Large profile sheet metal corrugator

Apparatus for corrugating sheet metal comprising:

• a frame, a plurality of serially arranged corrugating stands mounted to the frame, each stand being defined by a pair of cooperating corrugating rolls;
• the rolls of at least one stand comprising a pair of spaced apart, parallel first and second shafts, and a plurality of generally disc shaped roll dies carried on each shaft, the roll dies being axially arranged over a portion of the length of each shaft and alternatingly defining a relatively large diameter convex roll die, a relatively smaller diameter concave roll die and an intermediate roll die disposed on the shafts intermediate adjacent convex and concave roll dies, the intermediate die having a corrugated sheet engaging surface which generally slopes relative to an axis of the shaft and which has a radial extent intermediate that of the convex and the concave dies;
• means for power rotating at least some of the dies on at least one of the shafts of the one stand;
• whereby the sheet metal is grasped by opposing roll dies of the one stand and the power-rotated roll dies frictionally engage the sheet and advance it in a downstream direction while causing a deformation of the profile of the sheet as it passes between the rolls;
• and means for rotating at least some of the roll dies on the shafts of the one stand at differing rates which take into account differences in the diameters of the dies so that a peripherial speed of the convex die at a first diameter, a peripheral speed of the concave die at a second, different diameter, and a peripheral speed of the intermediate die at a third diameter which differs from the first and second diameters are substantially equal to the speed with which the sheet passes the one stand.

In an apparatus for corrugating sheet metal, the apparatus having a frame, a plurality of serially arranged corrugating stands each defined by opposing and cooperating first and second corrugating rolls and means rotatably mounting the rolls to the frame, and power means for driving the rolls at predetermined speeds so that a flat sheet inserted between the first and second rolls of the first stand is grasped by the rolls and transported in a downstream direction towards the last stand of rolls while the flat sheet becomes longitudinally corrugated and issues from the last stand as a finish corrugated sheet, the improvement to the frame comprising:

• a base, a bearing block for each roll having a generally rectangular outline;
• means rigidly connected with the base and defining a mounting flange;
• bolt means for the bearing blocks of each stand rigidly biasing the bearing blocks against each other and against the mounting flange so that the mounting flange and the bearing blocks form a rigid and immovable member;
• and means establishing metal-to-metal contact areas over substantially the full extent of the members between adjoining bearing blocks for the first and second rollers, respectively, of all stands;
• whereby upon the tightening of the bolt means the bearing blocks define a continuous, rigid beam which mounts all rolls and which, upon the loosening of the bolt means, permits the ready removal of any one or all of the rolls.

In an apparatus for roll forming a flat sheet into a corrugated sheet having an undulating profile defined by alternating corrugation peaks and corrugation troughs each forming a generally concave surface and a parallel, generally convex surface, the apparatus including at least an upper forming roll disposed on one side of the sheet and a cooperating lower forming roll disposed on another side of the sheet, a first, generally disc shaped die having, in profile, a generally convexly shaped periphery and a relatively large maximum diameter, means for rotatably mounting the first die;

• a second, generally disc shaped die having, in profile, a generally concave periphery and a relatively smaller maximum diameter;
• means for rotatably mounting the second die in an axially spaced relation from the first die so that the peripheries of the dies, in profile, correspond to the desired shape of the convex and concave surfaces of the corrugated sheet and so that the dies rotate about parallel axes, the disc shaped dies being defined by pairs of opposing, disc shaped, axially spaced die halves;
• adjustable spacing means disposed between cooperating die halves and threadably engaging at least one of each pair of opposing die halves for selectively and continuously varying the spacing between such die halves;
• and means for power-rotating at least one of the disc shaped dies.

Apparatus for corrugating sheet metal comprising:

• a frame, a plurality of serially arranged corrugating stands mounted to the frame, each stand being defined by a pair of cooperating corrugating rows, the rows of at least one stand comprising a pair of spaced apart, parallel first and second shafts, and a plurality of generally disc shaped roll dies carried on each shaft, the roll dies being axially arranged over a portion of the length of each shaft and alternatingly defining a relatively large diameter convex roll die and a relatively smaller diameter concave roll die;
• at least one of the roll dies being defined by a disc mounted to the corresponding shaft, the disc including on its periphery a radially protruding lip;
• first and second die rings demountably applied over the periphery of the disc and defined by spaced apart, angularly shaped ring halves, the ring halves including grooves formed and arranged to engage the lip;
• means securing the ring halves to the disc;
• means biasing the ring halves towards each other and into engagement with the lip, whereby the interengagement of the grooves and the lip opposes forces acting on the rings in a generally axial direction during the corrugation of the sheet;
• and means for power-rotating at least some of the dies on at least one of the shafts of the one stand;
• whereby the sheet metal is grasped by opposing roll dies of the one stand and the power-rotated roll dies frictionally engage the sheet and advance it in a downstream direction, causing a deformation of the profile of the sheet as it passes between the rolls.