Apparatus for producing elongated workpieces of predetermined transverse profile

Apparatus for converting flat metal strip of indeterminate length into identical workpieces, each having opposite front and rear end edges of predetermined shape between which the workpiece has a predetermined length, and each curved out of flatness across its width to a predetermined profile that is uniform along its length, said apparatus comprising a plurality of roller forming heads cooperating to define a straight path and whereby strip is advanced lengthwise along said path in a forward direction at a substantially constant speed and is progressively formed to said profile, said apparatus being characterized by:

• a punch press along said path, spaced to the rear of the roller forming heads, for performing an operation on the strip each time it is advanced through substantially a predetermined distance that is longer than said length, said press having flying punch and die elements which cooperate to punch through the strip at each said operation,
• said elements being formed and arranged to produce, at each said operation, a front aperture and a rear aperture,
• (1) said apertures being spaced apart lengthwise along the strip and respectively substantially defining said front and rear end edges, and
• (2) each said aperture extending across a substantially major portion of the width of the strip but terminating inwardly from the side edges of the strip to leave strap-like portions of the strip, one near each of its side edges, which maintain edgewise lateral rigidity of the strip that enables the roller forming heads to confine it to said path.

Apparatus for converting lengthwise continuous flat metal strip into substantially identical elongated workpieces, each having a fold along its length intermediate its side edges and having curvature across its width between said fold and at least one of its side edges, said apparatus comprising:

• A. roller forming means through which strip passes in constant lengthwise motion in one direction at a first speed and by which said curvature is imparted;
• B. a flying shear at a cutoff station spaced in said direction from the roller forming means whereby transverse cuts are made through the strip as it continues in said motion, to sever workpiece blanks from it;
• C. an endless conveyor comprising a pair of laterally spaced apart top stretches cooperable to support a workpiece blank bridging across them and
• (1) which extend from said cutoff station to a folding station spaced in said direction from the cutoff station and
• (2) which move constantly in said direction at a second speed, faster than said first speed, to lengthwise separate each severed blank from the strip while carrying the blank to the folding station;
• D. a folding press at said folding station comprising
• (1) a ram having a blade-like upper portion movable up and down between said stretches and having an upper edge extending in said direction,
• (2) means for actuating said ram up from and down to a lowered position at which said top edge is below a blank on said stretches, and
• (3) a folding die above said ram, said folding die
• (a) having a downwardly opening groove wherein the upper edge portion of the ram is receivable and which cooperates with the same in folding a workpiece that is between the ram and the folding die, and
• (b) being movable up and down between
• (i) a defined lower position wherein the folding die is above said stretches and a workpiece blank on them but is engageable by the blank as it is lifted off of said stretches by the rising ram, and from which the folding die is raised by the ram, and
• (ii) a defined raised position which the folding die attains while the ram continues to rise and at which the ram cooperates with the folding die to fold a workpiece.

A press for performing, on each of a succession of workpieces that move steadily into the press in a forward direction along a defined substantially horizontal path, an operation whereby a width dimension of each workpiece that is transverse to said direction is substantially reduced, said press comprising a ram which is substantially narrower than the workpiece as it moves into the press and a die which cooperates with the ram in performing said operation and which is substantially wider than the ram, said press being characterized by:

• A. a conveyor having
• (1) endless elements that define a pair of upwardly facing and parallel stretches that extend in said forward direction and have front portions at opposite sides of the ram, said stretches being cooperable to support workpieces that bridge across them as those workpieces move towards the ram, and
• (2) means for driving said endless elements to cause said stretches to move steadily in unison in said direction;
• B. said ram being movable between
• (1) a lowered position in which workpieces carried on said stretches can pass over the ram, and
• (2) a raised position in which the ram supports a workpiece at an elevation above said stretches;
• and
• C. said die
• (1) being above the ram, and
• (2) being movable between
• (a) a defined lowered position wherein the die is above said stretches and clear of a workpiece supported on them but is engageable by a workpiece as it is lifted off of said stretches by the rising ram, and
• (b) a defined raised position to which the die is lifted by the rising ram, which the die attains while the ram continues to rise, and at which the die cooperates with the rising ram to perform said operation.

A press comprising a die and a ram that is movable relatively toward and from the die between first and second positions, said ram being spaced from the die in its first position to permit workpieces to be loaded into and unloaded from the press and being cooperable with the die in moving to its second position to perform an operation upon a workpiece confined between it and the die whereby a width dimension of the workpiece is substantially reduced, said press being characterized by:

• A. a conveyor having a pair of upwardly facing parallel stretches which extend horizontally in a forward direction and have front end portions at opposite sides of the ram, said stretches being driven for steady unison movement in said forward direction and being laterally spaced apart to cooperate in carrying into the press a workpiece that bridges across them with its said width dimension transverse to said direction;
• B. said ram
• (1) having a width transverse to said direction that is smaller than said width diemension of workpieces supported on said conveyor,
• (2) having its first position at a level such that workpieces supported on said conveyor can pass over it, and
• (3) having its second position at a substantially distance above its first position such that in moving from its first position to its second position it lifts a workpiece off of the conveyor and to an elevation above the same;
• and
• C. said die
• (1) having a width substantially greater than that of the ram, and
• (2) being movable up and down between
• (a) a defined lower position at which the die is above the conveyor and a workpiece thereon but is engaged by a workpiece lifted by the ram, and
• (b) a defined raised position to which the die is raised by the ram, which the die attains while the ram continues to move to its second position, and at which the die cooperates with the ram in performing said operation.