Adjustable multi-axial roll former

Abstract

A multi-axial roll-forming apparatus that is configured to be quickly and efficiently modifiable so as to allow the formation of a variety of differently shaped component pieces from a variety of different shaped pieces of material. A variously adjustable roll-forming device is held in a variety of vertical and horizontal orientations within a variously adjustable frame. The variously adjustable frame allows for various adjustments so as to provide an aperture consistent with the dimensions of the material being processed or the pieces which are to be formed.

1 . A method for obtaining stacked pieces of material having desired characteristics utilizing an assembly of selectively modifiable multi-axial roll-forming apparatuses comprising the steps of: 
 configuring a plurality of individual multi-axial roll-forming devices into a forming assembly line to form a plurality of first pieces oriented in a first direction, feeding a first piece of a material to be configured in to said forming assembly line to form a portion of a first piece oriented in a first direction;    monitoring progress of said first piece while said first piece progresses through said assembly line;    sensing when a portion of said first piece has passed a designated location;    reconfiguring a portion of said forming assembly positioned upstream from said designated location to form a second piece oriented in a second orientation;    feeding a second piece of material into said device;    continuously feeding said first piece of material through said assembly to form said first piece oriented in a first orientation;    continuously sensing passage of said first piece of material through said assembly at designated locations;    continuously reconfiguring varying portions of said forming assembly positioned up stream of said designated locations to form a second piece oriented in a second direction;    continuously sensing passage of said second piece of material through said assembly at designated locations;    receiving said first pieces formed in a first orientation upon a positioning conveyor;    receiving said second pieces formed in a second orientation upon said first pieces;    stacking said first and second pieces on to a positioning conveyor;    repeating said process until a desired number of pieces have been formed.    
     
     
         2 . The method of  claim 1  wherein reconfiguring varying portions of said assembly comprises pivoting an adjustable shaft to change a forming roll from a first forming roll configured to form a piece of material in a first direction to a second forming roll configured to form a piece of material in a second direction.  
     
     
         3 . The method of  claim 2  further comprising the step of collecting said pieces of material in a stacked formation, and 
 binding said stacks.    
     
     
         4 . The method of  claim 1  wherein said material is a material having apertures which were pre-formed to have a desired features prior to entrance into said assembly.  
     
     
         5 . The method of  claim 4  further comprising the steps of aligning said first and second pieces so that the apertures of said first and second pieces align, and fastening said first pieces to said second pieces through said apertures with a fastener.  
     
     
         6 . A multi-axial straightening device configured to form portions such as a corner portion from in a piece of material being formed by roll-forming assembly, said straightening device comprised of: 
 a first form roller and a second form roller connected along a vertically extendable securing device, said first and second form rollers freely rotatably and slideably connected to an upper arbor and a lower arbor, said first and second roll-forming devices held in a desired horizontal position along said upper and lower arbors by a horizontal positioning device;    an upper angled form roller held in a fixed connection with said upper arbor and a lower angled form roller held in a fixed connection with said lower arbor said upper and lower angled form rollers held in a desired position and orientation by an arbor locking device.    
     
     
         7 . The straightening device of  claim 6  wherein said arbor locking device is comprised of a first upper gear wheel connected to a second upper gear wheel, said first and second gear wheels each connected to said upper arbor, said first and second gear wheels each having a plurality of teeth circumvolving said wheels, said first gear wheel teeth and said second gear wheel teeth each configured so that when said first and second gear wheels are placed into contact with a lower gear wheel having teeth that said lower gear wheel prevents said first and second gear wheels from rotating and that when said lower arbor is rotated, that said lower gear wheel interacts with said first and second upper gear wheel teeth to rotate said upper arbor and adjust the positioning of said angled forming rolls to over bend a piece of material so as to accommodate material having higher yields.  
     
     
         8 . The straightening device of  claim 7  wherein said first and second form rollers are each configured to have a variety of multiply angled forming tools configured to over bend material at various selected angles, and wherein said configuration allows for various material forming configurations to be achieved.