Roll forming device bent in multiple direction of roll and method of roll forming

BACKGROUND

The present invention relates to curved beams in multiple directions, and the roll molding machine and methods of forming curved in multiple directions of beams and structural members such as can be used as bumper reinforcement beams, vehicle frames, and nonlinear structural members. The present invention further relates to beams and structural members manufactured by them. The present invention is not limited to reinforcing beams bumpers and / or frames of vehicles, as well as machine and methods of education / production of only those items.

Roller forming can be particularly cost-effective method for manufacturing the elongated beams and structural members (channel section and tubular), since the roller molding enables the mass production of large volumes with relatively lower cost tooling and longer lasting tooling (as compared to stamping dies, especially when molded high-strength materials which quickly wear stamping punches). However, the roller forming has limitations, such as limited formability nonlinear products.

Several methods are known for the formation of bends and curved elongated structural members. For example, see. U.S. Patent number 5,092,512 in the name of Sturrus, US patent number 5,454,504 in the name of Sturrus and published US patent application 2006/0277960 in the name of Lyons, which disclose methods of imparting a bend (s) a continuous beam made of high-strength material having a strength and shape suitable for use as bumper reinforcement beams. However, these methods are limited to performing beam bent to form a uni-directional concave shapes. These methods are not capable of forming a beam with alternating (back and forth) curves, which are formed in opposite directions from preformed rolls longitudinal axis.

In particular, the difficulty of uniformly forming by bending beams and structural members into non-linear shapes increase significantly when the size and bending moment of a structural beam increases, such as when the beam has a tubular cross section of greater than 50 mm × 50 mm, and / or when the sheet material It has a high strength (e.g., tensile strength greater than about 60 thousand psi. inch until the tensile strength of 220 thousand pounds per sq. inch), and / or when the bent bending is relatively acute, such as to form a smaller radius 1500 mm, and / or when the sheet thickness more than 2 mm, especially for combinations of the foregoing.

Disclosure of invention

In one aspect of the present invention, the roller forming machine includes a roll molding apparatus with rollers for forming a sheet of steel material into a structural beam defining a longitudinal line. The machine further includes the bending station arranged in line with arrangement of roll forming, and bending station includes a device formation curves for selective bending of structural beams in a first direction from the longitudinal line and in a second direction opposite the first direction from a longitudinal line, with continuously operating device for roll forming.

In another aspect, the present invention provides for the bending station for bending portions of the beam from the longitudinal line defined by the beam. The bending station includes a main frame and the device formation of bends, including an auxiliary frame operably supported on the main frame for movement in a first position for bending the first portion of the beam in the first direction from the longitudinal line and for movement to a second position for bending the second portion of the beam in the second direction from the longitudinal line, and the second area is located on the side opposite to the first direction.

In another aspect of the present invention, the roller forming method includes the steps of roll forming a sheet of material into a continuous beam defining an axis; bending the first portion and the continuous beam in a first direction from a longitudinal line and bending the second portion of the beam from the continuous longitudinal line in a second direction different from the first direction, during the step of roll forming.

In a narrower aspect of the present invention, the method comprises forming a frame comprising a beam having first and second oppositely curved portions.

In a narrower aspect of the present invention, the beam forms a bumper reinforcement beam and / or vehicle frame member.

In a narrower aspect of the present invention, energy-absorbing mounting bracket attached to the bumper beam on the end of the beam.

In a narrower aspect of the present invention, the beam is tubular and has a cross sectional size in the direction of bending which is at least about 25 mm. Moreover, the strength of the material is preferably a tensile strength of at least about 60 thousand psi. inch for large strength-to-weight.

The object of the present invention to provide a beam, either channel section, or tubular, made from steel sheet material (or having similar or greater tensile strength) and with a cross section of substantial size (e.g., 2 inches or more in a bending direction), and the beam is bent to and back in the opposite direction from the formed rolls, the longitudinal axis during the roll forming process.

The object of the present invention is to provide a machine and method for allowing the beam to bend to a substantial material strength and transverse flexural strength Scheme bending back and forth, including curved portions curved in opposite directions from preformed rolls longitudinal axis.

The object of the present invention is to provide a frame using the beam elements to bend back and forth, as indicated above.

The object of the present invention is to provide internal and / or external stabilizers in a roll forming machine to enable the machine to perform more sharp bends in the beam while maintaining dimensional accuracy and consistency of the cross-section of the beam.

These and other aspects and features of the present invention will become apparent to those skilled in the art upon examination of the following description, claims and accompanying drawings.

BRIEF DESCRIPTION OF DRAWINGS

1 is a side view of a roll forming machine comprising a station for bidirectional bending, according to the present invention.

Figures 2-3 are perspective views of the end of the roll forming machine comprising a station for bidirectional bending of Figure 1, with 3 elements removed to better show the elements beneath.

Fig.4-5 is a perspective view and a top view of the bending station shown in Figure 3 in the rest position, wherein the continuous beam remains linear as it passes through the bending station.

6-7 are views in perspective view and a plan view similar to Figures 2-3 the bending station in a first position, wherein the continuous beam is bent in a first direction «B» from its preformed rolls longitudinal axis.

8-10 are two perspective views and a top view of the bending station shown in Figure 3 in a second position, wherein the continuous beam is bent in a second direction «C», opposite the first direction, and from its preformed rolls longitudinal axis.

11 is a top view of a bumper reinforcement beam (also called "girder element") formed in two directions by the machine shown in Figure 1, so that the end portions of the beam are collinear but a center portion is displaced.

12 is a perspective view of the frame of the vehicle, comprising curved in two directions beam elements which are welded together along with mounting brackets (such as for mounting bumper reinforcement beams) to form a complete vehicle frame.

13 is a schematic block diagram showing a method / process of manufacturing the vehicle frame.

Fig.14-18 are side views, top sectional view, in perspective, an exploded perspective and perspective elements with dotted lines inside the mandrel, and Figure 19 is a view of the modified residue, as shown in Figure 17.

Fig.20-28 2-10 are similar, but showing another embodiment of a bidirectional bending station.

Fig.29-30 are perspective views of a frame and an auxiliary bending unit, while in Figure 30, some parts have been removed to better show other components inside.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Proposed machine 30 for molding the roller (1) which includes a roller molding apparatus 31 (also called "roller forming device") for forming a continuous beam 33 along the linear direction "A" and the bending station 32, located in line with the device forming roller 31 for bending (i.e., bending in the longitudinal direction) of the continuous beam 33 in first and second opposite directions relative to the longitudinal axis of the continuous beam (also referred to herein as "bidirectional bending" or "bidirectional bending") "on the fly" during Continuous operation of the device 31, roller molding. Also, there is provided a corresponding method of forming a roller, comprising the steps of roll forming a sheet of material into a continuous beam and bending the first and second portions of the beam in opposite directions relative to the longitudinal axis. Namely, the roll forming machine can form a beam with the presence of any number of different curved sections, depending on the functional requirements of the application where the structural beam will be used, as discussed below. Machine for roll forming that includes the bending station is robust and hence is able to mold a plurality of metal materials having different strengths (e.g., tensile strength of 40 thousand pounds per sq. Inch or less, down to material with a tensile strength 220 thousand pounds per sq. inch or more) and many different sizes including large cross-sectional beam (e.g., 40 mm × 150 mm or 40 mm × 40 mm or 80 mm × 120 mm) and many different shapes of cross sections (e.g., «B» -shaped, «D» -shaped, «C» -shaped or other cross-sectional shapes). The illustrated continuous beam 33 is cut into beam units 34 (also called "reinforcing beam" or "structural beams" or "bumper beam") having a length and shape suitable for use as bumper reinforcement beams.

The exemplary bumper 34 of the reinforcing bar (11) is made of high strength material such as steel with a tensile strength of 60 000 psi. inch and a wall thickness of about 2 mm sheet thickness, and has a tubular cross-sectional shape with a width of 80 mm and similar height (in the established state of the vehicle). Beam 34 may be used as a bumper reinforcement beam, and can include an opening 34 ', for example, to maintain the coupling device / trailer hitch ball. The illustrated beam has a cross section forming a tube, but it is assumed that the beam can form a plurality of tubes (for example, «B» -shaped) or an open channel (for example, «C» -shaped). The illustrated beam 34 is formed with a machine 30 for forming the roller and has a plurality of sections 35-40, with sections 36/37 bent at the bending station in opposite directions and sections 38/39 bent in opposite directions as part of the bending process at the same time and during the roll forming. As shown, beam 34 may be used as a bumper reinforcement beam, with ends 35 and 40 comprise welded mounting brackets (not specifically shown) that are configured for attachment to the vehicle. Many bumper mounting brackets are known in the art, so their detailed examination is required.

In particular, the central portion 37/38 forms a single plane with ends 35 and 40, but the central portion 37/38 is bent in an offset position relative to the ends 35 and 40 as part of the operation of the roller shaping and bending. The central portion 37/38 may further be formed during the auxiliary operations to accommodate the central portion 37/38 behind, and below the aligned ends 35 and 40 (with top and bottom surfaces maintained in a horizontal position mounted on a vehicle state). This enables the use of a single transverse beam (34) to maintain the coupling device (and trailer tongue) (see. The hole 34 'to accommodate a ball hitch), and also provides the proper height and longitudinal position of the coupling relative to the vehicle frame. Moreover, this allows optimum positioning of the mutually perpendicular walls of the beam (34) in the horizontal and vertical positions to maintain weight.

A variety of different frame and structural components can be fabricated using the ideas incorporated in the form of the beam 34. For example, Figure 12 shows a vehicle frame, in which the elements 111, 121, 125-127 are welded (or bolted) together to Education main frame of the passenger vehicle (see para. 12), including elements for providing space for the wheels of the vehicle and to provide optimal support for its non-linear motor and the suspension elements of the vehicle. Namely, the curved sections in two directions of the beam formed by this machine 30 to roll forming may be used to form side frame members and cross beam members. Each one of the beams includes strategically placed bends, with at least two bends are formed in opposite directions with respect to the longitudinal axis of the continuous beam. It is assumed that can be made a large number of additional structural frame members and components, including frames for sport vehicles such as snowmobiles and all-terrain vehicles; the frame for other vehicles, such as agricultural machinery and equipment, trucks, trains, and any land, water, air and / or snowmobile vehicles; other structural members for vehicles such as car roof arch, door beams, and the like; structural components for furniture, for example panels of partitions, desks, a complex of office equipment and the like; and a plurality of other structural members that are elongated and require bi-directional bending in at least two places.

More specifically, with regard to the machine 30 for molding the roller (1), an unwinding device 50 delivers the sheet material 51 from a roll 51 'on the correct device 52 (and / or stamped prior to puncturing) device 31 and the roller molding. Rollers 53 formed sheet material 51 into the desired cross-sectional shape, such as a continuous beam 33 defining a «D» -shaped tube. Welding device 54 (optional, used to continuously lock tube with a closed tubular cross-section) welds the sheet material to form a permanent tube. Located upstream fixing device 55 (optional, used if the inner mandrel are necessary to maintain the shape of the hollow section during bending) supports located downstream stretching to fix internal (s) of the mandrel (s) in a fixed position on the course (see . 14-19).

The bending station 32 is connected inline on the end of the roll forming apparatus 31 and includes bending rollers for selectively bending / deformation continuous beam 33 in either of opposite directions relative to the longitudinal axis of the continuous beam 33. The cutting device 57 takes a curved beam in two directions 33 and cuts it at selected locations relative to the bends formed in a curved beam in two directions 33, to obtain beam units 34 having a desired length and curved portions located at strategic locations along the beam units 34. The illustrated curved in two directions Trimmer unit 34 includes 35-40 themselves portions (11) lying in a common plane, wherein the deformed portions 36-39 (toward the plane of the sheet and the plane of the sheet, as shown in Figure 1), so the elements can lie on bumpers ( and continuously supported on) the supporting member 58 with a flat table top, as they are separated by a cutting device 57 with a guillotine cutting element 57 '.

The bending station 32 (Figure 2) includes a support frame 60 with a pair of reinforcement struts 61 attached to the frame 62 forming the roller unit 31, and further includes a box-shaped supporting frame 63 for maintaining the function of the movable bending rollers 64 and 65 for bending double rotational and translational movement on bearing structures 80 and 100 of the frame 60.

The auxiliary frame 63 includes end plates 66 and top / bottom cross plates 67 as well as front / rear cross plates 67 'assembled to form a box structure with bending rollers 64 and 65 for bending arranged inside. Shafts 68 and 69 (see. The longitudinal axis indicated in Figure 2) extend through and adjustably support the bending rollers 64 and 65 for bending. Each of the shafts 68 and 69 include ends that extend through bearings 70 and 71 to maintain a controlled manner on the cross plates 67. Pumps / motors 72 and 73 are attached to the upper end of the shafts 68 and 69. The motors 72 and 73 are operatively connected to and independently controlled by the controller 74 for adjustable speed (see FIG. 4). The motor housing 72 and 73 are attached to subframe 63 by structural housings (not specifically shown but are located in positions 74 and 75).

Auxiliary frame 63 operably supported for double rotational and translational movement by adjustable support structure that engages with the supporting structures 80 and 100 on the frame 60 as shown in Figures 5, 7 and 10 (2-10 and, in general). More specifically, the auxiliary frame 63 is supported in the initial position (fig.4-5, the rollers 64 and 65 define a line perpendicular to the longitudinal direction of «A» of the beam 33 when the beam 33 is shaped rollers). As shown in Figures 7 and 10, the auxiliary frame 63 can be selectively rotated (in the direction downstream) around the bearing slide member 85 and 86 which support shaft 68 and the shaft 69.

In particular, the adjustable support structure (2) includes top and bottom bearing structures 80 and 100 as described below. Outer support structure 80 includes upper and lower bearing plates 81 and 82 are attached to each other by struts 83 to form a top gap 84. The adjustable support structure further includes first and second sliding plate moving along the guide rails, the sliding elements 85 and 86 at the top (and two other sliding member 85 and 86 at the bottom) that are slidably supported in the gap 84 between the plates 81 and 82 in adjacent positions. Moving along the guides, the slide member 85 includes a large end 88 (Figure 5) with a bearing for maintaining the subframe 63 and allow rotation of the auxiliary frame 63 in an arcuate path downstream. The auxiliary frame 63 also includes a bearing that in turn supports the shaft 68. The slide member 85 further includes a narrow end 90 which is disposed between sopryagaemo and stably engages the spacers 83 and 83 '. In the initial position upstream (fig.4-5), the inclined surface between the large and narrow ends 88 and 90 adjacent to the end stops 83 'for accurate positioning of the subframe 63. The slide member 86 is similar to the sliding member 85 with respect to its movement, the clutch with bearing supports and the maintenance of the auxiliary frame 63.

Two of the spacers 83 form a wedge type stopper for limiting movement of upstream plate moving on rails, the slide member 85. When both plate moving on rails, the slide member 85 and 86 are in their position adjacent upstream (4 -5), the auxiliary frame 63 is a rectangular solid to the beam 33, the rollers 64 and 65 are opposite each other in a perpendicular arrangement with respect to the continuous beam 33. When in the adjoining position, bending station 32 does not bend the continuous beam 33, the beam 33 remains linear .

Two pairs of hydraulic actuators 91 (Figure 4) connected between the auxiliary frame 63 and the racks 61, with one top and one bottom actuator on each side. Actuators 91 are operatively connected to each side of the pump-motor 92, which are controlled by the bending machine, which in turn is controlled by the main controller 77 for controlling the roll forming device (1). (In particular, the controller 77 may be a separate device, or the main computer that controls various auxiliary control devices around the car 20) Ladder 94 (also called "stop bending") connects the auxiliary frame 63 with the racks 61 to limit the maximum angular displacement of the downstream the auxiliary frame 63 on the main frame 60. The chain 94 provides safety to reduce the chance of moving the auxiliary frame 63 in a critical situation downstream, which could result in the state of stress and damage the machine elements, for example, if one of the actuators 91 fails, or got out of control.

As noted above, the adjustable support structure further includes a bottom bearing structure 100 (Figure 2), which contains identical elements and function as the top bearing structure 80, including upper and lower plate moving elements stops / spacers, and actuators .

As shown in fig.4-5, bending station 32 has a starting position, in which the continuous beam 33 is not bent / deformed / bent. (In particular, the curved portion of the beam 33 shown on fig.4-5, which is located downstream with respect to the bending station was bent / flexed to move the auxiliary frame 63 back to its original position as in fig.4-5) bending station 32 also has a first rotated position (6-7) for deforming circular beam 33 in a first direction «B» of the longitudinal axis 95 of the beam 33 and an opposite second rotated position (FIGS. 8-10) for deforming circular beam 33 in the second direction «C», opposite to the first direction from the longitudinal axis.

6 In the first position, the plate moving on rails, the slide member 86 is in the rest position and the plate moving on rails, the slide member 85 is moved in the direction downstream and pivoted slightly so that the distance between the shafts 68 and 69 stored (so they continue to interact with opposite sides of the continuous beam 33). As a result, the beam 33 is bent in the direction of «B», when it passes between the rollers 64, 65. In the second position (Figures 8-10), the plate moving on rails, the slide member 85 is in the rest position and the plate, moving on guides, the slide member 86 is extended (downstream). As a result, the beam 33 is bent in the direction of «C», when it passes between the rollers 64, 65.

Tests have shown that this bending station 32 can deform the continuous beam 33 with a bend radius of 1000 mm in any selected direction when forming material having a tensile strength of 190 thousand psi. inch, and a tubular beam with a cross section of about 70 mm × 70 mm. Further, bending station 32 is managed in a controlled manner by the controller 77 so that the curvature of the bend can be made constant for a particular section of the beam 33, or can be made constantly changing along a particular section of the beam 33, or may be implemented as a combination of linear portions and bends . Moreover, bending can be performed so that the beam 34 is cut off from the continuous beam 33 can be symmetrical and can include aligned end sections (see. Figure 11, end portions 35 and 40) and the displacement of the central portion.

As described above, an exemplary vehicle frame 110 (Figure 12) can be made from beams made according to the principles of the present invention and by means of this machine and process. The frame 110 includes various structural beams / components having features is now possible using bending machine 30 according to the present invention. It should be noted that the opposite sides of the vehicle frame 110, will tend to be mirror images of each other (or very similar to mirror images) in an actual vehicle frame. However, the opposite side to illustrate the various displays that can be provided with various options.

In particular, the right half of the vehicle frame 110 shown in Figure 12, includes a single elongated tubular side frame member 111 bent with a complex bidirectional bending (with all bends are arranged in a vertical plane) at location 112, which is located at the rear vehicle wheel mounted on a vehicle condition, to provide space for the rear axle of the vehicle. Side frame member 111 further includes a complex bend (wherein all the bends are arranged in a horizontal plane) at location 113 (but the bends are located in an orthogonal direction relative to the first bends). The illustrated second bend at location 113 slightly less deep than the first bend at location 112. It is assumed that the second bend can be formed during stamping or by a separate auxiliary folding operation / shaping (see. Figure 13), which is supported by tubular beam 34, with providing a desired three-dimensional shape. The final element / frame bracket 115 (sometimes called "frangible supports") welded to a front portion of a side frame member 111, for example, to install a reinforcing beam 119 to the bumper mounting bracket 119 'welded / fixed thereto. The illustrated bracket 115 is rectangular in cross section. However, it is contemplated that the bracket may have a circular cross section or another shape. As suggested earlier herein, typically, the frame of the vehicle has a symmetrical shape, the difference occurs here for purposes of illustration to show alternatives, as will be appreciated by those skilled in the art. Shown bracket 115 and frame components are tubular, and may include initiating the destruction of the holes to provide a consistent and predictable energy absorption in a crash / collision of the vehicle.

The left half of the frame 110 of the vehicle (12) includes a pair of elongated tubular side frame members 121 and 122 overlap joints 123. The overlap joints 123 may be accomplished by direct blending all the elements 121 and 122 or may be formed by providing an intermediate tube having shaped to telescopingly extend into the ends of the elements 121 and 122. Elements 121 and 122 are welded together, connecting them in substantially aligned manner to form a side frame member which is not different from the member 111. An advantage of using frame members 121 and 122 is that they may be the final form of the molding machine 30 for molding roll bending station 32. Brackets 115 'may be welded or attached by bolts to the (rear) end of the frame for attachment of the rear bumper reinforcement beam 34.

The frame of the vehicle 110 also includes cross members 125, 126 and 127, which are located between the side frame elements 111 and rigidly connect them. Cross members 125 and 126 are tubular beams (or can be open channels), and include one or more bidirectional bends to meet their size requirements. End flanges are formed on the transverse member engaging the surface of the respective side frame elements and to facilitate the connections by welding. Also, if necessary, initiate destruction of cells and / or energy management devices can be incorporated into the cross members 125 and / or 126 and / or 127.

13 is a block diagram showing elements making and welding assembly together to form a vehicle frame.

Under certain circumstances, it may be necessary to provide more steeply curved bends which "poses challenges" to the above features bending station 32. In this case, to the bending station may be added to the auxiliary equipment, further enhancing its ability to provide accurate size and consistent, cool curved bend. Three major types of such auxiliary equipment, including (1) additional disposed downstream external support attached to the side downstream of the bending station 32 (e.g., trailing roller or rollers) that cooperates with the continuous beam 33 (called an "external stabilizer "), (2) located upstream external support (called located upstream stabilizer folding or" support yoke ") cooperating with the beam 33 immediately before the rollers 64, 65, and / or (3) an internal stabilizer 142 (illustrated as "internal mandrel chain 'connected along a serpentine manner) (see FIG. 14-18). These principles can be useful in a folding machine for the manufacture of curved in two directions of the beam or to manufacture curved in one direction of the beam, but is not considered necessarily required unless the beam 33 is not large (e.g., greater than 2 "× 2") or uses high strength materials (e.g., greater than 80 thousand pounds per sq. inch) or uses thin-walled materials (e.g., less than 2.2 mm in thickness).

Located upstream support (called located upstream stabilizer folding or "traverse support") (Figure 4) located immediately adjacent to the bending rollers, to maintain beam 33 in its linear shape when it reaches the rollers 64, 65 in the bending station 32. Situated upstream support is supported at side location 141 and has a side adapted to the shape of the engaging surface for sliding with the beam 33 to maintain beam 33 as it moves along its preformed rollers in the longitudinal axis between the pinch rollers 64 and the bending station 65. By performing situated upstream of the support in the form of a continuous element (rather than a wheel, for example), the front end located upstream support can be made wedge-shaped, so that the support it provides is closer to the zone of crushing between rollers 64 and 65 when the beam 33 is bent around a roller (for example, a roller 64 or roller 65).

By maintaining the beam 33 immediately adjacent to the upstream side of the bending station 32, the dimensional accuracy of the beam 33 can be greatly increased. The reason is that the wall beams are stabilized and supported to prevent undesired bending and deformation from "counteracting bending forces." Counteracting bending forces (as used herein) represent the reaction forces which cause deformation upstream on the beam 33 in the direction of the direction of bending. These forces of reaction caused by the fact that the bar 33 acts like a swing, when it forcibly deformed around the bending roller (eg, roller 64). More specifically, the beam strength and resultant stresses on the beam 33 cause the bending portion upstream of the beam 33 (e.g., 1-5 inches upstream relative to the location where the beam 33 touches the bending roller 65) in the direction of the bending roller (64).

It is assumed that located upstream external support can be located on one side of the beam 33, but it is assumed that disposed upstream external supports will likely be positioned on both sides of the beam 33 so that the wall beams are supported regardless of a direction which bends the beam 33 (i.e., located upstream external support would stabilize the walls of the beam 33 regardless of whether the beam 33 is deformed around roller 64 in a first bending direction, or deformed around roller 65 in a second (opposite) direction of bending ).

The internal stabilizer 142 (FIGS. 14-19) (also called "multi-link internal mandrel" or "flexible mandrel") includes a plurality of inner mandrel units connected together ladder circuit 151, which in turn is connected to an upstream fastening device 55 with the rod 152, e.g., a solid rod with a diameter of about 1 ". The links 160-163 have an outer shape to fill the inner cavity of the continuous beam 33 and slide along the beam 33 when the beam 33 moves through the bending station. The links 160-163 have an outer cross-sectional dimension, defined thereby that the walls of the beam 33 do not collapse into the cavity and the cross-sectional shape of the beam 33 is maintained during the process of formation of the bend.

Shown most upstream first link 160 is elongated (such as 3-4 inches) and includes a hole to accommodate a pin 153 that connects the chain 151 (and unit 160) with an eye on the rod 152 of the fixing device. The first link 160 is held in a stationary position located upstream relative to the zone between the pinch rollers 64 and 65. The second link 161 is also elongated (such as about 4-6 inches), thereby keeping it aligned with the linear direction of the roll forming process. The second link 161 is also held in a stationary position located upstream relative to the zone between the pinch rollers 64 and 65. For the element 161 is followed by several shorter links 162 (each about an inch or two long) and an elongated locking unit 163 last (long 2 -3 inches). Links 162 form stacked one behind the other a number of modules / mandrels extending behind the pinch between the rollers 64 and 65, and a link 163 placed downstream relative to the rollers 64 and 65. The length of the links 160, 161 and 163 helps to maintain their alignment with the continuous beam moldable 33. Moving units 162 and 163 adheres to the shape defined by the rollers 64 and 65, when the rollers 64 and 65 are moved to different positions (see. 2-10), thereby increasing the stability of the continuous beam 33 as it is moved through the bending station.

Each unit 161-162 has a through-hole, and the links 160 and 163 are designed for attachment to opposite ends of the links of the chain 151. The chain 151 passes through the links connecting units 161-162 and 160-163. Each link 160-163 is structurally made and interconnected in such a manner as to allow rotation in either direction from side to side. More specifically, each link 161-163 has a joint formed tapering facing towards upstream, having a cylindrical projection and the mating facing toward downstream cylindrical recess, so that they abut to form a pivot bearing surface, which allows rotation serpentine internal mandrel in either direction. It is assumed that the elements for fastening the inner mandrel with each other can be used various chain. The illustrated chain 151 includes flat links 155 and transverse pins 156 that are connected in a manner similar bicycle chain or motorcycle drive chain for engaging with the sprocket. Shown links 155 are flat and each has the shape of the digit "8" (see. FIGS. 15 and 17) and can be arranged in two or three levels, and the ends of the links 155 offset longitudinally and jointly rotated due to the pins, thus that is formed by high-strength endless chain which can bend in any direction in a horizontal plane ... but not bend in the direction of the plane.

Figure 19 shows a modified unit 162A, wherein at least one of the outwardly facing side unit 162A includes a roller pin 162B. This provides reduced frictional engagement side units 162A, since the roller pin 162B rolls along the inner surface of the continuous beam 33 (instead of sliding contact). This design is more durable than with the links 162, but certainly units 162A are more expensive, and are potentially not practical (or less practical) unless the size of the link 162A is not large enough and simultaneously pressure molding the beam 33 are not large enough to justify the use of link 162A.

Also shown is a modified machine 30A for molding the roller (Fig. 20-28). Elements that are similar and / or identical to drive 30 are denoted with the same positions but with the letter «A» or «B». This is done to reduce redundant descriptions. Fig.20-28, in general, are similar to 2-10, respectively, but with modifications as described below.

The machine 30A (Figure 20) includes a forming roll unit 31A and the bending station 32A. Bending station 32A fixed rigid supporting frame 200A and functionality is supported on the basis of 201A. In particular, the supporting frame 200A and the base 201A can be set to maintain an appropriate size of the weight and size of the bending station 32A, if necessary for its specific embodiments.

The bending station 32A, the sliding plate sliding elements 85A and 86A (Figure 20, but see. Figure 25) are modified for improved performance and flexible changeover process. More specifically, the sliding members 85A and 86A are mirror images of each other, so only one element needs to be described. The slide member 85A (Figure 25) includes a narrowed tail portion 90A, including a tail slot 203A and formed inner surface 204A. The tail has the form of a groove 203A for engaging a roller bearing 205A to a support fixed to the plate 82A. The sides of the groove 203A are slightly inclined, so that the entrance to the groove 203A forms a wide opening facing the roller bearing 205A. This allows the groove 203A to capture the roller bearing 205A, while still providing a non-linear movement of the sliding member 85A during extension. The lower part of the groove 203A defined dimensioned for tight engagement with a roller bearing 205A, thereby the slide member 85A is accurately positioned when it is in its initial position upstream.

The front part of moving elements 85A and 86A are attached to each other by a connecting rod 210A. The connecting rod 210A is adjustable in length so that the rollers 64A, 65A are set in relation to each other to interact with the beam 33A, whereby the connecting rod 210A can also be adjusted. When the slide member 85A moves toward downstream, a connecting rod 210A causes the large end 88A of the slide member 85A by an arcuate path downstream around axis 69A during extension. The formed inner surface 204A is shaped to accommodate this movement of the slide member 85A ... allowing the inner surface 204A to avoid collision with the spacer 83A 'and / or 83A.

Regulating mechanism (fig.29-30) provided in the bending station 32A to provide setup rollers 64A and 65A toward (and from) each other. There are adjusting screws 211A and adjustable bearing pad 212A to maintain the rollers 64A and 65A. They are functionally supported on an auxiliary frame 63A to position the bending rollers relative to each other (so as to be firmly against the continuous beam 33A). As noted above, the tie rod 210A is also adjustable to provide similar control over its length.

It should be noted that the chain (94) "bending strain" is excluded in the bending station. Instead, a system with sensors or potentiometers attached between the stationary part of the bending station 32A and 63A of the auxiliary frame. The potentiometers 215A are connected to controller 77 for controlling the actuators 91A ... which, in turn, control the position of the sub-frame 32A and bending rollers 64A, 65A, so that the beam 33A are given specifically required bending radii (i.e., longitudinal curvature). Potentiometers 215A are also working to determine when (if) the bending station "excessively pushed" toward downstream. More specifically, a potentiometer 215A (21) attached to each side of the bending station 32A, with one end 216A is attached to the plate 81A, while its other situated downstream end 217A attached to the subframe 63A. These potentiometers 215A are connected electrically to the controller 77, thus if a problem occurs, the machine stops immediately.

Various modifications made in the various elements to withstand the high stresses generated in this bending station. Also, modifications are made to improve work efficiency. For example, the hole 220A in the side end plates 66A and other auxiliary frame plates 63A allows the operator to view inside the bending station, providing better control, because you can see what is happening inside the bending station. Also, fixing the rack 200A is performed to further withstand voltage and withstand high voltage value without damage or unacceptable deformation.

It should be understood that the above structure may be made alterations and additions without departing from the teachings of the present invention and, furthermore, it is understood that such ideas covered in the following claims unless the claims are not otherwise specified.