Automated spacer frame fabrication

A method for 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 along a travel path;
• c) mounting a die to a die sur port in relation to the travel path for moving the die in and out of contact with the elongated strip:
• d) driving the die into contact with the elongated strip to form notches and closely adjacent deformed regions at spacer frame corner locations;
• e) limiting movement of the die by an amount to control deformation of the deformed regions based on the selection of the metal strip material by positioning a stop surface to contact the die support as the die is driven into contact with the elongated strip;
• f) 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.

A method for fabricating elongated window or door components from strip stock including multiple work stations fir 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 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 been notched and bent.

Apparatus for fabricating elongated spacer frames from an elongated metal strip as the elongated metal strip stock moves along a travel path work stations comprising:

• a) a corner forming station for forming controlled corner locations along a length of said elongated metal strip comprising:
• i) a first die for forming a weakened zone on one side of a centerline of the strip;
• ii) a second die for forming a weakened zone on an opposite side of the centerline of the elongated metal strip;
• iii) a ram assembly having a die support that extends across a region of the travel path and that supports the first and second dies for driving the first and second dies into engagement with the elongated metal strip;
• and
• iv) a stop assembly for limiting movement of the die support;
• and
• b) a roll forming station for bending the eloped metal strip into a desired shape;
• and
• c) a severing station for separating a lead spacer frame from the elongated metal strip after passing through the corner forming and roll forming stations;
• d) said stop assembly comprising first and second adjustable stops located on opposite sides of the travel path that ha its limit movement of the die support to control engagement between the strip stock and the first and second dies.

A method for forming corner locations by forming weakened zones along a length of elongated metal strip stock for fabricating a spacer frame from the elongated metal strip, said method comprising:

• mounting a first adjustable die assembly having a first die for back and forth movement perpendicular to a strip path of travel to accommodate different width;
• positioning a second die assembly having a second die on an opposite side of the strip path of travel;
• coupling a ram assembly to the first and second die assemblies for driving the dies into engagement with the strip to form weakened zones at a corner location;
• providing a reference position for locating the first adjustable die assembly by fixing reference surface in a position based on a width of the strip;
• 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 first adjustable die assembly.

An apparatus for fabricating multiple spacer frames from an elongated metal strip for use in fabricating insulating glass units, said apparatus comprising:

• a) a punching station comprising:
• i) a punch drive positioned with respect to a path of travel of the elongated metal strip;
• ii) a die for contacting a flat surface of the elongated metal strip at controlled locations along a length of said elongated metal strip to deform a surface of the elongated metal strip contacted by the die and thereby form a weakened zone at a spacer frame corner location;
• and
• iii) a die support supporting the die for movement in response to actuation of the punch drive;
• b) a channel forming station positioned with respect to the path of travel of the elongated metal strip for bending the elongated metal strip to include side walls;
• c) a severing station positioned with respect to the path of travel of the elongated metal strip for separating a lead, spacer frame defining portion of the elongated metal strip from said elongated metal strip after the lead, spacer frame defining portion of the elongated metal strip has moved through the punching and channel forming stations;
• and
• d) a control for adjusting energy transferred from the die to the elongated metal strip based upon a composition of the elongated metal strip comprising an adjustable stop having first and second surfaces generally parallel to a plane of the strip which define first and second limits of travel of said die support and an actuator for selectively moving one or the other of the first and second surfaces into die support engaging position for controllably limiting movement of the die support.