The present invention relates to a modular mold, a modular device, a universal insert for straightening profdes, in particular for repairing profiles of warehouse rack uprights for mounting of warehouse rack girders, an insert and a corresponding method for straightening such multiple profdes.

BACKGROUND

From the Applicant’s prior International Publication WO 2006/073304A1, a straightening device and a method for straightening an upright profile which has been bent out of an original position is known. The device comprises in particular an outer template, an inner template and pressing means for pressing the outer template against the outer side of the profile and the inner template against the inner side of the profde. The outer template and the inner template used in such a device are monolithic and specifically designed for the profile to be repaired. Yet multiple sorts of profiles exist on the market, each with specific dimensions and shapes.

SUMMARY

The object of the invention is to provide a modular mold, a modular device and a universal insert able to straighten more than one sort of profiles.

According to a first aspect of the invention, a mold for repairing a profile which has been bent out of an original position is provided, the profile being in particular a profile of warehouse rack uprights for mounting of warehouse rack girders, wherein an inner space accessible from an open side is defined in the profile. The mold is adapted to the form of the outer surface of the profile, and the mold partly encloses the profile during use. The mold is modular and comprises a plurality of mold parts, each mold part having a surface adapted to a respective part of the outer surface of the profile. According to a preferred embodiment, the plurality of mold parts comprise a front mold part having a surface adapted to a front outer surface of the profile to be repaired, the front outer surface of a profile facing away from the open side of said profde, and two side mold parts, each having a surface adapted to a side outer surface of the profile to be repaired.

According to a preferred embodiment, the side mold parts are selected, based on the profde to be repaired, from a plurality of side mold parts for repairing the plurality of different upright profdes. In this way, profdes having different side surfaces can be repaired, increasing the modularity of the mold. For instance side surfaces of the mold may have different shapes (number and/or shapes of indentation(s), location and/or values of (additional) comer angle(s), etc), or dimensions (width of the side surface, width of indentations, etc) among others.

According to a preferred embodiment, the front mold parts are selected, based on the profde to be repaired, from a plurality of front mold parts for repairing the plurality of different upright profdes. In this way, profdes having different front surfaces can be repaired, increasing the modularity of the mold. For instance, front surfaces may have different shapes (number and/or shape of indentation(s), etc) or dimensions (width of indentation(s)) among others.

According to a preferred embodiment, the mold further comprises at least two extension mold parts arranged in between a front mold part and a respective side mold part for adapting the width of the mold.

According to a preferred embodiment,, the mold further comprises at least one mold connecting mechanism for connecting all the mold parts together.

According to a preferred embodiment, the mold connecting mechanism is a manually operated mechanism.

According to a preferred embodiment, the connecting mechanism comprises a plurality of rods for passing through all the mold parts and a plurality of nuts engaging with the rods for connecting all the mold parts together.

According to a preferred embodiment, a device for repairing a profde which has been bent out of an original position is provided. The device comprises a mold according to any of the above embodiments, an insert configured to shape at least part of an inner surface of the profde, wherein during use the insert is arranged in the inner space of the profde via the open side, and a pressing unit for pressing the mold against the outer side of the profde and pressing the insert against the inner side of the profde with pressing force such that the profde is bent back into its original position. According to a preferred embodiment, the pressing unit comprises a pressing mechanism for engaging with the insert, and a frame for engaging both with the mold and the pressing mechanism. According to a preferred embodiment, the frame comprises a plurality of frame elements and at least one frame connecting mechanism for connecting the frame elements together.

According to a preferred embodiment, the frame connecting mechanism is a manually operated mechanism.

According to a preferred embodiment, the frame is configured to engage with each of the plurality of mold parts for repairing the plurality of different upright profiles.

According to a preferred embodiment, the frame comprises a groove and the mold comprises a protruding bar to be arranged in the groove of the frame.

According to a preferred embodiment, the insert is a universal insert comprising an insert head, a first insert part and a second insert part, wherein the first and the second insert parts are each connected to the insert head by a hinge and are configured such as to form, in use, inner comers of the profile.

According to a preferred embodiment, the first and second insert elements are configured such as to swivel around the hinges away from each other, straighten an inner surface of the profile against the mold and form the inner corners, when the pressing unit presses the insert head in the pressing direction.

According to a preferred embodiment, the profile comprises a front surface facing away from the open side of said profile and side surfaces, he first and second insert parts are arranged to straighten an inner front surface of the profile against the mold up to inner corners of the mold, to define the inner corners of the profile between the front surface of the profile and the side surfaces of the profile. In this way, a central portion of the front surface may be straightened if bent out of position and the inner comer with the side surfaces may be redrawn. For instance this may be useful as an initial step prior to forming the sides surfaces to be able to open the profile enough to insert inserts for the side surfaces.

According to a preferred embodiment, the first and second insert parts are dimensioned to form inner corners of profiles of different width. According to a preferred embodiment, wherein, when not in use, the first and second insert parts are configured to swivel towards each other such that the insert has a width smaller than the width of the open side of the profile.

According to a preferred embodiment, the insert comprises a first and second insert parts being arranged as separate elements, each having an external form which is adapted to a corresponding part of the given profile and wherein the pressing unit is adapted to press the first and second template parts against the profile through mutual displacement of the inserts parts.

According to a preferred embodiment, the insert comprises a pressing head with which the first and second template parts can be pressed against the profile, wherein the pressing head is selected, based on the profile to be repaired, from a plurality of pressing heads for repairing the plurality of different upright profiles.

According to a preferred embodiment, the selected pressing head has an external form which is adapted to a central part of the inner front surface of the given profile. In this way, profiles having different front surfaces can be repaired, increasing the modularity of the mold. For instance front surfaces of the mold may have different shapes (number and/or shapes of indentation(s),etc), or dimensions (width of indentations, etc) among others. Preferably the selected pressing head may correspond with the selected front mold part to having matching shapes.

According to a preferred embodiment, each of the first and second template parts is provided with a chamfered positioning edge and the pressing component is wedge shaped.

According to another aspect of the invention, an insert for repairing a profile which has been bent out of an original position is provided, the profile being in particular a profile of warehouse rack uprights for mounting of warehouse rack girders, wherein an inner space accessible from an open side is defined in the profile. The insert is configured to shape an inner surface of the profile, wherein during use the insert is arranged in the inner space of the profile via the open side. The insert is universal and comprises an insert head and a first and a second insert parts, each connected to the insert head by a hinge, to form, in use, inner comers of the profile.

According to a preferred embodiment, the first and second insert parts are configured, when not in use, to swivel towards each other such that the insert has a width smaller than the width of the open side of the profile. According to another aspect of the invention, a method for repairing a profde which has been bent out of an original position is provided, the profile being in particular a profile of warehouse rack uprights for mounting of warehouse rack girders, wherein an inner space accessible from an open side is defined in the profile. The method comprises the steps of selecting a plurality of mold parts, each having a surface which is adapted to a corresponding part of the outer surface of the profile, from a plurality of mold parts for repairing a plurality of different profiles, assembling the plurality of mold parts to form an mold, selecting an insert, adapted to shape at least part of an inner surface of the profile, arranging around the bent profile the mold adapted to the form of the outer surface of the profile and partially enclosing the profile, arranging the insert in the inner space of the profile via the open side, pressing the mold against the outer side of the profile and pressing the insert against the inner side of the profile in order to bend at least part of the profile back to its original position.

According to a preferred embodiment, selecting an insert adapted to shape at least part of the inner surface of the profile comprises selecting either an insert with an insert head and a first and a second insert parts connected by hinges to the insert head, or an insert with a separate first and second insert parts.

According to a preferred embodiment, if an insert with a first and a second insert parts connected by hinges is selected, pressing the mold against the outer side of the profile and pressing the insert against the inner side of the comprises at least forming inner edges of the profile.

According to a preferred embodiment, if an insert with separate first and second template parts is selected, the method further comprises the steps of selecting a pressing head in an intermediate space between the first and second insert part, pressing the pressing head further into the intermediate space in order to generate lateral and forward pressure whereby the insert parts are pressed against the profile.

According to a preferred embodiment, first a repair may be performed according to an embodiment using an insert with a first and a second insert parts connected by hinges, and subsequently a repair may be performed according to an embodiment using an insert with a separate first and second insert parts.

BRIEF DESCRIPTION OF THE FIGURES This and other aspects of the present invention will now be described in more detail, with reference to the appended drawings showing currently preferred embodiments of the invention. Like numbers refer to like features throughout the drawings

Figure 1 illustrates an exploded view from above of a modular mold, a modular device and a universal insert according to embodiments of the invention.

Figure 2 illustrates a perspective view from above of the universal insert, and a modular device incorporating the universal insert when repairing one sort of profile according to an embodiment. Figure 3 illustrates a perspective view from above of a modular device according to another embodiment alternative to the embodiment of Figure 2.

Figure 4 illustrates an exploded view from a side perspective of the modular device of Figure 1. Figure 5 illustrates an exploded view from a front perspective of the modular device of Figure 1. Figure 6 illustrates a method according to an exemplary embodiment.

DESCRIPTION OF THE EMBODIMENTS

Figure 1 illustrates an exploded view from above of multiple modular molds, multiple modular inserts adapted for multiple sorts of profiles, the common structure to multiple modular devices and a universal insert.

Figure 1 shows among other things a profile PI which has been repaired. The profde PI belongs to a list of n sorts of profdes, labelled PI to Pn, n being an integer higher than 1, which can be repaired using the modular device of the invention. The profiles PI to Pn may in particular be profiles of warehouse rack uprights for mounting of warehouse rack girders. An inner space accessible from an open side is defined in all the profiles PI to Pn. The presence of an open side is a common characteristic to all the profiles intended to be repaired by a device of the invention. The open side may be defined a back side of the profile, while an outer surface of the profile oriented away from the open side may be defined as a front side of the profile. In between the front side and the open back side, one or more side surfaces may be present. By n sorts of profiles PI to Pn is meant that the profiles PI to Pn are different from each other, in particular each have a specific shape and/or dimensions. For example the profile PI has a flat front surface of a given width and two flat side surfaces, while other profiles may have front surfaces with a different width, and additional indents in their front and/or side surfaces.

Figure 1, although representing only profile PI, shows many more parts than necessary for repairing this profile alone. Figure 1 shows indeed a plurality of parts used for repairing a plurality of profiles. Figure 1 is thus to be understood as showing the modularity of the invention in all its aspects.

In a first aspect of the invention, the modularity and versatility of the mold used for repairing a profile which has been bent out of an original position, will be discussed. In particular a plurality of mold parts 111-113, 121-123, 131-133, 141, 142, 151, 152 are shown exploded in Figure 1. The shown mold parts 111-113, 121-123, 131-133, 141, 142, 151, 152 enable to repair twenty seven different profiles, however the mold parts that can be used are not to be limited to only these elements. The here shown numbers of mold parts and their shapes should rather be understood as merely serving illustrative purposes.

When addressing the invention at a general level, the following explanation may be given: When looking to repair a profde Pi which has been bent out of an original position, where i may be an integer between 1 and n, some of the mold parts 111-113, 121-123, 131-133, 141, 142, 151, 152 may be selected to form a mold lOi, each selected mold part having a surface adapted to a respective part of the outer surface of the profile Pi. In this way, a modular mold may be obtained and versatility of the mold parts may be increased as mold parts may be efficiently reused to form molds for different profiles. The modularity of the mold increases thus the convenience for the user, as well as reduces the costs related to the maintenance of a plurality of different sorts of profiles.

The mold lOOi may comprise a front mold part 111-113 having a surface adapted to a front outer surface of the profile Pi to be repaired, the front outer surface of a profile facing away from the open side of said profile, and two side mold parts 121-123, 131-133, each having a surface adapted to a side outer surface of the profile to be repaired. In particular the front mold parts 111-113 may differ from each other in that they have a different dimension and/or a different shape. Mold parts 111-113 may have the same width and may differ by their shape, for example in their central part. Mold part 111 has a totally flat surface for repairing a profile having a flat front outer surface, while mold part 112 as a small V shape in its central part to repair a profile having a corresponding V shaped indent on its outer front surface, and mold part 113 has a larger U shaped protrusion to repair a profile having a corresponding U shaped indent on its outer front surface. In this way a large number of profiles with different front surfaces and/or sides surfaces may be repaired with a small number of mold parts.

The mold lOOi may further comprise extension mold parts 141, 142, 151, 152 arranged in between a front mold part 111-113 and a respective side mold part 121-123, 131-133. The extension mold parts 141, 142, 151, 152 may be selected based on the width of the profde Pi to be repaired to adjust the width of the mold lOOi to the width of the profile Pi. In this way, one front mold part may be reused to repair different profiles having the same front and central surface shape but different widths.

A mold lOi may further comprise at least one mold connecting mechanism 170 for connecting all the selected mold parts together. The mold connecting mechanism 170 may be a manually operated mechanism. In particular a manually operated mold mechanism mechanism may enable an operator on site to select and form a mold lOi adapted to the profile Pi to be repaired by connecting the selected mold parts together using the connecting mechanism 170. The connecting mechanism 170 may comprise a plurality of rods 172 for passing through all the mold parts and a plurality of nuts 171 engaging with the rods 172 for connecting all the mold parts together.

In a second aspect of the invention, the modularity of the device used for repairing a profile which has been bent out of an original position, will be discussed. Just as for the mold lOi, the insert 200 may as well be suitable for a plurality of profiles forming thus together with the modular mold lOOi a modular device lOOi.

Typically an insert 200 may be configured to shape an inner surface of a profile Pi. During use the insert 200 may typically be arranged in the inner space of the profile Pi via the open side. To interact with the profiles PI to Pn, the insert 200 may be either a universal insert 200A or a modular insert 20i. Both types of inserts, whether universal like insert 200A or modular like insert 20i, may comprise at least a first and a second insert parts 211-214, 221-224, 250, 260 being adapted to shape a respective part of the inner surface of the profile Pi.

In a third aspect, the modularity /versatility of the insert will be discussed. A modular insert 20i may comprise separate first and second insert parts 211-214, 221-224, each having an external form which is adapted to a corresponding part of the given profile Pi and may be configured such that the first and second template parts may be pressed against the profile through mutual displacement of the inserts parts. Further the insert 20i may comprise a pressing head with which the selected first and second insert parts may be pressed against the profile PI. The pressing head may be selected, based on the given profile, from a plurality of pressing heads for repairing a plurality of different upright profiles. In other words, the selected pressing head and front mold part may correspond with each other and with the profile Pi to be repaired. Typically each of the first and second template parts 211-214, 221-224 is provided with a chamfered positioning edge and the pressing head 231, 232, 233 is wedge shaped. The pressing head may be selected based on the profile to be repaired, from a plurality of pressing heads 231, 232, 233 for repairing the plurality of different upright profiles. For instance the pressing head 231 may have a flat outer surface while the pressing heads 232 and 233 may present indentations of different shapes and dimensions (curved or flat indentation). Other shapes of insert heads may be envisaged without inventive step by a person skilled in the art based on the type of profile to be repaired. Preferably the selected pressing head may correspond with the selected front mold part. The selected pressing head and he selected front mold part may have matching shapes.

Alternatively, the insert 200 may be a universal insert 200A comprising an insert head 240, a first insert part 150 and a second insert part 260, each connected to the insert head 240 by a hinge, to in use form inner comers of the profile. In this way, an insert suitable for forming at least the inner comers of any sort of Profile PI to Pn is realized. Such an insert increases the modularity of the whole device and in itself solves the problem of versatility as it can be used as a universal insert for multiple profiles.

A device lOOi may further comprises a pressing unit 300 for pressing the mold lOi against the outer side of the profile Pi and pressing the insert 200 A or 201 against the inner side of the profile with pressing force such that the profile is bent back into its original position. According to Figure 1, the pressing unit 300 may comprises a pressing mechanism 310 for engaging with the insert 220A or 20i, and a frame (320, 330) for engaging both with the mold lOi and the pressing mechanism 310. The frame (320, 330) may comprise a plurality of frame elements 321, 322 and at least one frame connecting mechanism 330 for connecting the frame elements 321, 322 together.

In this way, the device is rendered modular by the assembly of the mold, the insert and the pressing unit selected for a profile to be repaired.

In particular, the frame connecting mechanism 330 may be a manually operated mechanism. In this way, an operator may in situ select and manually assemble the device based on the profile to be repaired. More in particular the frame 320, 330 may be configured to engage with each of the plurality of mold parts for repairing the plurality of different upright profiles. In this a common frame may reused for a plurality of different molds lOi. The frame element 322 engaging with the mold lOi may comprise a groove 321a and the mold lOi comprises a protruding bar 1 lia to be arranged in the groove 321a of the frame element 322. Figure 2 illustrates in more details a perspective view from above of the universal insert, and a modular device incorporating the universal insert when repairing the profile PI according to an embodiment. In Figure 2, the profde PI has been repaired using a modular device 1001 A comprising a mold 101, a universal insert 200A and a pressing unit 300.

The mold 101 may be adapted to the form of the outer surface of the profile PI and may partly enclose the profile PI dining use. Such a mold 101 may be modular and may comprise three mold parts 111, 121 and 131 , the mold part 111 having a surface adapted to a front part of the outer surface of the profile PI, the mold part 121 having a surface adapted to one side part of the outer surface of the profile, the mold part 131 having a surface adapted to another side part of the outer surface of the profile.

The universal insert 200A may be configured such that in use the pressing unit 310 presses the insert head 240 in the pressing direction such that the first and second insert elements 250, 260, while swiveling around the hinges away from each other, straighten an inner surface of the profile Pi against the mold lOi and form the inner comers of the profile Pi. In particular, the insert head 240, the first and second insert parts 250 and 260 may be dimensioned to form inner corners of profiles of different width.

The first and second insert parts 250 and 260 may be configured when not in use to swivel towards each other such that the universal insert 200A has a width smaller than the width of the open side of the profile Pi. The swivel movement allows thus the easy insertion of the universal insert part in any type of open profile.

In a particular embodiment, the first and second insert parts 250 and 260 may be replaceable by longer or shorter insert parts, in correspondence with a width between the inner corners of the profile Pi, which width may vary dependent of the type or shape of profile to be repaired.

However, because the insert parts 250, 260 at any given length may be applicable for a range of widths between inner comers of the profile Pi for different types or shapes of profiles to be repaired, a number of sets of different lengths of insert parts may be minimized.

Figure 3 illustrates a perspective view from above of a modular device according to another embodiment alternative to the embodiment of Figure 2. In Figure 3, a profile PI has been repaired using a modular device 1001, comprising a mold 101 and a modular insert 201. The mold 101 may be same as the mold 101 of Figure 2. A modular insert 201 may be configured to shape an inner surface of the profile PI, wherein during use the insert 201 is arranged in the inner space of the profile PI via the open side. The insert 201 may comprising a first insert part 211 and a second insert part 221 being adapted to shape a respective part of the inner surface of the profile PI. The insert 201 may further comprise a pressing head 231 with which the first and second template parts 211 and 221 can be pressed against the profile PI. The pressing head 231 may be selected to have a front flat surface adapted to the front flat surface of the profile PI.

Figures 4 and 5 illustrate exploded view from a side perspective of the modular device of Figure 1. Figure 5 illustrates an exploded view from a front perspective of the modular device of Figure 1.

In Figures 4 and 5, the mold connecting mechanism 170 for connecting all the selected mold parts together is illustrated from different angles. The mold connecting mechanism 170 comprise in particular a plurality of rods 172 arranged for passing through all the mold parts along the main axis of the profile to be repaired and a plurality of nuts 171 engaging with the rods 172 for connecting all the mold parts together. Each mold part 111-113, 121-123, 131-133, 141, 142, 151, 152 may in particular comprise a plurality of openings through which the connecting rods 172 may pass.

The frame (320, 330) for engaging both with the mold lOi and the pressing mechanism 310 is also illustrated from different angles. The frame (320, 330) may comprise two frame elements 321, 322 arranged for respectively engaging with the pressing mechanism 310 or a front mold part. The frame may further comprises at least two rods 332 and 335 and nuts 331, 333, 334 and 336 for engaging with the rods and binding together the frame elements 321 and 322. The frame element 322 engaging with a mold lOi may comprise a groove 321a and the mold lOi may comprise a protruding bar 1 lia to be arranged in the groove 321a of the frame element 322 such that when binding together the frame elements 321 and 322, the font mold part of the mold lOOi is blocked in the pressing direction of the pressing mechanism 310.

The rods 332 and 335 may extend parallel to the mold side parts 121-124, 131-134 and at a distance from said mold side parts 121-124,131-134. In other words the frame (320, 330) may enclose the mold lOOi entirely.

Figure 6 illustrates a method according to an embodiment. In Figure 6, for repairing a profile PI which has been bent out of an original position, the method comprising the step 601 of selecting a plurality of mold parts 111, 121, 131, each having a surface which is adapted to a corresponding part of the outer surface of the profile PI, from a plurality of mold parts 111-113, 121-123, 131- 133, 141, 142, 151, 152 for repairing a plurality of different profiles. Next step 602 comprises assembling the plurality of mold parts 11, 121 and 131 to form a mold 101. Step 603 comprises selecting an insert 200, adapted to shape at least part of an inner surface of the profde. Step 604 comprises arranging around the bent profile the mold adapted to the form of the outer surface of the profde and partially enclosing the profde. Step 605 comprises arranging the insert 200 in the inner space of the profde PI via the open side. The step 606 comprises pressing the mold against the outer side of the profde and pressing the insert against the inner side of the profde in order to bend at least part of the upright profde back to its original position.

Method according to the previous claim, wherein the insert comprises a first insert part and a second insert part, each adapted to shape a respective part of the inner surface of the profde, and wherein pressing of the mold and insert against the profde comprises the steps of mutually displacing the first and second insert parts for shaping the inner side of the profde while pressing the mold against the outer side of the profde by pressing the inserts parts in both lateral and forward direction against the profde.

The step 603 may comprise selecting either an insert 200A with an insert head 240 and a first and a second insert parts 250, 260 connected by hinges 250a, 260a to the insert head 240, or an insert 201 with a separate first and second insert parts 211 and 221.

If an insert 200A is selected, step 606 may comprise at least forming inner edges of the profde PI.

If an insert 201 is selected, the method may further comprise the step of selecting a wedge-shaped pressing head 231 in an intermediate space between the first and second insert part 211, 221; and step 606 may further comprise pressing the wedge-shaped pressing head 231 further into the intermediate space in order to generate lateral and forward pressure whereby the insert parts 211, and 221 are pressed against the profde.

Although not illustrated, in case a profde has been so far bent that an insert 20i may not be inserted, a repair may then first be performed using an insert 200A. The insert 200A may then be locally used to form the inner comers of the profde where profde has a very bent shape. The whole device with the insert 200A may then be moved along the longitudinal direction of the profde to restore the comers of the profde. Once the shape of the repaired profde allows the insertion of elongated insert parts 211 and 221, a repair may be performed using an insert 201 with the separate first and second insert parts 211, 221. The insert 200 A may have a longitudinal dimension chosen to bend back into position a relatively small length of the profde with a relatively high amount of strength, while the insert 20i may have a larger longitudinal dimension than the insert 200A to bend back into position a relatively larger length of the profile but with a relatively smaller amount of strength.

Whilst the principles of the invention have been set out above in connection with specific embodiments, it is understood that this description is merely made by way of example and not as a limitation of the scope of protection which is determined by the appended claims.