FIELD OF THE INVENTION
This invention relates to a cutter for cutting a strip of metal from a coiled web, and more particularly, to a two-stage clamping device for handling a cut off strip.
BACKGROUND OF THE INVENTION
A metal web may be rolled into a coil to facilitate transportation, handling and storage of metal, for example. Such coils have an end section that extends tangentially outward from an outer diameter of the coil. It is desirable to cut off strips of metal having selected sizes from the end section in order to provide coil samples for laboratory testing and quality control purposes. A strip is formed by first rotating the coil to extend the length of the end section. A saw or cutting device is then used to transversely cut the end section along the width of the coil to form a loose strip which must then be handled. The strip may be fabricated from heavy gauge steel and may be up to one inch thick or more. As such, the strip is relatively heavy and large and thus difficult to handle.
In many manufacturing facilities, a robotic system is used which includes a robotic arm to facilitate handling of the strips. However, such robotic systems are expensive, difficult to maintain and utilize a substantial amount of space in the facility.
SUMMARY OF THE INVENTION
A cutter for cutting an end section of a coiled web is disclosed. The cutter includes roller elements for rotating the coiled web and a carriage assembly that is moveable in a first direction relative to a frame. The carriage assembly includes a saw element for cutting the end section to form a strip, wherein the saw element is moveable in a second direction transverse to the first direction. The carriage assembly also includes a contact wall and a spaced apart rotatable peeler element for separating the outer wrap of the coiled web. In addition, the carriage assembly includes first and second actuators for moving the peeler element to a first position wherein the end section and strip are both clamped between the peeler element and the contact wall. Further, the second actuator rotates the peeler element to a second position wherein the end section is not clamped while the strip remains clamped.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a cutter for cutting an end section of a coiled metal web.
FIG. 2 is a cross sectional view of a housing along view line 2-2 of FIG. 1
FIGS. 3A-3B depict enlarged front and rear perspective views of the housing.
FIGS. 4A-4B depict views of a peeler element.
FIG. 5 is an end view of an outer flange of a first arm and associated hydraulic cylinders.
FIG. 6 is an end view of an inner flange with the outer flange removed.
FIGS. 7A-7F depict operation of the cutter and a clamping device.
FIG. 8 is a cross sectional view along view line 8-8 of FIG. 1 and depicts an adjustment arm.
DESCRIPTION OF THE INVENTION
Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings. In the description below, like reference numerals and labels are used to describe the same, similar or corresponding parts in the several views of FIGS. 1-8.
Referring to FIG. 1, a cutter 10 for cutting an end section of a coiled metal web is shown. The cutter 10 includes a frame 12 having a moveable carriage assembly 14 that includes a housing 16 having a peeler element 18 shown in two positions as will be described. The housing 16 is located on a baseplate 20 having first 22 and second 24 ends positioned between spaced apart first 26 and second 28 guide rails, respectively, located in a top portion of the frame 12. The guide rails 26,28 are oriented to enable movement of the carriage 14 along a first axis 30. First 32 and second 34 straight gears or racks are affixed adjacent to the first 26 and second 28 guide rails, respectively, and are oriented substantially parallel to its associated guide rail 26,28. The first 32 and second 34 racks engage first 36 and second 38 (see FIG. 2) pinion gears, respectively, located on the baseplate 20. The first 36 and second 38 pinion gears are each rotated by a motor or other device to thus move the carriage 14 along the first axis 30 between a standby position wherein carriage 14 is located near an end of the frame 12 as shown in FIG. 1 and a cutting position wherein the carriage 14 is located adjacent a coiled web 116 as shown in FIG. 7B.
The cutter 10 also includes a collection container 40 located near a bottom portion of the frame 12. The collection container 40 serves to collect strips of metal which have been cut off from an end section of a coiled web. In addition, the cutter 10 includes first 42 and second 44 rollers and a third roller 46 located above the first 42 and second 44 rollers. An outer diameter of the coiled web is located between the first 42, second 44 and third 46 rollers which are rotated by first 48, second 50 and third 52 motors to thus rotate the coiled web. The third roller 46 includes a collar 54 located on a guide arm 56 which extends vertically from the frame 12. The collar 54 is adjustable relative to the guide arm 56 to enable adjustment of a position of the third roller 46 relative to the first 42 and second 44 rollers to accommodate different size coiled webs. The third roller 46 also exerts a downward force on the coiled web to restrain an outer wrap and end section of the coiled web.
Referring to FIG. 2, a cross sectional view of the housing 16 along view line 2-2 of FIG. 1 is shown. The housing 16 includes a circular saw device 58 driven by a motor 59 (see FIG. 7A) which is used to cut a thickness of the coiled web. It is understood that other cutting or shearing devices may be used to cut a thickness of the coiled web. In one embodiment, the saw 58 is adapted to cut a thickness of heavy gauge steel. The saw 58 is mounted on a second carriage assembly 60 that enables movement of the saw 58 along a second axis 62 that is transverse to the first axis 30 to transversely cut an end section of the coiled web along the width of the coil. This forms a strip that is used as a coil sample for laboratory testing and quality control purposes. The housing 16 also includes a sixth hydraulic cylinder element 61 which moves the saw 58 between a retracted saw position wherein the saw 58 is located within the housing 16 for safety purposes and a saw cutting position as shown in FIGS. 2 and 7B, wherein the saw 58 extends from the housing 16 to enable cutting of the end section 122 of the coiled web 116.
Referring to FIG. 3A, an enlarged front perspective view of the housing 16 is shown. In addition, FIG. 3B is a rear perspective view of the housing 16 along view line of 3B-3B of FIG. 3A. Referring to FIGS. 3A and 3B, the housing 16 includes a contact wall 64 and first 66 and second 68 arms each having spaced apart inner 70 and outer 72 flanges. The inner 70 and outer 72 flanges of the first 66 and second 68 arms are each rotatably mounted to the baseplate 20 by first 74 and second 76 lower arm pivot elements, respectively.
Referring to FIG. 4A, the peeler element 18 has an elongated configuration whose width substantially corresponds to the width of the coiled web. FIG. 4B is a view of the peeler element along view line 4B-4B of FIG. 4A. The peeler element 18 is located between the first 66 and second 68 arms and includes first 78 and second 80 pivots which extend from first 79 and second 81 pivot supports, respectively. The peeler element 18 includes a lower sloped portion 83 and an upper sloped portion 85 whose width narrows to form an edge 87. The peeler element 18 also includes a base portion 97 having a plurality of raised contact areas 95 that are raised relative to sections of the base portion 97 to form clearance areas 99 each located between a pair of contact areas 95. Use of the saw 58 to cut a clamped end section 122 of a coiled web 116, as will be described, causes the generation of metal chips and other debris. Each of the clearance areas 99 form a space to provide a relief for the chips to enable the chips to fall through the clearance areas 99 and away from the saw 58 so as to not interfere with operation of the saw 58. The first 79 and second 81 pivot supports each include a contact flat 91 which is aligned with the raised contact areas 95 to form a contact surface 89 for clamping an end section as will be described. The contact flats 91 are also aligned with the lower sloped portion 83.
Referring back to FIGS. 3A-3B, the first 78 and second 80 pivots extend through the inner 70 and outer 72 flanges of the first 66 and second 68 arms, respectively. The first 78 and second 80 pivots are rotatably mounted within the inner 70 and outer 72 flanges to enable rotation of the peeler element 18 relative to the first 66 and second 68 arms about a third axis 82 which is transverse to the first axis 30.
Referring to FIG. 5 in conjunction with FIGS. 3A and 3B, the housing 16 includes first 84 and second 86 hydraulic cylinder elements having first 88 and second 90 cylinder bodies and moveable first 92 and second 94 pistons, respectively. The first 92 and second 94 pistons are rotatably mounted between the inner 70 and outer 72 flanges of the first 66 and second 68 arms by first 96 and second 98 upper arm pivot elements, respectively. Extension of the first 92 and second 94 pistons out of a corresponding cylinder body 88,90 causes rotation of the first 66 and second 68 arms about the first 96 and second 98 upper pivot elements and the first 74 and second 76 lower pivot elements. This rotates the first 66 and second 68 arms, and thus peeler element 18, away from the contact wall 64 and into an extended arm position. Conversely, retraction of the first 92 and second 94 pistons into a corresponding cylinder body 88,90 causes rotation of the first 66 and second 68 arms, and thus peeler element 18, toward the contact wall 64 and into an retracted arm position.
In addition, third 100 and fourth 102 hydraulic cylinder elements are affixed to the inner 70 and outer 72 flanges of the first 66 and second 68 arms, respectively. Referring to FIG. 6, a view of an inner flange 70 with the outer flange 72 removed is shown. The third 100 and fourth 102 hydraulic cylinders include third 104 and fourth 106 cylinder bodies and moveable third 108 and 110 fourth pistons, respectively. The third 108 and fourth 110 pistons are rotatably mounted to the first 78 and second 80 pivots of the peeler element 18 by first 112 and second 114 crank arms, respectively. Extension of the third 108 and fourth 110 pistons out of a corresponding cylinder body 104,106 causes rotation of the first 112 and second 114 crank arms. This causes rotation of the first 78 and second 80 pivots and the peeler element 18 about the third axis 82 away from the contact wall 64 and places the peeler element 18 in an angled first position. Conversely, retraction of the third 108 and fourth 110 pistons into a corresponding cylinder body 104,106 causes rotation of the first 112 and second 114 crank arms, first 78 and second 80 pivots and the peeler element 18 about the third axis 82 toward the contact wall 64 and places the peeler element 18 in a second position. As will be described in relation to FIGS. 7C and 7D, movement of the first 66 and second 68 arms and peeler element 18 to the retracted and second positions, respectively, clamps the end section 122 between the peeler element 18 and the contact wall 64. The width of the end section 122 may be narrower than the width of the peeler element 18. In this circumstance, movement of the first 66 and second 68 arms and peeler element 18 to the retracted and second positions, respectively, causes ends of the peeler element 18 to bend. In an embodiment, the first 74 and second 76 lower pivot elements and the first 96 and second 98 upper pivot elements are configured as plain spherical bearings to enable rotation of the first 66 and second 68 arms to accommodate bending of the peeler element 18.
Referring back to FIG. 3A, simultaneous extension of the first 92, second 94, third 108 and fourth 110 pistons out of corresponding cylinder bodies 88,90,104,106 places the first 66 and second 68 arms in the extended arm position and the peeler element 18 in the first position. Simultaneous retraction of the first 92, second 94, third 108 and fourth 110 pistons into corresponding cylinder 88,90,104,106 bodies places the first 66 and second 68 arms in the retracted arm position and the peeler element 18 in the second position.
Referring to FIGS. 7A-7F, operation of the current invention will now be described. Referring to FIG. 7A, the coiled web 116 includes an outer diameter 118 and is placed between the first 42, second 44 and third 46 rollers. The coiled web 116 includes several layers of material (only an outermost layer 120 is partially shown for clarity), such as steel, and an end section 122 that extends tangentially from the outermost layer 120. The end section 122 may be oriented in a lower right position relative to the outer diameter 118. Initially, the carriage 14 is in the standby position, the first 66 and second 68 arms are in the extended position and the peeler element 18 is in the first position.
The carriage 14 is then moved to a position that is close to the outer diameter 118 of the coiled web 116. The motors 48,50,52 are then actuated thus rotating the rollers 42,44,46 and causing rotation of the coiled web 116. The coiled web 116 is rotated clockwise until the end section 122 is oriented in an upper left position of the outer diameter 118 such that the end section 122 is located between the contact wall 64 and the peeler element 18 and extends downward toward the first 66 and second 68 arms. The carriage 14 is then moved to a cutting position as shown in FIG. 7B. The coiled web 116 is then rotated counterclockwise until the end section 122 contacts the edge 87 and upper 85 and lower 83 portions of the peeler element 18. The peeler element 18 serves to tangentially separate the outermost layer 120 from the remaining layers as the coiled web 116 is rotated thus extending the length of the end section 122 past the contact surface 89. The peeler element 18 guides the extended end section 122 through a gap formed between the contact wall 64 and contact surface 89. Rotation of the coiled web 116 is stopped once the end section 122 has been extended a desired length to form a suitable strip.
A first stage in a two-stage clamping process will now be described. Referring to FIGS. 7C and 7D, the first 66 and second 68 arms and peeler element 18 are moved to the retracted and second positions, respectively, by simultaneously retracting the first 92, second 94, third 108 and fourth 110 pistons into corresponding cylinder 88,90,104,106 bodies. This clamps a section of the end section 122 between the contact surface 89 and the lower sloped portion 83 on one side, and the contact wall 64 on an opposite side to form a clamped section 134. The saw 58 is then moved from the retracted saw position to the saw cutting position as previously described. The second carriage assembly 60 then moves the saw 58 along the second axis 62 (see FIG. 2) to transversely cut the end section 122 along the width of the coiled web 116.
Referring to FIGS. 7E and 7F, a cut 124 made by the saw 58 forms a strip 126 and a shortened end section 122A which is part of the coiled web 116. The strip 126 may be fabricated from heavy gauge steel and may be up to one inch thick or more. As such, the strip 126 is relatively heavy and large and thus difficult to handle. In a second stage of the two-stage clamping process, the third 108 and fourth 110 pistons are then extended out of a corresponding cylinder body 104,106 thus placing the peeler element 18 in the first position wherein the lower sloped portion 83 of the peeler element 18 is rotated away from the shortened end section 122A and no longer contacts the shortened end section 122A, thus releasing the shortened end section 122A. Concurrently, the first 92 and second 94 pistons are maintained in the retracted position wherein the contact surface 89 maintains contact with strip 126 thus holding strip 126 in place. In one embodiment, simply deactivating the first 84 and second 86 cylinder elements causes the third 108 and fourth 110 to extend out thus releasing the shortened end section 122A.
The coiled web 116 is then rotated clockwise by a sufficient amount to provide clearance between the shortened end section 122A and the peeler element 18 to enable movement of the carriage 14. The carriage 14 is then moved along the first axis 30 to a position above the collection canister 40 (see FIG. 1). In this position, the first 92 and second 94 pistons are extended thus moving the first 66 and second 68 arms, and thus peeler element 18, to the extended arm position. This moves the peeler element 18 and the contact surface 89 away from the strip 126, thus releasing the strip 126. The strip 126 then falls into the collection canister 40. The collection canister 40 is sized to accommodate several strips 126. The collection canister 40 may then be used to transport the strips 126 to a laboratory for testing, for example.
It is desirable that all portions of the end section 122 that are clamped are in contact with the contact surface 89, the lower sloped portion 83 and the contact wall 64 before the end section 122 is cut. However, due to variability in the size of the outside diameter 118 of different coiled webs, the orientation and/or shape of the end section 122 may vary. By way of example, the end section 122 may be relatively straight and vertical. Alternatively, the end section 122 may have a curved shape. Therefore, all portions of the end section 122 that are clamped may not be in contact with the contact surface 89, the lower sloped portion 83 and the contact wall 64.
Referring to FIG. 8 a cross-sectional view along view line 8-8 of FIG. 1 is shown. In this view, the first 66 and second 68 arms and peeler element 18 are shown in the retracted and second positions, respectively, previously described in relation to FIGS. 7C and 7D, thus forming the clamped section 134. The carriage 14 further includes at least one adjustment arm 128 which is rotatable about an adjustment arm pivot 130. The adjustment arm 128 includes an adjustment surface 132 which contacts a portion of the clamped section 134 of the end section 122. Rotation of the adjustment arm 128 about the pivot 130 in a counterclockwise direction causes the adjustment surface 132 to press against the clamped section 134 thus providing an additional clamping force to compensate for any orientation or shape, such as a curved shape, of the end section 122. This results in contact between all portions of the clamped section 134 and the contact surface 89 and the lower sloped portion 83 and the contact wall 64. Conversely, clockwise rotation decreases the amount of pressure exerted against the clamped section 134.
The carriage 14 also includes a fifth hydraulic cylinder element 136 having a fifth cylinder body 138 and a fifth moveable piston 140. An upper end of the adjustment arm 128 is attached by a pivot 142 to the fifth piston 140. Retraction of the fifth piston 140 into the fifth cylinder body 138 causes counterclockwise rotation of the adjustment arm 128 thus providing additional clamping force as previously described. Conversely, extension of the fifth piston 140 out of the fifth cylinder body 138 causes clockwise rotation of the adjustment arm 128 to decrease the amount of pressure as previously described. In one embodiment, five adjustment arms 128 may be used having corresponding fifth hydraulic cylinder elements 136 as shown in FIG. 1.
It is noted that other types of actuators may be used instead of, or in combination with, the first 84, second 86, third 100, fourth 102, fifth 136 and sixth 61 hydraulic cylinder elements. While the invention has been described in conjunction with specific embodiments, it is evident that many alternatives, modifications, permutations and variations will become apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended that the present invention embrace all such alternatives, modifications and variations.
Patent Application
20140352507
