Automated spacer frame fabrication

A method for fabricating elongated window or door components from strip stock including multiple work stations for treating strip stock as the strip stock moves through the multiple work stations comprising:

• a) providing a dual acting fluid powered actuator at a corner forming station and coupling an output from the actuator to a die for moving the die into contact with the strip stock at controlled corner locations along a length of the strip stock for forming bendable corners;
• b) pressurizing a first chamber of the actuator to move a die into contact with a surface of the strip stock at the controlled corner locations while venting a second chamber of the actuator through a flow control valve for relieving pressure at a controlled rate in the second chamber of said actuator as fluid is pressurizing the first chamber of said actuator;
• c) bending the strip stock into a desired shape;
• and
• d) separating a lead component from subsequent components after the lead component has been contacted by the die and bent into the desired shape.

A method for fabricating elongated window or door components from strip stock including multiple work stations for treating strip stock as the strip stock moves through the multiple work stations comprising:

• a) providing a dual acting fluid powered actuator at a corner forming station and coupling an output from the actuator to a die for moving the die into contact with the strip stock at controlled corner locations along a length of the strip stock for forming bendable corners;
• b) pressurizing a first chamber of the actuator to move a die into contact with a surface of the strip stock at the controlled corner locations while venting a second chamber of the actuator through a flow control valve for relieving pressure at a controlled rate in the second chamber of said actuator as fluid is pressurizing the first chamber of said actuator;
• c) bending the strip stock into a desired shape;
• and
• d) separating a lead component from subsequent components after the lead component has been contacted by the die and bent into the desired shape;
• e) wherein an uncoiling station comprises multiple coils of strip stock and wherein a first coil of strip stock is unwound to form generally flat strip stock and then directed along a path to the corner forming station and having a first composition and wherein a second coil of strip stock is unwound to form generally flat strip stock and directed along a path to the corner forming station and having a second composition, said second composition different from the first composition.

A method for fabricating elongated window or door components from strip stock including multiple work stations for treating strip stock as the strip stock moves through the multiple work stations comprising:

• a) providing a dual acting fluid powered actuator at a corner forming station and coupling an output from the actuator to a die for moving the die into contact with the strip stock at controlled corner locations along a length of the strip stock for forming bendable corners;
• b) pressurizing a first chamber of the actuator to move a die into contact with a surface of the strip stock at the controlled corner locations while venting a second chamber of the actuator through a flow control valve for relieving pressure at a controlled rate in the second chamber of said actuator as fluid is pressurizing the first chamber of said actuator;
• c) bending the strip stock into a desired shape;
• d) separating a lead component from subsequent components after the lead component has been contacted by the die and bent into the desired shape;
• e) wherein the fluid powered actuator is coupled to a die support that moves the die into contact with the strip stock and further comprising a step of limiting movement of the die by moving a first movement limiting surface into a position for contacting the die support for an elongated strip comprising at least one material and moving a second movement limiting surface into said position for contacting the die support for an elongated strip comprising at least a second material.

A method for fabricating elongated window or door components from strip stock including multiple work stations for treating strip stock as the strip stock moves through the multiple work stations comprising:

• a) providing a dual acting fluid powered actuator at a corner forming station and coupling an output from the actuator to a die for moving the die into contact with the strip stock at controlled corner locations along a length of the strip stock for forming bendable corners;
• b) pressurizing a first chamber of the actuator to move a die into contact with a surface of the strip stock at the controlled corner locations while venting a second chamber of the actuator through a flow control valve for relieving pressure at a controlled rate in the second chamber of said actuator as fluid is pressurizing the first chamber of said actuator;
• c) bending the strip stock into a desired shape;
• d) separating a lead component from subsequent components after the lead component has been contacted by the die and bent into the desired shape;
• and
• e) additionally comprising a step of monitoring an engagement between the die and the strip stock and adjusting a rate at which the fluid exits the second chamber through the variable release valve based on said monitoring.

A method of fabricating multiple spacer frames from an elongated strip for use in fabricating insulating glass units, said method comprising:

• a) positioning a punch drive with respect to a path of travel of the elongated strip and moving a die toward and away from the elongated strip into and out of contact with a surface of the elongated strip at controlled locations along a length of said elongated strip to form a notch which extends inwardly from an edge of the elongated strip and to deform a surface of the elongated strip contacted by the die to form a weakened zone adjacent to the notch in the elongated strip at a spacer frame corner location;
• b) after the punch drive has formed a notch and weakened zone in the elongated strip, bending the elongated strip into a desired shape;
• and
• c) separating a lead, spacer frame defining portion of the elongated strip from said elongated strip after the lead, spacer frame defining portion of the elongated strip has been notched and bent;
• d) wherein energy transferred from the die to the elongated strip during contact between the die and the elongated strip to form the weakened zones is adjusted based upon a composition of the elongated strip.

A method for fabricating a spacer frame that forms part of an insulating glass unit comprising:

• advancing an elongated strip from which one or more spacer frames is fabricated along a travel path;
• mounting a die to a die support in relation to the travel path for moving the die in and out of contact with the elongated strip to form notches and closely adjacent deformed regions at spacer frame corner locations;
• providing a first movement limiting stop surface for contacting the die support as said die moves relative the elongated strip;
• providing a second movement limiting stop surface for contacting the die support as said die moves relative the elongated strip;
• driving the die into contact with the elongated strip to form said notches and said closely adjacent deformed regions;
• and
• limiting movement of the die to control deformation of the deformed regions by positioning a selected one of said first or second movement limiting stop surfaces to contact the die support as the die moves relative to the elongated strip.