System for automatically machining the ends of roll formed material

Abstract

A roll forming machine that can form material with a complex profile, such as a miter or coping, in the ends of the work piece is described. A length sensor provides information to a computer that monitors the amount of material being formed and a machining section is installed before the forming rollers. This allows the invention to cut the desired end profile before the material is roll formed into the final shape. Since the material is flat during the cutting operation, any of the standard cutting techniques known in the art, can be employed, such as shearing, punching or a CNC end mill.

I claim:  
     
         1 . A machine for cutting a profile into flat material and then roll forming that material into the desired cross sectional shape thus avoiding the difficultly of machining a complex cross section, Such machine consisting of: 
 a. A series of mechanical rollers that act as forming stations by bending the metal into the desired cross section,    b. A drive motor attached to the mechanical rollers that will force the material through the machine,    c. A frame assembly that houses the above components,    d. A cutting means mounted in such a manner to allow it to cut a pattern into the metal in two dimensions.    
     
     
         2 . The machine of  claim 1  where the workpieces are left attached to each other by small tabs of material.  
     
     
         3 . The machine of  claim 1  where the workpieces are cut apart from each other.  
     
     
         4 . The cutting means of  claim 1  that consists of a computer controlled endmill. 
 a. A cutting tool where the endmill is powered by an electric motor,  
 b. A cutting tool where the endmill is powered by a hydraulic motor,  
 c. A cutting tool where the endmill is powered by a pneumatic motor.  
 
     
     
         5 . The cutting means of  claim 1  that uses a high pressure water jet.  
     
     
         6 . The cutting means of  claim 1  that uses a LASER.  
     
     
         7 . The cutting means of  claim 1  that uses a torch, either plasma or gas.  
     
     
         8 . The cutting means of  claim 1  where the tool consists of a mechanically activated punch, 
 a. A punch that consists of a male and female die for cutting a left angle,  
 b. A punch that consists of a male and female die for cutting a right angle,  
 c. A punch that cuts any commonly needed shape or hole the material.  
 
     
     
         9 . A mechanical punch of  claim 5  that is powered by hydraulic pressure, pneumatic pressure or electrical current.  
     
     
         10 . The cutting means of  claim 7  where the mechanical punch is activated by the controlling computer.  
     
     
         11 . A mechanical punch of  claim 5  that is power by a mechanical lever moved by the operator of the machine when prompted by the computer.  
     
     
         12 . A device for controlling the operation of a roll forming machine that produces pre-formed ends and other desired cutouts in the workpiece; such a device consisting of: 
 a. A microprocessor    b. Memory storage    c. Input and output control lines    d. An means for displaying information to the user,    e. A keypad to allow the user to input desired data,    f. A button for activating the motor of  claim 1 ,    g. A button for stopping the motor of  claim 1 ,    h. A length sensor interfaced to the microprocessor for measuring the amount of material formed,    i. A power conversion unit for powering the control device,    j. An enclosure to house the control unit,    k. An on/off switch to control power to the unit.    
     
     
         13 . A bypass switch to allow manual operation of the machine if the controller of  claim 10  fails.  
     
     
         14 . A sensor for measuring the current being drawn by the motor of  claim 1 .  
     
     
         15 . An sensor for detecting the presence of material in the machine, 
 a. An optical sensor that detects light,    b. A magnetic sensor that detects the magnetic field of the material.    
     
     
         16 . The cutting tool of  claim 2  where the endmill is mounted on a three axis movable assembly allowing the tool to be moved in the X, Y or Z axis, 
 a. A movable assembly that uses stepping motors,  
 b. A movable assembly that uses servo motors,  
 c. A movable assembly that uses hydraulic motors,  
 d. A movable assembly that uses pneumatic motors.  
 
     
     
         17 . The cutting mechanism of  claim 2  where the endmill is mounted on a two axis movable assembly. One axis perpendicular to the surface of the material being cut (the Z axis) and the other axis parallel to the material and perpendicular to the path through the roll forming machine (the Y axis), 
 a. A software algorithm for monitoring the location of the material as it moves through the roll forming stations under power from the drive motor of  claim 1 , Such an algorithm cuts the desired profile by positioning the cutting tool of  claim 1  in the Y axis and Z axis based on the position of the material in the X axis.  
 
     
     
         18 . A means for controlling the direction of the drive motor of  claim 1 .  
     
     
         19 . A means for monitoring the rotational speed of the cutting tool of  claim 2 , 
 a. A software algorithm for determining the condition of the cutting tool cutting edges based on the rotational speed,    b. A software algorithm that will reposition the tool in the Z axis to optimize tool life,    c. A means of notifying the operator of the machine that the tool has become dull.    
     
     
         20 . A software algorithm that optimizes the accuracy of the length measurements by compensating for the mechanical momentum of material being formed, Such an algorithm consisting of: 
 a. stopping the drive motor of  claim 1  before the desired length is reached    b. measuring how much material passed through before actually stopping    c. adjust the compensation factors    d. restarting the motor    e. stopping the motor based on the new compensation factor such that the exact amount of material desired is formed.    
     
     
         21 . A length measurement sensor built into the roll forming machine that consists of: 
 a. a decal or other marking means that consists of a series of strips or dots, The decal is mounted to a rotating member of the roll forming machine that moves in time with the material being formed,    b. A plurality of optical sensors that are mounted 90 degrees out of phase from each other, Such sensors can detect the alternating bands or markings on the decal and generate a quadrature encoded signal,    c. A decal or other marking means that consists of two series of marks    
     
     
         22 . A mechanism that could be attached to an existing roll forming machine, Such attachment would cut a profile into flat material and then feed the material into the roll forming machine which would then roll form that material into the desired cross sectional shape thus avoiding the difficultly of machining a complex cross section or requiring the user to purchase an entire new machine, Such mechanism consisting of: 
 a. Brackets that would attach it to the roll forming machine,    b. A guide means that would provide for the smooth transition of material from the cutting mechanism to the roll forming machine,    c. A cutting means mounted in such a manner to allow it to cut a pattern into the metal in two dimensions,    d. A frame assembly that houses the above components.    
     
     
         23 . A software algorithm that optimizes the order in which workpieces are machine in order to reduce waste.