substantially stationary relative to the upper adapter during pressing operations, and the lower forming insert has a main body adapted to remain substantially stationary relative to the lower adapter during pressing operations.

14. The adapter-based forming tool system of claim 11, wherein the upper and lower forming inserts are self-stripping forming inserts each having at least one resiliently-biased part configured to contact the workpiece during pressing operations.

15. The adapter-based forming tool system of claim 11, wherein the upper adapter includes a main body, the upper adapter tang projects from the upper adapter main body and has a smaller width than the upper adapter main body, and wherein the lower adapter includes a main body, the lower adapter tang projects from the lower adapter main body and has a smaller width than the lower adapter main body.

16. The adapter-based forming tool system of claim 11, wherein the upper forming insert is a modular forming-insert assembly comprising at least two upper insert modules adapted to be secured in an end-to-end arrangement longitudinally, and wherein the lower forming insert is a modular forming- insert assembly comprising at least two lower insert modules adapted to be secured in an end-to-end arrangement longitudinally.

17. The adapter-based forming tool system of claim 16 further comprising an upper alignment mechanism adapted for securing the upper insert modules in said end-to-end arrangement, and a lower alignment mechanism adapted for securing the lower insert modules in said end-to-end arrangement.

18. The adapter-based forming tool system of claim 11, wherein the upper forming insert has an interfacing surface opposite its forming surface that is adapted to be interfaced removably with the upper adapter's channel, the interfacing surface of the upper forming insert having a width that is substantially equal to a maximum width of the upper forming insert, and wherein the lower forming insert has an interfacing surface opposite its forming surface that is adapted to be interfaced removably with the lower adapter's channel, the interfacing surface of the lower forming insert having a width that is substantially equal to a maximum width of the lower forming insert.

19. The adapter-based forming tool system of claim 11, wherein the upper forming insert includes a female receptacle adapted to receive a male projection of the upper adapter, the male projection being configured to be inserted into the receptacle to secure the upper forming insert to the adapter.

20. A modular forming-insert assembly for a press brake that is elongated along a longitudinal axis, comprising: (a) at least two insert modules,

(i) each insert module being configured to be mounted removably in a channel having a generally rectangular cross section,

(ii) each insert module having (A) an interfacing surface configured to interface removably with the channel and (B) a face comprising a forming surface opposite the interfacing surface, the forming surface configured to contact a surface of a workpiece during pressing operations, and (iii) the insert modules being configured to be secured in an end-to-end arrangement longitudinally to collectively define a mechanical forming tool configured to create a complex form in the workpiece, at least part of the complex form comprising a bend arranged so as to be oblique to the press brake's longitudinal axis.

21. The modular forming-insert assembly of claim 20, wherein the insert modules are configured such that the complex form is selected from the group consisting of card guides, louvers, bridges, lance and forms, embosses, and electrical knock-outs.

22. The modular forming-insert assembly of claim 20, wherein the insert modules are self-stripping insert modules each having at least one resiliently-biased part configured to contact the workpiece during pressing operations.

23. The modular forming-insert assembly of claim 20, wherein the interfacing surface of each insert module has a width that is substantially equal to a width of the face of such insert module.

24. The modular forming-insert assembly of claim 20, wherein each insert module has opposed lateral sides each with a female recess formed therein.

25. The modular forming-insert assembly of claim 20, wherein there are at least three insert modules including two end-piece insert modules and at least one middle-piece insert module.