US 4,006,617 A · Method and apparatus for roll forming tapered structural members

Abstract

A plurality of forming stations, each individually numerically controlled to sequentially roll form a blank into a tapered structural member, is disclosed. Each forming station includes upper and lower assemblies of forming rolls mounted on a pair of adjacent shafts so as to generally define an orifice through which the blank passes as it is roll formed. One of the shafts is continuously position adjustable, as are selected forming rolls of the forming roll assemblies. Thus, both the size and shape of the orifice are continuously adjustable. Position sensors continuously sense the positions of the position controllable shaft and forming rolls of each station and generate feedback signals related thereto. The feedback signals are continuously compared with numerical control signals received by a controller. The results of the comparisons produce error signals that are used to continuously control the position of the position controllable shafts and forming rolls.

Claims42

Dependent claims

A method of roll forming tapered structural members comprising the steps of:

passing a blank through a plurality of roll forming stations, each of said stations including assemblies of forming rolls, at least one of said forming rolls of each assembly being individually and differently position adjustable with respect to the position of the position adjustable forming rolls of the other of said plurality of roll forming stations;
and,
controlling the position of said position adjustable forming rolls of said plurality of roll forming stations as said blank passes through said plurality of roll forming stations in a manner such that the position of said position adjustable forming rolls of each roll forming station are selectively, independently varied in an individual and different manner between zero variation and continuous variation as a given point of said blank passes through said plurality of roll forming stations such that at least a portion of said blank is tapered.

Numerically controlled apparatus for roll forming tapered structural members comprising:

a plurality of forming stations positioned so as to sequentially roll form a blank passing therethrough, each of said forming stations including an assembly of forming rolls, at least one of said forming rolls of each of said assemblies of forming rolls being individually and differently position adjustable with respect to the position of the position adjustable forming rolls of the other of said plurality of roll forming stations;
and,
control means for receiving numerical control signals connected to said plurality of forming stations for selectively controlling the position adjustable rolls of said assemblies of forming rolls in accordance with said numerical control signals such that the position adjustable forming rolls of said assemblies of forming rolls are separately, independently adjusted in an individual and different manner.

A roll forming station suitable for numerical control comprising:

a first shaft;
a second shaft mounted parallel to said first shaft;
a first assembly of forming rolls mounted on said first shaft;
a second assembly of forming rolls mounted on said second shaft;
a first position control means for varying the position of at least one of the forming rolls of said first and second assemblies of forming rolls between a zero position change and continuous position changes as a blank to be roll formed passes through said roll forming station;
and,
a first position sensing means for sensing the position of the forming roll whose position is varied by said first control means.

4 more elements

Dependencies are inferred from the claim text.

Method and apparatus for roll forming tapered structural members

Life of this patent

Method and apparatus for roll forming tapered structural members

Life of this patent

Abstract

Claims42