Patent Application
20090056402
The present invention relates generally to shaping and/or straightening segments of material. More specifically, the present invention relates to a tool and method for shaping and/or straightening metal strips or sheets.
Various structures are constructed from elongate segments of material with relatively narrow widths and thicknesses. The construction industry, especially, relies on devices such as aerial work platforms, articulating and telescoping booms, material lifts, scissor lifts, and telehandlers to accomplish various construction-oriented tasks. Each of these types of devices includes a boom or extension constructed from long narrow segments of metal.
Typically, the material used is sheet steel, which is often sold in large rolls. The steel is unrolled, and cut into segments for the desired application. Stresses in the sheet steel, either inherent or created by the cutting process, can cause the segments to deform in one or more planes. Deformations in the plane of the sheet steel (in the x-z plane) can cause the side edges of the sheets to bow and curve, and not align when two sheets are brought together edge-to-edge to be welded to make, for example, a boom structure.
Deformations in the metal sheet can take the form of distortions in the plane (x-z plane) of the metal sheet, as noted above, and can also take the form of distortions perpendicular to the plane of the material (in the x-y plane) such that the metal sheet is not flat. Known devices and methods are capable of flattening the metal strip, to remove curvature in the surface of the metal strip. For example, U.S. Pat. No. 5,953,946 to Mücke et al. is directed to an apparatus and a method for bend-straightening metal strips. U.S. Pat. No. 5,953,946, herein incorporated by reference, discloses passing a metal strip through at least one straightening roll assembly comprising two guide rolls and a straightening roll, such that the guide rolls press the metal strip directly onto the straightening roll as the metal strip is unwound from a supply roll, thus straightening the metal strip. Other patents, such as U.S. Pat. No. 4,949,565 to Kodera et al., U.S. Pat. No. 4,226,111 to Wahli and U.S. Pat. No. 2,486,844 to Hercik, all hereby incorporated by reference, disclose methods and devices used to rectify distortions in metal bodies. U.S. Pat. No. 4,949,565 is directed to straightening an elongated metal member through use of a set of press heads positioned above the metal member and a set of press heads positioned below the metal member, the press heads all positioned substantially perpendicularly to the surface of the metal member. Dependent upon the orientation of the distortion in the surface of the metal member, either the press heads above the metal member, or below the metal member will be used to upwardly or downwardly press the metal member to press out the distortion.
U.S. Pat. No. 4,226,111 is directed to a method and apparatus for working or reshaping elongated workpieces. A strike bolt strikes the inner side of the curvature of the workpiece at high frequency to apply a plurality of strikes to the workpiece. The strike bolt is arranged orthogonally above the length of the elongated workpiece. U.S. Pat. No. 2,486,844 is directed to a method and apparatus for eliminating deformities and/or truing the conformation of metallic parts, especially elongated steel bars. A rotatable cylindrical anvil supports an elongated metallic body, wherein the metallic body is advanced in the direction of its length. An impact means such as an air hammer is positioned vertically above and in the plane with the axis of the rotatable anvil. The metal piece is stretched or elongated locally by convexly flexing the area to be stretched and applying to the convexly stretched face relatively light blows of high frequency, for example, blows delivered by an air hammer. Curvature in the plane of the metal piece requires convex flexing and application of the high frequency blows first to one flat side of the metal piece and then to the other flat side, in order that the hammering may not produce any additional undesired distortion in the metal piece. Generally, the above-noted patents are directed to rectifying distortions in the metal piece that are perpendicular to the plane of the metal piece, that is, in the x-y plane.
However, multiple segments of sheet steel are often welded together along interfacing side edges to form a structure, and if each segment includes curvature or bowing in its side edges (in the x-z plane), the segments must be manually pried and hammered to line up. It is therefore desirable to have as little deformation as possible in each segment to ensure quality of the finished structure as well as to reduce the time and cost in manufacturing.
The present invention comprises a shaping tool capable of shaping and/or straightening edges of a material segment and, particularly, reducing deformities or distortions in side edges of metal sheets. For purposes of this application, the terms “distortion” and “deformity” are synonymous. The shaping tool includes a base, a base material segment supporting assembly, including a transport assembly, adapted to support the material segment; a clamping assembly to hold the material segment in place on the transport assembly; a stopper assembly positioned along the base material segment supporting assembly engageable with a first side edge of the material segment; and a ram assembly selectively engageable with a second side edge of the material segment. The ram assembly engages with a second side edge of the material segment, where the second side edge contains a deformity, removes or reduces the deformity that was present to within acceptable tolerances or, where the second side edge requires shaping, imparts the required shape into the second side edge.
In another aspect, the present invention comprises a method of reducing deformities present in a material segment, particularly metal sheets or bars of material. The method generally comprises placing a material segment on the transport assembly on the base material segment supporting assembly of the tool, such that the edge containing the deformity is positioned proximate a ram assembly. The material segment is held on the transport assembly under a clamping surface of a press plate. Further, the material segment is held snugly laterally against the ram assembly by way of at least two alignment guides. The ram assembly, particularly a ram head component of the ram assembly, engages with the side edge of the material segment, applies force, and reduces/removes the deformity, thus straightening the material segment to within acceptable tolerances established for the material segment. The material segment is measured to confirm that the side edges of the material segment are sufficiently linearly true to meet established requirements.
In yet another aspect, the present invention comprises a shaping tool capable of reducing deformities in the side edges of metal sheets, metal bars, wood sheets, and the like. The shaping tool includes a base, a base metal sheet supporting assembly including a transport assembly adapted to support a metal sheet; a clamping assembly to hold the metal sheet in place on the transport assembly, a stopper assembly to hold the metal sheet laterally in place on the transport assembly; and a ram assembly that selectively forcibly engages an edge of the metal sheet and imparts a desired shape or distortion in the edge of the metal sheet, or reduces/removes a distortion in the side edge of the metal sheet to within acceptable tolerances.
In another aspect, the present invention comprises a method of imparting a desired shape or distortion into a material segment, particularly a metal or wood segment of material. The method generally comprises placing a material segment on the base material segment supporting assembly of the tool such that the side edge requiring shaping is positioned proximate a ram assembly. The material segment is held on the transport assembly on the base material segment supporting assembly under a clamping surface of a press plate. Further, the material segment is held snugly laterally against the ram assembly by way of at least two alignment guides. The ram assembly, in particular, a ram head component of the ram assembly, engages with the side edge of the material segment, applies force, and imparts the desired shape to the side edge of the segment within determined acceptable tolerances. The material segment is measured to confirm that the side edges of the material segment meet established requirements.
The above summary of the various representative embodiments of the invention is not intended to describe each illustrated embodiment or every implementation of the invention. Rather, the embodiments are chosen and described so that others skilled in the art may appreciate and understand the principles and practices of the invention. The figures in the detailed description that follows more particularly exemplify these embodiments.
The present invention can be more completely understood and appreciated by referring to the following more detailed description of the presently preferred exemplary embodiments of the invention in conjunction with the accompanying drawings, of which:
While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives.
Referring to
The base 22 includes a base material segment supporting assembly 28 adapted to receive a material segment 60. The base material segment support assembly 28 includes a material segment supporting assembly first side 21 opposite a material segment supporting assembly second side 23. Further, the material segment supporting assembly 28 also includes a material segment supporting assembly first end 25 opposite a material segment supporting assembly second end 27.
The base material segment support assembly 28 includes a transport assembly 32. The transport assembly 32 is adapted to receive a material segment 60. In one embodiment, the transport assembly 32 includes a frame 30, a plurality of rollers 34, the rollers 34 composing substantially the entire length of the transport assembly 32. In another embodiment, the rollers 34 compose a portion of the length of the transport assembly 32, and in yet another embodiment the transport assembly 32 can have a generally flat, smooth surface. The rollers 34 can assist with loading and unloading materials from the base material segment supporting assembly 28, as well as assist in moving materials longitudinally along the transport assembly 32. The ends 31, 33 of the transport assembly 32 can extend beyond the end 25, 27 of the base material segment supporting assembly 28.
Optionally, a plurality of ball transfers 70 are removably affixed in apertures 72 in the transport assembly frame 30, at the ends 31, 33 of the transport assembly 32. The ends 31, 33 of the transport assembly frame 30 include apertures 72 adapted to receive the ball transfers 70. A ball transfer 70 is depicted in
The transport assembly 32 includes a channel 40. The channel 40 is oriented transversely, crossing the width of the transport assembly 32. Further, the channel 40 includes channel guides 41, 45. The channel guides 41, 45 are engageable with a structure traversing the channel 40. Alternatively, the channel 40 can operate without the channel guides 41, 45.
A stopper assembly 35 is operably positioned along a first side 21 of the base material segment supporting assembly 28. The stopper assembly 35 includes a plurality of mounts 38 which are affixed to the base material segment supporting assembly first side 21. The mounts 38 can be in the form of tubes, stanchions, and the like. The form of the mount 38 is designed to facilitate attachment of an alignment guide 36. In one embodiment, the alignment guide 36 takes the form of a disk with a shaft attached to the disk. In this embodiment, the mount 38 takes the form of a tube. The opening of the tube is adapted to receive the shaft attached to the disk 36. A pin can be slid through an aperture in the shaft, where the aperture has been aligned with an aperture in the tube, thus securing the alignment guide 36 in place. Optionally, a pin does not need to be used and the alignment guide 36 can generally remain in place. In another embodiment, the mount 38 is a stanchion. The alignment guide 36 is disk-shaped, with a central aperture adapted to receive the stanchion. The aperture in the disk-shaped alignment guide 36 is positioned over the stanchion and the disk-shaped guide 36 is mated to the stanchion.
The mounts 38 can extend along the entire length of the base material segment supporting assembly first side 21. Alternatively, the mounts 38 extend only along the length of the base material segment supporting assembly first side 21 proximate the base material segment supporting assembly end 25, 27, leaving the central portion of the base material segment supporting assembly first side 21 without mounts 38. This lack of mounts 38, and therefore alignment guides 36, which is positioned opposite the ram assembly 52, assists in preventing buckling of the material segment 60 when the ram assembly 52 is engaged with the material segment 60.
The stopper assembly 35 is designed to assist in holding a material segment 60 laterally in place on the transport assembly 32. At any given time, all of the mounts 38 do not need to be utilized. However, generally at least two alignment guides 36 are removably affixed to two of the plurality of mounts 38. A range of alignment guides 36 is available for use, with the disk-shaped alignment guides 36 having variously-sized diameters. The choice of which alignment guide 36 to use at any given time is dependent on a number of factors, including the width of the material segment 60. To assist in holding the material segment 60 laterally in place on the transport assembly 32 when the material segment 60 is somewhat narrow, a larger diameter alignment guide 36 can be used. For a material segment 60 of a greater width, a smaller diameter alignment guide 36 can be used to assist in holding the material segment 60 laterally in place on the transport assembly 32. In one embodiment, the alignment guides 36 are made of metal. In another embodiment, the alignment guides 36 are made of hard rubber. Other materials that provide a strong hard surface to the alignment guide 36 are contemplated.
The clamping assembly 24 is configured to hold a material segment 60 in place during a shaping operation. The clamping assembly 24 includes a press plate 42 having a clamping surface 44. At least one rocker arm 46 is pivotably coupled to press plate 42, and anchored to the base 22. Preferably, at least two rocker arms 46 are pivotably coupled to press plate 42 to provide adequate clamping support for longer material segment 60 lengths, as shown in the Figures. The rocker arm 46 includes a first jaw 47 that is pivotably coupled to the top surface 37 of the press plate 42, and a second jaw 49 that is pivotably anchored to the base 22. A clamping assembly actuator 48 is pivotably coupled to a rocker arm 46 and to the base 22, to move the press plate 42 between a material segment 60 clamping position and a material segment 60 clearing position. The clamping assembly actuator 48 may be of the pneumatic, hydraulic, or electric type. The press plate 42 also includes a passage structure 43 such as a relief or bridge 43 to provide clearance for the ram head 54, particularly when the press plate 42 is in a material segment 60 clamping position and the ram head 54 is engaged with the material segment 60.
The ram assembly 26 includes a ram assembly actuator 52 coupled to a ram head 54. The ram assembly actuator 52 may be of the pneumatic, hydraulic, or electric type. The ram head 54 is configured to be shiftable in channel 40 of the transport assembly 32 between a material segment 60 side edge engaging position and a clearing position. The front surface 50 of the ram head 54 includes structure defining a first slot 56; a material segment 60 engagement slot 56. A top surface 51, a bottom surface 58 and a material segment 60 engagement surface 53 define the parameters of the engagement slot 56. The engagement slot 56 is positioned in the upper portion of the ram head 54. The material segment engagement surface 53 of the engagement slot 56 is radiused to provide the required contour for shaping the material segment side edge 64. The rear surface of the ram head 54 includes a tab 67, facilitating the ram head 54 being coupled to the ram assembly actuator 52.
The ram head 54 further includes a guide slot 55, and preferably two guide slots 55, 57. The guide slots 55, 57 are positioned in the lower portion of the side surfaces 59, 61 of the ram head 54, and generally orthogonal to the position of the engagement slot 56. The guide slots 55, 57 are engageable with the channel guides 41, 45. The channel 40 includes channel guides 41, 45 which engage with the guide slots 55, 57, and guide the ram head 54 through the channel 40 to the material segment 60 when there is a material segment 60 positioned on the transport assembly 32. Alternatively, the channel guides 41, 45 can guide the ram head 54 through the channel 40, across the transport assembly 32. The ram head 54 can take various shapes, for example, a sphere or a right rectilinear parallelpiped, for example, a cube.
The shaping tool 20 can be used to remove a deformity 65 from the first side edge 64 of a material segment 60, for example, to make the first side edge more linear or straighter. The first side edge 64 is measured, the material segment 60 is constrained, the ram assembly applied, the constraints on the material segment are loosened, and the first side edge 64 is measured to determine if the first side edge 64 meets requirements. If not, the procedure is repeated. The first side edge 64 can be measured against a line drawn on the base material segment supporting assembly, or by use of a laser beam.
Alternatively, the shaping tool 20 can be used to impart a desired shape into the first side edge of the material segment 60. A particular use can require a certain bowing in the first side edge 64 of the material segment 60. The shaping apparatus 20 can be used as described above, to impart the desired distortion or shape into the first side edge 64 of a material segment. Further, the material segment 60 can be repositioned such that side edge 62 is positioned proximate the ram assembly 26, and a shape in second side edge 62 can be removed or added, using the process as described above for first side edge 64.
Referring to
The material segment 60 shown in the Figures is generally made of metal. In one embodiment, the material segment 60 is a metal sheet. In another embodiment, the material segment 60 is a metal bar. The material segment 60 can range generally from about 10 feet in length to about 30 feet in length. However, the straightening or shaping tool 20 can accommodate shorter and longer lengths. The side edge thickness of the material segment 60 is generally between ⅛ inch to ½ inch, however, other thicknesses can be accommodated. The measurements for the ram head can be adjusted to accommodate various material segment 60 thicknesses, such that the side edge 64 is engageable with the engagement slot 56 and there is some play between the side edge 64 and the interior surfaces 51, 58, of the engagement slot 56. Further, the width of the material segment 60 is generally between about ½ foot to 2 feet, however, narrower and wider widths can be accommodated. Generally, the material segment 60 is an elongated metal segment, however other materials that require edge straightening or shaping are contemplated.
In operation, a material segment 60 is loaded onto a base material segment supporting assembly 28, with press plate 42 being in a cleared position. The material segment 60 can be, for example, a metal sheet, a metal bar, a wood sheet, and the like. In the following example, a metal sheet is used as an example of a material segment 60 that requires shaping. Therefore, terms such as “a base material segment supporting assembly” are adjusted to “a base metal sheet supporting assembly.” The metal sheet 60 has a metal sheet first side edge 64 and a metal sheet second side edge 62, and requires shaping in the metal sheet first side edge 64. For example, the camber of metal sheet 60 along metal sheet first side edge 64 can exceed allowable camber for the sheet. Camber is the edgewise curvature, or lateral deviation of an edge, from a straight line. In certain instances, the camber or curvature in the metal sheet first side edge 64 of the metal sheet 60 must be reduced or removed from the metal sheet 60 to be used for its intended purpose. The metal sheet 60 also includes a metal sheet first surface 68 and a metal sheet second surface 66.
For example, the metal sheet 60 can have the shape of the material segment depicted in
The ball transfers 70 positioned in the transport assembly frame 30 along the ends 31, 33, of the transport assembly 32 assist in transporting the metal sheet 60 onto and off of the base metal sheet supporting assembly 28 and the transport assembly 32. A metal sheet 60 is positioned on the base metal sheet supporting assembly 28, on the transport assembly 32, such that the metal sheet first surface 68 engages with the base metal sheet supporting assembly 28 and the transport assembly 32. Alignment guides 36 are chosen relative to the width of the metal sheet 60 such that the alignment guides 36 abuttingly engage the metal sheet second edge 62. The alignment guides are removably affixed to the mounts 38. The choice of on which mounts 38 to removably affix the alignment guides 36 is dependent on several parameters, including the length of the metal sheet 60. The mounts 38, with alignment guides 36 removably affixed where the alignment guides 36 abuttingly engage the metal sheet first side edge 64 at at least the longitudinal end portions of the metal sheet 60, are generally chosen to provide support to the metal sheet 60. Optionally, all of the mounts 38 positioned along the base metal sheet supporting assembly first side 21 can have alignment guides 36 removably affixed, thereby providing additional support along the length of the metal sheet 60. Various combinations of mounts 38 on which to removably affix the alignment guides 36 can be chosen dependent on, for example, size of the metal sheet 60, flexibility of the metal sheet 60, and the like.
The portion of the metal sheet 60 requiring shaping is positioned proximate the ram assembly 26. The clamping assembly actuators 48 are operated to lower the press plate 42 toward the base metal sheet supporting assembly 28, until the material sheet 60 is held between the transport assembly 32 and the clamping surface 44. The ram assembly actuator 52 is then operated, such that the engagement slot 56 of the ram head 54 translates laterally in channel 40 and engages first side edge 64 of the metal sheet 60. The channel guides 41, 45 engaged with guide slots 55, 57 in the ram head 54, assist in maintaining the ram head 54 in position within the channel 40. The force applied to the first side edge 64 of the metal sheet 60 imparts a shape to the first side edge 64. The press plate 42 is raised to a cleared position to relieve pressure, and the first side edge 64 of the metal sheet is measured to determine if the desired shape or contour has been achieved. If the desired shape or contour is not achieved, the press plate 42 is lowered to a clamping position. The ram assembly actuator 52 is operated repeatedly, with the ram head 54 applying force to the first side edge of the metal sheet 60, until the metal sheet 60 has achieved the desired shape, within acceptable tolerances. The first side edge 64 is measured against a desired template or by laser beam to determine if the desired shape has been achieved.
Generally, the metal sheet 60 contains a deformity 65 in the first side edge 64 of the metal sheet 60, wherein a linear or more straightened first side edge 64 is desired. The first side edge 64 is measured against a line drawn on the base metal sheet supporting assembly 28 or, alternatively, is measured via laser beam. The section of the first side edge 64 of the metal sheet 60 containing the deformity 65 is positioned proximate the ram assembly 26. The press plate 42 is lowered to a clamping position, and the engagement slot 56 of the ram head 54 engages the deformity 65 and exerts force on the deformity. When the ram head 54 is in a cleared position and the press plate 42 is in a cleared position, the first side edge 64 of the metal sheet 60 can be measured to determine if the deformity 65 has been removed to within acceptable tolerances. If not, the press plate 42 is lowered to a clamping position and the ram assembly actuator 52 is activated again. The process is repeated until measurement shows that the deformation 65 has been removed to within acceptable tolerances. The amount of permissible curvature will vary depending on the particular application.
As noted above, the press plate 42 is raised to a cleared position to allow the metal sheet 60 to relax prior to measurement. Support from the ball transfers 70 assists in allowing the metal sheet 60 to relax, yet remain positioned against the alignment guides 36. As noted above, a laser beam or a line previously drawn along the base metal sheet supporting assembly 28, can be used to determine if the metal sheet 60 has been sufficiently shaped. Generally, the middle length of the metal sheet 60 is measured to determine the amount of bowing, if any. The side edge 64 of the metal sheet 60 is measured to ensure that the side edge dimensions 62, 64 are within acceptable tolerances.
The shaping tool 20 is adjustable, such that it may be used to shape and/or straighten material segments 60 of differing sizes. As noted above, for example, alignment guides 36 may be placed in any of the mounts 38 to accommodate material segments 60 of differing lengths. Further, alignment guides 36 may be of differing diameters or thicknesses, to accommodate material segments 60 of differing widths. In addition, if the length of the material segment 60 is longer than the base or the transport assembly 32, additional segments of transport assembly, wherein the transport assembly segments are supported at the same height as the original transport assembly 32 of the shaping tool 20, can be added to the longitudinal ends of the shaping tool 20. In the case of the material segment 60 extending beyond the end of the shaping tool 20 and the press plate 42, the material segment side edge 64 can still be shaped by ensuring that the desired material segment 60 portion is engaged by the ram head 54.
Those skilled in the art will recognize that the present invention may be manifested in a variety of forms other than the specific embodiments described and contemplated herein. Accordingly, departures in form and detail may be made without departing from the scope and spirit of the present invention as described in the appended claims.
For purposes of interpreting the claims for the present invention, it is expressly intended that the provisions of Section 112, sixth paragraph of 35 U.S.C. are not to be invoked unless the specific terms “means for” or “step for” are recited in a claim.
The present application claims priority to U.S. Provisional Application Ser. No. 60/966,789 filed Aug. 30, 2007, and entitled, “DEVICE AND METHODS FOR STRAIGHTENING DEFORMED MATERIALS”, which is herein incorporated by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 60966789 | Aug 2007 | US |
