Automated spacer frame fabrication

Apparatus for fabricating elongated window or door components from strip stock of different material including multiple work stations for treating strip stock as the strip stock moves through the multiple work stations comprising:

• a) a corner forming station having a punch drive for moving a die into contact with a flat surface of the metal strip at controlled corner locations along a length of said strip;
• b) a forming station for bending the strip into a desired shape;
• and
• c) a severing station for separating a lead component from subsequent components after the lead component has moved through the notching and forming stations;
• d) said corner forming station comprising an adjustable stop that limits movement of the punch drive to control engagement between the strip and the die.

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

• a) selecting one of a multiple number of possible spacer frame materials for use in fabricating the spacer frame;
• b) advancing an elongated strip of said selected one material to a notching station;
• c) forming notches at corner locations of a specific character that are adjusted based on the selection of the metal strip material;
• d) bending the metal strip into a channel shaped elongated frame member having side walls;
• and
• e) severing a leading strip of channel shaped material from succeeding material passing through a notching and bending location.

Apparatus 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) a corner forming station having a dual acting fluid powered actuator for moving a die into contact with a surface of the strip stock at controlled corner locations along a length of said strip stock;
• said actuator including a variable release valve for relieving pressure at a controlled rate in one chamber of said actuator as fluid is pressurizing a second chamber of said actuator,
• b) a forming station for bending the stock strip into a desired shape;
• and
• c) a severing station for separating a lead component from subsequent components after the lead component has moved through the notching and forming stations.

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 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 variable release valve for relieving pressure at a controlled rate in the second chamber of said actuator as fluid is pressurizing a the first chamber of said actuator,
• c) bending the stock strip into a desired shape;
• d) separating a lead component from subsequent components after the lead component has notched and bent.

Apparatus for fabricating elongated window or door components from strip stock including multiple work stations for treating the strip stock as the strip stock moves along a travel path through the multiple work stations comprising:

• a) a corner forming station for forming controlled corner locations along a length of said strip stock comprising:
• i) a first die for deforming one side of the strip stock;
• ii) a second die for deforming an opposite side of the strip stock;
• iii) a ram assembly having a punch drive that supports the first and second dies for driving the first and second dies into engagment with the strip stock;
• iv) a stop assembly for limiting movement of the ram assembly;
• and
• v) an adjustable width spacer for controlling a separation between the first and second dies;
• b) a roll forming station for bending the strip into a desired shape;
• and
• c) a severing station for separating a lead component from subsequent components after the lead component has moved through the corner forming and roll forming stations;
• d) said stop assembly comprising an adjustable stop that limits movement of the ram assembly to control engagement between the strip stock and the first and second dies.

A method for punching corner locations along a length of strip stock for fabricating a window or door component from the strip stock, said method comprising:

• mounting a first adjustable die assembly having a first die for back and forth movement perpendicular to a strip stock path of travel to accommodate different width strip stock;
• positioning a second die assembly having a second die on an opposite side of the strip stock path of travel;
• coupling a ram assembly to the first and second die assemblies for driving the dies into engagment with the strip stock to form a corner location;
• providing a reference position for locating the first adjustable die assembly by fixing a reference surface in a position based on a width of the strip stock;
• and
• trapping an adjustable width spacer element between the reference surface and a die assembly surface of the adjustable die assembly that is generally parallel to the reference surface to set a distance between the path of travel and the reference surface.