Method of forming three-dimensional multi-plane beam
First Claim
1. A method comprising steps of:
- providing a roll former with rolls constructed to form sheet material into a structural beam defining a longitudinal line level; and
providing a sweep unit in-line with the roll former; and
selectively sweeping the beam away from the longitudinal line level in both vertical and horizontal directions during continuous operation of the roll former by selectively moving four orthogonally-related forming rolls that rollingly engage four sides of the structural beam in at least one of an upstream and downstream direction.
1 Assignment
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Accused Products
Abstract
A method includes, in combination, a roll former with rolls configured to form a structural beam from sheet material, and a sweep unit for longitudinally sweeping a beam in any of vertical, horizontal, or combination directions. The sweep unit has a first pair of forming rolls positioned to engage first opposing sides of the structural beam and has a second pair of forming rolls positioned to engage second opposing sides of the structural beam. The sweep unit movably supports the first and second pairs of forming rolls so that any selected one of the forming rolls continuously engages an associated side of the structural beam while an associated one of the forming rolls opposing the selected one forming roll moves downstream and around the selected one forming roll. This provides a very stable beam-bending condition promoting dimensional stability during the sweeping process, and hence dimensional accuracy and repeatability.
83 Citations
11 Claims
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1. A method comprising steps of:
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providing a roll former with rolls constructed to form sheet material into a structural beam defining a longitudinal line level; and providing a sweep unit in-line with the roll former; and selectively sweeping the beam away from the longitudinal line level in both vertical and horizontal directions during continuous operation of the roll former by selectively moving four orthogonally-related forming rolls that rollingly engage four sides of the structural beam in at least one of an upstream and downstream direction. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8)
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9. A method comprising steps of:
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providing a roll former with rolls constructed to form sheet material into a structural beam defining a line level; providing a sweep unit downstream of the roll former, the sweep unit including beam-deforming components and a structural ring supported by a curvilinear bearing that supports the beam-deforming components for selective movement; and selectively repeatedly sweeping the beam as the beam exits the roll former along multiple different planes and with varying radii by selective movement of the beam-deforming components upstream parallel the line level and selective movement downstream into the line level.
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10. A method comprising steps of:
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providing a roll former adapted to roll form a sheet into a continuous beam defining a line level; providing a sweep unit attached to the roll former with opposing rollers configured to impart a longitudinal sweep into the continuous beam in any direction vertically or horizontally or at angles in-between, the opposing rollers including at least one pair of opposing first forming rollers and including at least one pair of opposing second forming rollers, and including curvilinear bearings that operably support the opposing first and second forming rollers for movement; and selectively imparting at least two different sweeps into the beam, including moving one of the pair of first forming rollers linearly upstream while another of the pair of first forming rollers is moved downstream along a curvilinear line into the line level.
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11. A method comprising steps of:
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providing a roll former with rolls configured to form a structural beam from sheet material; and providing a sweep unit having a first pair of forming rolls positioned to engage first opposing sides of the structural beam and having a second pair of forming rolls positioned to engage second opposing sides of the structural beam, the first and second pair of forming rolls being operably supported on curvilinear bearings that supports movement along a multi curved path, that extend along an upstream direction; and operating the sweep unit so that all of the first and second pairs of forming rolls move along the bearings to continuously engage the beam, but so that at least one pair of the first and second pairs of forming rolls move so that one of the forming rolls in the one pair moves downstream and into a line level of the structural beam while maintaining a constant distance to the other of the one pair of forming rolls.
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Specification