# US 11,298,734 B2 · Multi-axis roll-forming of stepped-diameter cylinder > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,298,734 B2 - Document ID: US11298734B2 - Status: Granted - Kind: B2 - Application number: 16/586,046 - Filed: 2019-09-27 - Published: 2020-04-02 - Granted: 2022-04-12 - Earliest claimed: 2018-09-27 - Assignees: Inno-Spin LLC - Applicants: Inno-Spin LLC - Inventors: Doug Watchorn; Michael Nasson; Maximilian Linder; Brian Ford; Robert Chrouch - Web page: https://patentgrep.com/patent/US11298734B2 ## CPC - B21D 5/086: {for obtaining closed hollow profiles} - B21D 41/02: Enlarging - B21D 22/16: over shaping mandrels or formers - B21D 39/03: of sheet metal otherwise than by folding - B21D: WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL (working or processing of wire B21F) ## Abstract A multi-axis roll-forming system for forming a stepped diameter in a cylinder. The system includes a support configured to spin about a rotation axis while supporting a workpiece including a cylinder. A first actuator is configured to translate a first roller perpendicular to rotation axis. The first roller includes a truncated conical work surface configured to press against the inward-facing surface of the cylinder to angle it outward according to a slant angle of the truncated conical work surface. ## Claims ### Claim 1 A multi-axis roll-forming method for forming a stepped diameter in a cylinder, comprising: spinning the cylinder about a rotation axis encircled by the cylinder, the cylinder having a first diameter; and during the step of spinning: (a) translating a first roller radially outward, relative to the rotation axis, against an inward-facing surface of a lower portion of the cylinder to angle the lower portion radially outward; and (b) after the step of translating, moving at least one multi-axis roller radially outward and upward, against the inward-facing surface as angled radially outward, to press the lower portion against an anvil so as to shape the lower portion into (i) a cylindrical wall having a second diameter that is greater than the first diameter and (ii) a ledge connecting the cylindrical wall characterized by the second diameter to an upper portion of the cylinder characterized by the first diameter, wherein the step of translating maintains a material thickness at a bend connecting the lower portion and the upper portion to no more than six percent of the original material thickness of the cylinder prior to the step of translating. ### Claim 2 (depends on 1) The multi-axis roll-forming method of claim 1, the lower portion being associated with a lower segment of the rotation axis, the step of moving comprising moving the at least one multi-axis roller radially outward, relative to the rotation axis, and upward, parallel to the rotation axis. ### Claim 3 (depends on 1) The multi-axis roll-forming method of claim 1, the step of translating the first roller comprising angling the lower portion radially outward, relative to the rotation axis, to shape the lower portion as a truncated cone connected to the upper portion at a circular inflexion line encircling the rotation axis. ### Claim 4 (depends on 3) The multi-axis roll-forming method of claim 3, a surface of the first roller, contacting the lower portion in the step of translating, being conical. ### Claim 5 (depends on 1) The multi-axis roll-forming method of claim 1, the step of moving comprising maintaining, at the bend and to within six percent, the original material thickness. ### Claim 6 (depends on 1) The multi-axis roll-forming method of claim 1, the step of moving comprising pivoting the at least one multi-axis roller to move the at least one multi-axis roller radially outward and upward along the rotation axis. ### Claim 7 (depends on 6) The multi-axis roll-forming method of claim 6, the step of moving further comprising, during the step of pivoting, translating the at least one multi-axis roller radially outward. ### Claim 8 (depends on 6) The multi-axis roll-forming method of claim 6, the step of pivoting comprising actuating a translation drive to effect said pivoting. ### Claim 9 (depends on 6) The multi-axis roll-forming method of claim 6, the step of pivoting comprising actuating a rotation drive to effect said pivoting. ### Claim 10 (depends on 1) The multi-axis roll-forming method of claim 1, the step of moving comprising translating the at least one multi-axis roller along a direction that is at an oblique angle to the rotation axis, to move the at least one multi-axis roller radially outward and upward along the rotation axis. ### Claim 11 (depends on 1) The multi-axis roll-forming method of claim 1, the step of moving comprising: actuating a first translation drive that translates the at least one multi-axis roller radially outward; and actuating a second translation drive that translates the at least one multi-axis roller in a direction parallel to the rotation axis. ### Claim 12 (depends on 1) The multi-axis roll-forming method of claim 1, wherein the at least one multi-axis roller comprises a first multi-axis roller and a second multi-axis roller, the step of moving comprising: using the first multi-axis roller, forming an initial shape of the cylindrical wall; and subsequently, using the second multi-axis roller, refining the initial shape. ### Claim 13 (depends on 12) The multi-axis roll-forming method of claim 12, the first multi-axis roller including a first circular edge, the step of forming the initial shape comprising pressing the first circular edge against the inward-facing surface, as angled radially outward, to bend the lower portion into the cylindrical wall and the ledge. ### Claim 14 (depends on 12) The multi-axis roll-forming method of claim 12, the second multi-axis roller including a cylindrical work surface and a planar top surface connected to each other at a second circular edge, the step of refining comprising: pressing the cylindrical work surface against the inward-facing surface of the cylindrical wall; and pressing the planar top surface against downward-facing surface of the ledge. ### Claim 15 (depends on 1) The multi-axis roll-forming method of claim 1, the step of moving comprising pressing a circular edge of the multi-axis roller against the inward-facing surface, as angled radially outward, to bend the lower portion into the cylindrical wall and the ledge. ### Claim 16 (depends on 1) The multi-axis roll-forming method of claim 1, the cylinder being part of a single continuous workpiece that further includes a lip at an upper end of the cylinder, the lip extending inwards toward the axis of the cylinder, the step of spinning comprising spinning a support that supports the lip. ### Claim 17 (depends on 1) The multi-axis roll-forming method of claim 1, the anvil including surfaces that define a cavity around the cylinder and are shaped to cooperate with the at least one multi-axis roller to shape the lower portion into the cylindrical wall and the ledge. ### Claim 18 (depends on 1) The multi-axis roll-forming method of claim 1, comprising sequentially processing a plurality of instances of the cylinder at a throughput of at least one cylinder per minute, the step of sequentially processing including, for each cylinder, performing the steps of spinning, translating, and moving. ### Claim 19 (depends on 1) The multi-axis roll-forming method of claim 1, further comprising roll-forming the cylinder from a metal sheet, the step of roll-forming including: bending the metal sheet to contact two opposite ends of the metal sheet to each other; and welding the two opposite ends together.