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Coubray, Bruce Arthur (47 Paunui Street St Heliers Auckland 1005, NZ)
| 1. | Elongate processing equipment having an elongate structure for the conveyance of an elongate body to be processed, and means to process all faces of the elongate member. |
| 2. | Elongate processing equipment as claimed in claim 1 wherein said means to cut or shape is a cutting means adapted to move around the elongate member to access all faces thereof. |
| 3. | Elongate processing equipment as claimed in claim 1 wherein said elongate structure includes a plurality of coaxial holding stations spaced along the structure and a processing station aligned with the holding stations, the holding stations being adapted to receive and support an elongate body to be processed, and to allow the body to pass through or past the processing station, in which a process is performed on the elongate body. |
| 4. | Elongate processing equipment as claimed in any one of the preceding claims, wherein, at least one holding station includes a pair of rollers of which the axes of rotation are substantially parallel and normal to a plane including the elongate central axis of the elongate body. |
| 5. | Elongate processing equipment as claimed in any one of the preceding claims, wherein each said holding station includes a pair of said rollers. |
| 6. | Elongate processing equipment as claimed in any one of the preceding claims, wherein the rollers in each said pair are both movable towards and away from the elongate central axis of the elongate body, whereby to grip the body between the rollers and to adapt to elongate bodies of different crosssections. |
| 7. | Elongate processing equipment as claimed in any one of the preceding claims, wherein the surface of each roller is in the form of a pair of truncated cones, the smaller ends of which are together in the roller centre. |
| 8. | Elongate processing equipment as claimed in any one of the preceding claims, wherein the included angle of the cone surface is between 10 and 30 degrees. |
| 9. | Elongate processing equipment as claimed in any one of the preceding claims, wherein a circumferential groove is formed in each roller at the junction of said cones. |
| 10. | Elongate processing equipment as claimed in any one of the preceding claims, wherein at least some of said rollers are power rotatable, whereby the elongate body can be moved in a direction of the elongate central axis thereof towards and/or away from the processing station. |
| 11. | Elongate processing equipment as claimed in any one of the preceding claims, wherein a plurality of said holding stations are located coaxially on both sides of the processing station. |
| 12. | Elongate processing equipment as claimed in any one of the preceding claims, wherein the beam can be moved by a hitch feeder which can grip the beam and move it longitudinally relative to the processing station. |
| 13. | Elongate processing equipment as claimed in any one of the preceding claims, wherein the elongate body processing equipment includes a waterjet cutting apparatus, especially such apparatus adapted to cut metals, such as steel beams or girders. |
| 14. | Elongate processing equipment as claimed in any one of the preceding claims, wherein and especially where the processing equipment include the waterjet cutting apparatus, the pairs of rollers holding the elongate body are mounted so as to be rotatable about the elongate axis of the body. |
| 15. | An elongate body processed by any of the above mentioned elongate body processing equipment. |
| 16. | An elongate body as claimed in claim 13 wherein the elongate body is a tapered castellated beam. |
| 17. | A method of processing an elongate body by moving it relative to a processing station which is capable of processing all faces of the elongate member wherein the processing includes a cutting operation of the elongate body to cut holes, slots or castellations of various shapes and sizes. |
| 18. | A method of processing an elongate body as claimed in the preceding claim wherein the elongate body is a tapered castellated beam produced by making a castellated cut centred about a line along the web of a beam, the line being inclined to the central elongate axis of the web, rotating through 180° one half of the beam so cut and fastening together the tips of the castellations remote from the flanges of the beam. |
Elongate bodies which may be processed by the equipment include metal beams, bars, angle sections, tubes or the like. For some applications the equipment may be used to process beams of wood or other non-metallic materials.
STATEMENT OF THE INVENTION According to one aspect of the present invention there is provided elongate processing equipment having an elongate structure for the conveyance of an elongate body to be processed, and means to process all faces of the elongate member.
Preferably the means to cut or shape is a cutting means adapted to move around the elongate member to access all faces thereof.
Preferably the elongate body processing equipment has an elongate structure including a plurality of co-axial holding stations spaced along the structure and a processing station aligned with the holding stations, the holding stations being adapted to receive and support an elongate body to be processed, and to allow the body to pass through or past the processing station, in which a process is performed on the elongate body.
Preferably, at least one holding station includes a pair of rollers of which the axes of rotation are substantially parallel and normal to a plane including the elongate central axis of the elongate
body.
Conveniently each said holding station includes a pair of said rollers.
Preferably the rollers in each said pair are both movable towards and away from the elongate central axis of the elongate body, whereby to grip the body between the rollers and to adapt to elongate bodies of different cross-sections.
Conveniently the surface of each roller is in the form of a pair of truncated cones, the smaller ends of which are together in the roller centre.
Preferably the included angle of the cone surface is between 10 and 30 degrees, and more preferably is between 15 and 25 degrees.
Preferably a circumferential groove is formed in each roller at the junction of said cones.
Conveniently at least some of said rollers are power rotatable, whereby the elongate body can be moved in a direction of the elongate central axis thereof towards and/or away from the processing station.
Advantageously a plurality of said holding stations are located co-axially on both sides of the processing station.
Preferably the beam can be moved by a hitch feeder which can grip the beam and move it longitudinally relative to the processing station.
The processing equipment can include any form of processing including but not limited to cutting or shaping by water cutters, laser cutting machines, gas cutters, plasma cutters, or operations involving drilling, planing, routing, shearing, cutting, punching, welding or the like.
In its most preferred form, the elongate body processing equipment includes a water-jet cutting apparatus, especially such apparatus adapted to cut metals, such as steel beams or girders. This may include a water bath with the cutter movable above the water bath so that the water jet is directed downwards through the elongate body towards the surface of the water bath.
Conveniently and especially where the processing equipment includes the water-jet cutting
apparatus, the pairs of rollers holding the elongate body are mounted so as to be rotatable about the elongate axis of the body.
According to another aspect of the present invention there is provided an elongate body processed by any of the above mentioned elongate body processing equipment.
The processing may include a cutting operation of the elongate body, which may include cutting holes, slots or castellations of various shapes and sizes.
The elongate body may comprise a tapered castellated beam produced by making a castellated cut centred about a line along the web of a beam, the line being inclined to the central elongate axis of the web, rotating through 180° one half of the beam so cut and fastening together the tips of the castellations remote from the flanges of the beam.
The invention also includes a method of processing an elongate body by moving it relative to a processing station which is capable of processing all faces of the elongate member wherein the processing includes a cutting operation of the elongate body to cut holes, slots or castellations of various shapes and sizes.
Various embodiments of the present invention are described, by way of example only, with reference to the accompanied drawings, in which : - BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a perspective view of a beam cutting apparatus, according to the invention, Figure 2 is a section at enlarged scale of part of Figure 1, Figure 3 is an end view of Figure 2, Figures 4 to 12 show, in diagrammatic form, the equipment of Figure 2 processing elongate bodies of different cross-section, Figures 13 and 14 are elevations showing different stages in the manufacture of a beam, and
Figures 15 and 16 show the manufacture of a tapered beam.
DESCRIPTION In Figure 1 a plurality of I-section beams or girders 10 which are to be processed are placed on parallel input rails 11 or conveyors, along which the beams 10 are moved to the input end of beam processing equipment 13 the beams 10 pass from the rails 11 into a plurality of support and manipulating units 14, of the kind shown in more detail in Figures 2 and 3.
The support units 14 can rotate the beam 10 about the longitudinal axis thereof and can also feed the beam 10 through a brush seal 15 into an enclosed water-jet cutting apparatus 16. After processing within the cutting apparatus 16, the support units 14 drive the beam 10 out to a plurality of output support units 17 at the output end 18 of the processing equipment 13. On completion of operations on the beam 10, it is discharged onto a plurality of output rails 19 for removal.
Usually, the cutting apparatus 16 includes a very high pressure water pump which feeds high pressure water containing an abrasive powder such as garnet to a nozzle from which a very high velocity jet of water and abrasive emerges in a generally downwards direction into a water receiving trough.
When a solid object such as the steel beam 10 intercepts the water-jet, the abrasive therein rapidly cuts through the steel, making a fine accurate cut. The water-jet nozzle of the cutting apparatus 16 is capable of limited angular movement across the beam 10, so that chamfers, bevels and weld preparation can be made. By use of this water-jet cutting technique, metals other than steel can be cut, as can other material such as wood.
Figures 2 and 3 show one of the support units 14 having a C-shaped frame 20 with an opening 21 through which the beam 10 can pass.
A plurality of rollers 22 carry and locate a C-shaped chain sprocket 23. A shaft 24 which extends along the length of the beam processing equipment 13 is rotatable to drive a chain sprocket thereon around which a chain 25 passes around two of the rollers 22, so as to engage with a peripheral portion of the C-shaped sprocket 23. The peripheral length between the two rollers 22 is greater than the gap 26 in the C-shaped sprocket 23, to ensure that drive is always
maintained from the chain 25.
The sprocket 23 carries, or has affixed thereto, a sub-frame 27 on which are mounted a pair of parallel pillars 28 along which a pair of axle units 29 are slidable. The axle units 29 are moved equal amounts towards or away from the axis of rotation of the sprocket 23 by a hydraulic or other motor 30 driving a pinion 31 engaged with racks 32 connected to the axle units 29.
Each axle unit 29 has a roller 33 accurately mounted on bearings thereon. Each roller 33 is rotatable by a further hydraulic or other motor 34. The axes of the rollers 33 in each support unit 14 are parallel. Each roller 33 has an outer surface 35 in the form of a pair of truncated cones of which the smaller ends are joined adjacent the centre of the roller 33, except for a groove 36 formed therein. A suitable included angle for the cones is around 10° to 30°, and in our 40 metre long machine we have found that the best included angle to accommodate sections from 100-600mm diameter (and beam lengths of 18 meters) is an included angle of 18°.
However the included angle can be varied within this range depending upon the diameter of the sections to be accommodated.
By moving the rollers 32 apart, elongate objects such as beams 10, tubes etc having a wide range of size or cross-section can be entered between the rollers 33, which can then be brought together until the beam 10 is gripped there between. The conical form of the rollers 33 and the groove 36 cause the beam 10 or the like to become centred automatically along the length of the rollers 33.
Figures 4 to 12 show diagrammatically how such a wide range of elongate objects can be processed. In Figures 4 to 12 only half of each roller is shown, and they suggest that one of the rollers 33 is fixed, whereas, as described above, both rollers 33 move equally towards and away from the central longitudinal axis of the beam 10.
Figure 4 shows how a large I-beam 10 having a long web 37 relative to the flanges 38 can be held and centred between the rollers 33. A much smaller beam 10 of similar proportions can equally well be held and centred between the rollers 33, by moving the rollers together.
Figure 5 is similar to Figure 4 but shows the range of beams 10 which can be accommodated when the web 37 is of comparable size to the flanges 38.
Figure 6 shows how a square-section bar or tube can be held diagonally in the grooves 36.
Figure 7 shows the diagonal location of rectangular section bars or tubes.
Figure 8 shows the location of channel section beams 10.
Figure 9 shows the location of symmetrical angle-section beams 10.
Figure 10 shows the location of circular-section bar or tube.
Figure 11 shows the location of rectangular-section bar or tube, and Figure 12 shows the location of asymmetrical angle-section beams 10.
Rotation of the hydraulic motor 30, to control the spacing of the rollers 33, operation of the further hydraulic motors 34 to rotate the rollers 33, rotation of the shaft 24 so as to rotate the beam 10 about its longitudinal axis, movement of the water-emitting nozzle transverse to the axis of the beam 10 and inclination of the nozzle are computer controlled, so that, for example, apertures of circular, rectangular or many other shapes can be formed through the web or other parts of the beam 10 or long fine cuts of selected shape can be made along the beam 10. For example, the equipment can be connected direct, and controlled by CAD apparatus.
Figures 13 to 16 show how castellated cuts can be made quickly and cheaply, thereby enabling castellated beams 10 to be fabricated.
Figure 13 shows an I-section beam 10 along the web of which a fine castellated shaped cut 39 has been made, dividing the beam 10 into upper and lower sections.
Figure 14 shows how the upper section of the beam 10 has been raised and moved along relative to the lower section until the tips of the castellations 40 abut and are welded together to form a strong stiff and lightweight beam.
Figure 15 is similar to Figure 13 except that the cut 39 is symmetrical about an inclined line. By raising the upper portion of the beam 10 and rotating it 180° about an axis through the centre of its length, the tips of the castellations can again be brought together and welded, in this case forming a tapered final beam 10.
ADVANTAGES The conical and centre-grooved profile of the rollers 33 enable a wide range of beams or the like to be handled without changing the rollers.
The holding stations also allow a beam or girder to be moved forwards or backwards and rotated about their longitudinal axes to allow the water-jet cutter to cut all faces of the beam or girder.
By using a water-jet cutter it is possible to cold cut steel or other metals without degrading the structural properties of the material.
An additional advantage of the watercutting process of the preferred embodiment in relation to the structural performance of the beam is that it provides a smooth surface, which is required particularly in bolt holes for"bolted connection".
VARIATIONS Instead of moving the beam longitudinally by powered rollers it is possible (and in fact preferable) to move the beam by a hitch feeder which can grip the beam and move it longitudinally relative to the processing station. In which case it is preferably to provide a pair of hitch feeders with one on either side of the central processing station.
For example, the support units 14,17 directly adjacent the cutting apparatus 16 may be in the form of a hitch feeder having jaws which can securely grip the beam (without rollers) with the jaws being movable longitudinally so as to grip and move the beam towards or away from the cutting apparatus. In which case it is preferable that longitudinal movement of the jaws on either side of the cutting apparatus is synchronised. Similar movable jaws could be positioned anywhere along the length of the machine, but it is preferable that at least one set of such jaws be positioned adjacent the cutting apparatus so as to accommodate shorter beam lengths.
Although the cutting medium has been described as a high-pressure water-jet with or without abrasive, an oxy-acetylene torch, a plasma gun, a laser or other guidable cutting head can be used, either alone or in combination with the water jet cutting equipment.
If preferred, the input or output support units 14,17 away from the cutting apparatus 16 may have free running rollers 33. Furthermore, the support units 14,17 adjacent the cutting
apparatus 16 may have two sets of driven rollers 33, so as to handle short lengths of beam 10. For the manufacture of short lengths of beam 10, it may be convenient to cut a long beam almost through but leave the ensuing short lengths held end to end by short uncut portions, which can subsequently be broken or cut through at the end of the operation, or even on site.
The equipment can be scaled up or down, and in the case of equipment designed to process smaller beams, the holding stations need not have the side openings shown in Figure 1 but could allow for beams or girders to be fed into the equipment at one end rather than at the sides as shown in Figure 1.
In its most preferred form the invention makes use of water-jet cutting and the rotation of the beam relative to the cutting head. Alternatively it is possible to provide a cutting head that can rotate fully around the beam - without any need to rotate the beam. In which case the holding stations could be simplified or replaced by relatively simple conveying means. A fully rotatable cutting head is more likely to be a laser cutter, although it would be possible to achieve this with a water-jet cutter.
The equipment can be configured with any combination of direction of flow, i. e. left to right, right to left and also infeed and outfeed rails in front or behind the processing station.
The opening and closing of the rollers has been described above as being driven by a hydraulic motor. In an alternative version they can be driven by hydraulic cylinders with the roller shafts centralised on a rack and pinion arrangement.
The rollers need not have a central groove as described and illustrated.
Instead of each holding station having a hydraulic motor for rotation, so that the beam can be actively rotated by each holding station as described above, in an alternative arrangement the beam can be rotated by way of a pair of servo motors, one servo motor on each side of the central cutting station, each servo motor linked by a common shaft to each holding station.
Finally various other alterations or modifications may be made to this equipment or how it is used, within the scope of this invention as claimed.