POWER ADJUSTED SWEEP DEVICE

• US 20080053178A1
• Filed: 10/26/2007
• Published: 03/06/2008
• Est. Priority Date: 06/13/2005
• Status: Abandoned Application

• Current Assignee: Bruce Lyons, Bryan Gould, James Dodd, Richard Heinz
• Original Assignee: Bruce Lyons, Bryan Gould, James Dodd, Richard Heinz
• Inventors: Heinz, Richard, Dodd, James, Lyons, Bruce, Gould, Bryan
• Application Number:
  US11/925,122
• Publication Number:
  US 20080053178A1
• Time in Patent Office: Days
• US Class Current: 72/168
• CPC Class Codes: B21D 5/08 making use of forming-rollers B21D5/12 takes precedence
• CPC Class Codes: B21D 53/88 other parts for vehicles, e.g. cowlings, mudguards
• CPC Class Codes: B21D 7/028 and altering the profile at the same time, e.g. forming bumpers

Abstract

A computer controlled roll-forming apparatus is adapted to provide a repeating pattern of different longitudinal shapes to a continuous beam “on the fly” during the roll-forming process. A sweep station on the apparatus includes a primary bending roller tangentially engaging the continuous beam along the line level and an armature for biasing the continuous beam against the primary bending roller for a distance partially around a downstream side of the primary bending roller to form a sweep. Further, actuators adjustably move the armature at least partially around the downstream side of the primary bending roller between at least first and second positions for imparting multiple different longitudinal shapes into the continuous beam. In one form, the apparatus also includes a coordinated cut-off, so that when separated into bumper beam segments, the ends of the individual beam segments have a greater sweep than their center sections.

Claims

1. An apparatus comprising:

a sweep apparatus having a primary bending roller tangentially engaging a continuous beam, an opposing holding roller adjustable to different positions downstream of the primary bending roller and that holds the continuous beam against the primary bending roller to cause a desired sweep to be imparted into the continuous beam, and at least one stabilizing roller tangentially engaging the continuous beam upstream of the primary bending roller;

first, second, and third drive motors driving the primary bending roller, the holding roller and the stabilizing roller, respectively; and

a controller independently controlling a drive speed of each of the first, second, and third rollers at different speeds to control and manage stress on the continuous beam while in the sweep station in order to form a more consistent swept shape of the continuous beam.

2. The apparatus defined in claim 1 wherein at least one of the first, second, and third rollers is driven at a rotational speed different than the other two of the first, second, and third rollers.

3. The apparatus defined in claim 2, including a roll-forming apparatus adapted to roll-form a sheet of material into a continuous beam having a line level.

4. The apparatus defined in claim 1, wherein the controller is programmed to vary a position of the opposing holding roller to at least two of the different positions.

5. The apparatus defined in claim 4, wherein the controller is programmed to adjust a speed of at least one of the first, second, and third rollers to achieve different desired sweeps in the continuous beam.

6. The apparatus defined in claim 1, including a cutoff connected to the controller for cutting the continuous beam into segments of desired length, and wherein the controller is programmed to operate the cutoff to engage and cut the continuous beam at desired locations.

7. The apparatus defined in claim 1, wherein the primary bending roller and holding roller are configured to engage opposing surfaces of the continuous beam and where the continuous beam has an open non-tubular cross section.

8. The apparatus defined in claim 1, wherein the primary bending roller and holding roller are configured to engage opposing surfaces of the continuous beam and where the continuous beam has a tubular cross section.

9. A roll former comprising:

a roll form mill;

a sweep apparatus positioned in-line with the roll form mill and connected to a downstream end thereof, the sweep apparatus having a primary bending roller tangentially engaging a continuous beam, an opposing holding roller adjustable to different positions downstream of the primary bending roller and that holds the continuous beam against the primary bending roller to cause a desired sweep to be imparted into the continuous beam, and at least one stabilizing roller tangentially engaging the continuous beam upstream of the primary bending roller;

first, second, and third drive motors driving the primary bending roller, the holding roller and the stabilizing roller, respectively; and

a controller operably connected to the roll form mill and connected to the drive motors for independently controlling a drive speed of each of the first, second, and third rollers at different speeds to control and manage stress on the continuous beam while in the sweep apparatus in order to form a more consistent swept shape of the continuous beam.

10. The apparatus defined in claim 9, wherein the roll form mill forms the continuous beam to have an open cross section.

11. The apparatus defined in claim 9, wherein the roll form mill forms the continuous beam to have a tubular cross section.

12. The apparatus defined in claim 9, including a cutoff positioned in-line with and downstream of the sweep apparatus and connected to the controller for cutting the continuous beam into segments of desired length, and wherein the controller is programmed to operate the cutoff to engage and cut the continuous beam at desired locations.

13. An apparatus comprising:

a sweep apparatus including rollers and axles for supporting the rollers, the rollers being adapted and arranged to selectively form a sweep into a continuous beam;

the rollers including a primary bending roller, a holding roller, and at least one stabilizing roller;

a stationary one of the axles supporting the primary bending roller;

an armature operably mounted on the stationary axle, the armature supporting at least the holding roller for adjustable movement to impart a varied sweep into the continuous beam;

an automated adjustment device for repeatedly arcuately adjusting an angular position of the armature to create a repeating pattern of longitudinal shapes in the continuous beam, including automatically moving the holding roller toward different downstream positions relative to the primary bending roller to change the sweep being imparted into the continuous beam;

the adjustment device including motors for independently driving each of the axles for the primary bending roller, the holding roller, and the at least one stabilizing roller and further including a controller operably connected to each of the motors for independent control thereof to control and manage stress on the continuous beam while in the sweep apparatus in order to form a more consistent swept shape of the continuous beam.

14. The apparatus defined in claim 13, wherein the roll form mill forms the continuous beam to have an open cross section.

15. The apparatus defined in claim 13, wherein the roll form mill forms the continuous beam to have a tubular cross section.

16. The apparatus defined in claim 13, including a cutoff positioned in-line with and downstream of the sweep apparatus and connected to the controller for cutting the continuous beam into segments of desired length, and wherein the controller is programmed to operate the cutoff to engage and cut the continuous beam at desired locations.