Variable width roll forming apparatus

A method for adjusting an axial displacement of at least two roller die assemblies of a roll forming apparatus relative to a side plate through which said roller die assemblies are housed, each of said roller die assemblies comprising an upper die assembly and a lower die assembly configured to receive a web therebetween, said method comprising the steps of:

• securing a collector plate to only one of said upper die assemblies and said lower die assemblies;
• operatively linking said collector plate to said side plate via a drive mechanism;
• selectively operating said drive mechanism to move said collector plate in an orthogonal direction to said side plate, wherein said drive mechanism operates to move said collector plate without rotation of said upper die assembly and said lower die assembly;
• and
• moving one of said upper die assemblies and said lower die assemblies not secured to said collector plate in registration with said movement of said collector plate.

A variable width roll forming apparatus for progressively forming a web of material directed therethrough, said roll forming apparatus comprising:

• a first side plate extending substantially an entire length of said roll forming apparatus;
• a second side plate extending substantially an entire length of said roll forming apparatus, said first side plate and said second side plate being oriented on opposing sides of an axis of movement of said web substantially equidistant from one another;
• a plurality of roller die assemblies disposed in apertures formed in said first side plate and said second side plate, said roller die assemblies each include an upper die assembly and a lower die assembly;
• an adjusting apparatus for selectively changing a separation width between predetermined roller die assemblies in said first side plate and said second side plate, said adjusting apparatus includes a collector plate fixed to one of said upper die assembly and said lower die assembly disposed in one of said first side plate and said second side plate, wherein said roll forming apparatus defines thereby at least two differing widths between roller die assemblies disposed in said first side plate and said second side plate while maintaining said substantially equidistant spacing between said first side plate and said second side plate;
• and
• wherein operation of said adjusting apparatus causes said collector plate to move in a direction substantially orthogonal to said one of said first side plate and said second side plate.