Automated spacer frame fabrication

An apparatus for fabricating spacer frames from strip stock including multiple work stations for treating the strip stock as the strip stock moves through the multiple work stations, the apparatus comprising:

• a) a corner forming station for moving first and second dies into contact with a flat surface of the strip stock utilizing a dual acting fluid powered actuator at controlled corner locations along a length of said strip stock, the corner forming station comprising:
• i) a first die assembly supporting the first die, the first die for deforming one side of the strip stock;
• ii) a second die assembly supporting the second die, the second die for deforming an opposite side of the strip stock;
• iii) a ram assembly coupled to the first and second die assemblies, the ram assembly for driving the first and second dies into engagement with the strip stock, the ram assembly comprising the dual acting fluid powered actuator, the dual acting fluid powered actuator having first and second chambers, wherein a valve delivers pressurized fluid to the second chamber during an actuator return stroke as the dual acting fluid powered actuator retracts one of the first or second die and exhausts fluid from said second chamber as pressure in the first chamber moves the die downward into contact with the elongated strip, wherein a combination of a quick exhaust valve and a flow control valve, that are both coupled to a body of the dual acting fluid powered actuator, allow air to exhaust from the second pressure chamber of said dual acting fluid powered actuator at a controllable rate;
• and
• iv) a stop assembly for limiting movement of the ram assembly, the stop assembly comprising first and second adjustable stops on opposite sides of a strip stock path of travel, the first and second adjustable stops are contacted by the ram assembly to limit movement of the ram assembly to control deformation of the strip by the first and second die assemblies;
• b) a channel forming station for bending the strip stock into a channel having side walls;
• and
• c) a severing station for separating a lead spacer frame from subsequent spacer frames after the lead spacer frame has moved through the corner forming and channel forming stations;
• d) further wherein said first and second die assemblies punch material from respective strip stock edges to form corner notches and stamp the strip stock to define weakened zones in the strip stock for facilitating folding of the spacer frame at its controlled corner locations.

An apparatus for fabricating elongated window or door components from strip as the strip moves through multiple work stations, the apparatus comprising:

• a) an uncoiling station comprising multiple coils of the strip stock wherein a first coil of the strip stock is unwound to form an elongated strip directed along a path to a corner forming station;
• b) the corner forming station comprising:
• i) a dual acting fluid powered actuator having alternatively pressurizable first and second chambers, further the dual acting fluid powered actuator is operatively connected to a die and die support, the die support for moving the die into contact with said elongated strip at controlled corner locations along a length of the elongated strip for forming bendable corners, wherein said dual acting fluid powered actuator is coupled to the die support, to supply motive force supplied by pressure in the first chamber to the die support;
• ii) a combination of a quick exhaust valve and a flow control valve which are both coupled to a body of the dual acting fluid powered actuator to allow air to exhaust from the second pressure chamber of said dual acting fluid powered actuator at a controllable rate;
• and
• iii) a controller coupled to a valve for alternately pressurizing the first and second chambers of the dual acting fluid powered actuator;
• c) a bending station for bending the elongated strip into a desired shape;
• d) a severing station for 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) a stop including a contact region that engages the die support to limit movement of the die and wherein a position of the contact region of the stop is adjustable.

An apparatus for fabricating elongated window or door components from strip stock as the strip stock moves through multiple work stations, the apparatus comprising:

• a) an uncoiling station comprising multiple coils of the strip stock wherein a first coil of the strip stock is unwound to form an elongated strip directed along a path to a corner forming station;
• b) the corner forming station comprising an dual acting fluid powered actuator having alternately pressurizable first and second pressure chambers coupled to a controller, wherein a valve is provided for alternately pressurizing the first and second pressure chambers to selectively provide pressure to move a die and die support toward and away from the path, respectively, the dual acting fluid powered actuator for moving the die support, and moving the die into contact with said elongated strip at controlled corner locations along a length of the elongated strip for forming bendable corners, and wherein the corner forming station further comprises a combination of a flow control valve and a quick exhaust valve which are both coupled to a body of the dual acting fluid powered actuator so as to allow air to exhaust from the second pressure chamber of said dual acting fluid powered actuator at a controllable rate;
• c) a bending station for bending the elongated strip into a desired shape;
• d) a severing station for separating a lead component of the elongated strip from subsequent components of the elongated strip after the lead component has been contacted by the die and bent into the desired shape;
• and
• e) a stop including a contact region that engages the die support to limit movement of the die and wherein a position of the contact region of the stop is adjustable.