DESCRIPTION

The subject of this invention is a combined multifunction machine, adapted to perform bends and/or longitudinal counter- bends with continuous variable radius, folds and/or tilted counter-folds, folded and flattened edges, and sheet metal tubes and spirals in a single structure. A distinctive feature of the machine in question is that the processing steps take place in a programmable manner by means of a numerical controller, simultaneously all along the edge of the strip and in progressive sequences until completion of the product. The invention intends to create a machine capable of producing consistent products in shaped sheet metal profiles in various lengths and thicknesses, of different materials, in different sizes, and in mixed shapes such as straight, curved and counter-curves, arcs, parabolas, in angles from zero to one hundred thirty-five degrees, with edges and counter-edges, edges folded back in hemming, spirals both on the outside edges and inside along the strip, and in progressive sequential steps without replacing and manual adjusting the tools. The set and combination of these functions makes it a machine able to produce sheet metal profiles for the civil, agricultural, industrial, and other sectors, and wherever needed to protect, collect and channel rainwater or other liquids, cover profiles, and create roofs, protection from the elements, and structures in the gardening industry such as gazebos, canopies, covers, pergolas, etc. A considerable economic advantage of the above device is in the fact that countless products can be created by merely programming the various intrinsic functions, storing each program, recalling it as needed, performing the necessary pieces (even a single item) , and then moving on to the next product in other shapes, without additional investments in other machinery. This factor allows the company using it to distribute the initial investment cost over the entire range of products that can be created, as well as the opportunity to add new items to the production cycle in the future using the same device. There are many known systems that bend, calender, curl edges of metal sheets and/or strips and/or belts using simple machines, manually, or by means of automatic machines. The one used most for making folds is the pressing-bending machine, which bases its principle of operation referred to as "coining", where a shaped blade presses the sheet and pushes it inside a hollow of suitable dimensions and shapes based on the thickness of the sheet and the shape of the sheet you want to create. These pressing-bending machines create the folds simultaneously along the entire length of the edge. These machines can be operated mechanically by means of kinematic mechanisms, electrically using screw and lead screw jacks and with one or more standards or more commonly by means of hydraulic jacks. These types of folding machines can fold both thin and thick sheets. They are machines that can be run by a human operator who oversees the proper positioning of the sheet metal in the positions in which it must be folded or be run by automatic systems such as robots, positioners, etc. To perform a counter-fold with this type of machine, the strip to be worked must be extracted from the bending zone, inverted and reinserted in the machine and repositioned at the position of the counter-fold. Another type of bending machine, called a "tilt" machine, that is suitable to bend thin sheet metal, is operated either manually, for short lengths, or mechanically, electrically, and more commonly using hydraulic linear actuators operating levers distributed along the entire machine in order to distribute the stress along the entire flap, and is able to transform its linear motion into rotary motion. A peculiar characteristic of these machines is that they rotate the sheet against an edge in order to obtain a bend based on the desired angle, but that presents the part of the sheet metal flap that is yet to be bent, pressed against and parallel to the surface of the machine, ready to be moved beyond the edge-presser and be folded again. This type of machine can be equipped with positioning pliers which maintain a constant grip on the sheet, and thus the units of measure and move it toward the flap, thus automatically performing folds in sequence. Even this type of machine has the drawback of not being able to perform counter-folds in automatic sequences. Also, with this type of machine the sheet metal must be pulled out, turned over and again re-inserted and repositioned manually. There are also variants of the flap bender, in which the folding function is entrusted to a slide that by moves obliquely, pushes the sheet against the presser profile and as a function of its advancement determines the angle of the fold. The drawback of this system is that it produces a sliding friction against the sheet, ruining the surface. In order to avoid this undesired effect, the profile of the slide is covered with plastic which must be replaced frequently. Also, with this type of bending machines, in order to perform counter-folds, the strip must be extracted from the machine, turned over and reinserted. These negative characteristics actually prevent their widespread use in the production system. There are also double-flap folding machines, which can perform folds and counter-folds and turned and pressed edges but the drawback is that the strip must be manually manipulated, especially when performing the final flanging-crushing . The current state of the art indicates multiple sheet metal bending and/or deformation systems, such as moulding, for example, where the sheet metal is pushed and pressed against the walls of the matrix by means of a counter- matrix driven by a machine adapted to exert a suitable pressure (press) . In this case, the shapes and dimensions of the product are determined and predefined by the shape of the mould. "Panelling" machines are also widespread in the production system. They are able to fold strips on all sides. These machines are usually automatic. That is, they rotate the side to be bent towards the bending tool in a predetermined sequence in order to produce predominantly square and/or rectangular shapes with the edges folded to form a "box". These are high- productivity machines, producing a narrow range of panel sizes which are used in many industrial sectors, usually in series production such as household appliances, machinery in general, electrical panels, fagade insulation and cladding, ducting systems, air conditioning systems, etc. There are different methods to create curved sheets along the longitudinal axis of the strips (shells) : The less conventional is a machine with two rollers, one of which is made of elastomer. This method has success in line production. In this system the upper steel roller works as punch and the lower roller, which is covered with elastomer (usually urethane) , acts as a matrix which surrounds the sheet metal on the steel roll. The radius obtained depends on the diameter of the upper roller and by the elastic return of the sheet. This is not a suitable method for producing small series and/or shells of different diameters. The method commonly called the three pyramidal roller method, with two or three feed rollers, where the two lower rollers have fixed axes and the third roller is located equidistant between the two and moves only along its vertical axis according to the distance between the two lower rollers and determines the bending radius of the sheet metal is the most simple, common, and less expensive method in terms of initial investment but it has the serious drawback of presenting a straight part on the leading and trailing edges, which must later be refinished. To overcome this drawback, bending machine manufacturers have developed different types of calenders such as the three-roller variable axis calender, which is characterized by the vertical movement of the upper roller and the horizontal one of the two lower rollers, which when moving forward and backward behave as a press and can thus perform the pre-curvature (call) to the edges at the beginning and end and then perform the curvature of the sheet, finishing the piece. This is a system suitable for calendering thick plates. In another variant of the three roller method, the upper roller has a fixed axis and the lower rollers move both horizontally and vertically. In this way they are able to perform the call (pre-bend) along the longitudinal edges and then perform the shell bend in a single pass. Further evolution of the state of the art is represented by the calender with four driving rolls, two of which are central and are able to constantly keep the sheet "stapled" (tight) , with constant position control, while the two lower side rollers opposite the centre ones can perform pre-bending and then determine the radius of curvature in a single cycle. This type of machine can also efficiently calender cones since the side rollers can independently and obliquely be moved vertically. This is a type of machine that can be inserted in automatic plants as the sheet is inserted horizontally. The types of machines described here are suitable to perform closed shells (pipes, rings, cones) and are not recommended for producing open ducts, especially thin ones. The asymmetric three-roll calenders are suitable for the processing of light and medium thicknesses. These machines are used in aluminium processing, industrial bodywork and generally in laboratories and small metal processing industries. They have two opposing feed rollers and the third roller, usually idle, moves vertically at the exit of the rollers and determines the bending radius of the sheet. All these bending systems (calenders) can perform bends in one direction only. To perform more complex profiles, folds and counter-folds, bends and counter-bends, tubes, spirals, and parabolas, in all shapes and combinations, the present state of the art indicates the best solution applied in profiling machines. They are high- productivity machines capable of performing very complex profiles. Their peculiar characteristic is the fact that they perform the deformation of the sheet metal strip progressively, in subsequent passes through suitably shaped rollers that are increasingly similar to the profile to be obtained. They are fed continuously from rolls (coils) of sheet metal which is cut to the desired length, at the end of the deformation line (profiler) . They continuously produce the same profile based on the progressive shaping by the rollers that "drag" the sheet metal strip to the end of the line, continuously ejecting the shaped profile which is cut to the desired length and sent to packaging and/or further processing. These are very expensive machines, always performing the same product, and as seen from this description, are not suitable to produce profiles in small series The machine referred to here is a compact structure (Fig 1), composed of load-bearing parts made of sheet steel in a suitable amount and thickness depending on the length of the different models, is suitably shaped (Fig 1, a - Fig . 12, a), integrally joined by tubular longitudinal pieces (Fig 1, b - Fig. 12, b) electro-welded together (Fig 1, c - Fig. 12, c) and subsequently machined with chip removal machine tools to order to ensure dimensionality, flatness, squareness and precision in the points where the various components are positioned integrally with the fastening elements (bolts, screws, plugs, etc. ) .

The machine is equipped with a recess (Fig 1, d - Figure 12, d) inside which is placed a roller conveyor (Fig 1, e, - Fig. 3-4, e - Fig 12, e) above which the sheet metal to be worked is laterally inserted (Fig. 2, f) . On the inner side edge there are grippers (fig. 3, g) which are mounted on a sliding structure by means of recirculating ball guides (fig. n. 3-4-5, h) able to move both laterally and longitudinally and also asynchronous to each other (fig. 5 - 5, i) , which, being equipped with rotary jaws (fig. no. 5, 1), are arranged to position the strip in the various stages of processing described below. The machine is equipped with a bending device composed of two prisms with protruding profiles (blades) (Fig 1, ml, m2 -, Fig. 16, ml, m2), arranged along the front side of the machine and their length determines the working capacity. These profiles (prisms) also clamp onto the sheet metal during the bending since the upper prism (Fig 1, ml -, fig. 16, ml) is built into a carriage operated by linear hydraulic actuators (Fig 1, n, fig. n. 12-16-17, n) , The carriage slides on linear recirculating ball guides (Fig 1, o, Fig. 12-16-17, o) , that are appropriately sized for accurate and controlled vertical movement (fig 12-16, pi - fig. n. 17, p2), orthogonal to the fixed part of the machine bottom (fig 12, p3) . These blades (prisms) have a triangular profile tapered along their length whose angle is 135 degrees. This corresponds to the maximum value of the sheet bending angles that can be executed as they determine its internal profile since the edge of the prism has the function of "containment" and contrast the tilting action, one lower (Fig 1. ql -, fig. n. 12th - 13th - 17 - 18 - 19 ql ) , and one upper (Fig 1, q2 - , Fig. 12 - 13 -14 - 15, q2 ) . These flaps are built into retractable slides so they independently move in the fold position, actuated by hydraulic linear actuators operating the lower flap (fig. n. 16-17, rl) and (Fig. 12 -13, r2 ) the upper one. When moved into the bending position, the flap doors rotate about an axis which corresponds to the edge of the folding prisms which are tightened, preventing the sheet from moving (Fig. No. 18-19, ml, m2 -, fig. N. 22-23, ml, ιτι2). These flaps are actuated by linear hydraulic actuators (Fig. 16-17-18-19, si, fig. No. 22-23, si) which transmit the rotary motion through a system of parallelogram levers (FIG. 18 -19, tl, t2, fig. n. 22-23, tl, t2), where the distance of their hubs around which the various levers rotate is in ratio with the bending centre, so that their axis of rotation (of the joints) is always located in a concentric position with the axis of rotation of the flaps (fig. no. 22, ul - fig. no. 23, u2) .

To perform upwards folds, the upper flap must remain in the retracted position (Fig. 18, q2) and the lower flap must rotate (fig n. 19, ql) while in to perform downward folds (reverse), the bottom flap must be located in the retracted position (fig. no. 14, ql) and it will be the top one that rotates (fig. 15, q2) . The machine referred to in question is also equipped with a calendering (bending) device adapted to perform curves, v- curves, arcs, spirals, parabolas, cones, arcs with continuously varying radius, etc. This device is made up of four rollers (Fig 1, vl, v2, v3, v4 , Fig. No. 20-21-22, vl, v2, v3, v4, Fig. N. 24-25-26, vl, v2, v3, v4 - fig. no. 29, v) , each driven by an independent gear motor mechanically connected to the rotation axis at one end of the rollers (Fig 1, wl, w3, w4, fig. n. 24- 25-26, wl, w2, w3. W4) . These rollers are on supports (Fig 1, zl, z4, Fig. 20, zl, z2, z3, z4, fig. No. 24, zl, z4 - fig. No. 29, z) that are adeguately sized to support the deformation force generated by the resistance to the bending deformation of the sheet metal, distributed along the entire length and transferred from the roller to the support by means of the cradle segments (Semi-shells) , made of wear- resistant and self-lubricating materials (Ampco or carbon fibre embedded in phenolic resin) , (Fig 1, k, Fig. n. 24- 28, k) . By wrapping the rollers on the contact side with the support and exceeding the middle of the arc described by the roller section as sufficient to prevent extraction from the housing (of the half-shells) (fig. n. 5, kl, k2), presenting the free opposite surface without continuity, it is able to support the contact with the sheet to be bent. This particular layout gives the rollers significant rigidity, allowing the machine to run very long sheet metal bends, from three to twelve meters, which are impossible to perform with roller calenders that do not have such supports. This calendering device is commonly defined in the present state of the art as an "asymmetric calender" in which the sheet metal (Fig. 38, f) is moved and inserted between the first two rollers ( fig. n. 20-21, v2, v3, fig. no. 38-39, v2, v3)), by grippers (fig. n. 20-21, 1, fig. 38-39, 1) and the action of deformation (curvature) of the sheet is carried out by the lower outer roller (fig. no. 20-21, v4 -Fig. 38, v4, fl) if the curvature is directed upwards, while for a downward curve, the lower roller will be set back (fig. no. 39, v4) and the upper roller will be positioned in the calendering zone, (fig. 39, vl, f2) and performs the curvature. The rollers are located in the machine in such a way as to be retractable, handled independently, moving on slides with recirculating balls, inside and outside of the machine. The lower inner roller on the stand (fig. 23, z3) and operated by hydraulic linear actuators (Fig. No. 23, y3) and the upper inner roller on the stand (fig. 23, z2) and operated by hydraulic linear actuators (Fig 23, y2) , are able to change from their retracted position (when the machine must perform bends) (Fig. no. 23), to the calendering position (advanced), when the machine must perform curvatures (fig. no. 21). The external asymmetric rollers are positioned on the lower (ql) and upper (q2) flaps whose supports are built-in using sliding guides with a central pivot (j) which allows them to rotate while tilting (fig. N. 25-26) . They are moved at different heights from each other by the actuators (fig. 25, Y1A, Y1B - fig. n. 26, y4a, y4b) in order to present an oblique profile to the calendering functional position. Along with the possibility of grippers to move and advance at different speeds and heights (fig. no. 4, i, f2), they are able to perform conical curvatures (fig. no. 28, f3) . These grippers and sheet positioners (Fig. 3, g - fig. No. 6, gl, g2), are built into a rod that can move both horizontally and transversely, handled by independent motors (Fig. 5, im) , whose positions are managed by the numerical controller on the machine and are able to rotate the metal sheet to be bent. This function is made possible by setting the cycles for the handling of components in the program of the CNC (numerical control) . The sheet, after notching the corners (Fig. No. 7, f5g) , is inserted between the gripping pliers (Fig. No. 7, gl, g2) and given the start to the sequence of handling cycles. The sheet is inserted between the gripping and bending prisms, is bent with the flap, and then the rod facing the side to rotate will move forward (fig. N. 8, i2) , thereby rotating the sheet 45 degrees in a clockwise direction (fig. no. 8, F5B) . The rod (fig. n. 8, il) opens the chuck, moves back and goes to position on the anti-clockwise side and closes the vice (fig. n. 9, il) , then the rod (fig. 9, i2) opens the vice and relocates on the same side as the opposite rod and closes the grip (fig. n. 10, i2). Then the il rod moves backward, which causes the sheet to rotate another 45 ° in a clockwise direction and which, when added to the previous rotation, will bring the sheets below the fold prisms, on the next side (fig. n. 11, F5E) . Continuing the rotating and folding sequences, the sheet will be bent on all sides, thus creating a closed panel on all four sides, made possible along with a discharge function (groove) on the upper prism (Fig. 6, MIA) which will be able to clamp the sheet on the last side to be bent without crushing the previously bent side (fig. 6, f5f) . In technical jargon this function is commonly called "panelling" and is performed at the extreme ends of the folding prisms to allow the folded sides to remain outside of their field of work (Fig. No. 6, f5g) . Another characteristic of this invention is that you can perform edging (in jargon, bending and crushing) , all along the external profile of the sheet metal. This process is essentially performed in two stages, the first of which consists of bending the edge to a 135 ° angle (Fig.40, q2) and then "crushing" the folded side by positioning it between the folding prisms, performing also a pressing function (fig. no. 41, ml, m2 ) . Since the multifunction combined pressing-bending-calender machine in this invention is equipped with a calendering device with four independent rollers, controlled both in their positions and the rotation speed, along with the possibility of controlling the speed of the positioning callipers, it can also perform closed ring curvatures (tubes) . The cycle to perform a closed tube begins with the execution of a fold along the outer edge as previously described, performed by the upper flap more precisely towards the bottom, in such a way to present the fold to the opposite of the centre. In sequence, a first arc of curvature is executed with the inner rollers in calendering position (Fig. 38, v2, v3) and with the lower outer roller in bending position and rotated at the desired angle (Fig. No. 38, v4 ) narrower than the end radius (fig. 1, F6A) . Then the radius of curvature is widened by decreasing the angle of rotation of the lower roller (Fig. 38, v4 ) , positioning the upper roller (fig. 39, vl) at an appropriate altitude to "contain" and compress the tube, on the outside of the machine (fig. 39, F6B) . Continuing the curvature sequence, the lower roll rotates upwards again, reducing the radius of curvature (Fig. 40, v ) while maintaining the upper roller pressed to the appropriate proportion to "guide" the rotation of the tube (fig. 40, vl, F6C) . After the bending, the lower roller is repositioned in the starting position (Fig. 41, v 4), the gripper (fig. 41, 1) pushes the sheet forward (Fig. 41, F6D) , the upper roller withdraws into the starting position (fig. 41, vl) and the result of the calendering sequences is a semi- closed tube (fig. 42, F6E) with the end part still straight and held integrally by grippers (fig. 42, 1) . The subsequent processing is carried out by a carriage (Fig 1, x -Fig. 43, x) that runs along the bottom flap starting from one end of the tube (Fig. 24, ql ) and, since it is equipped with a series of pairs of circular tools and is actuated by a gear motor (fig. 43, xlm) , introduces the series of upper rollers (circular tools) inside the tube and the lower series outside so that the flaps are tight on the tangents of the circular tool. The first pair of rollers performs the cutting (Fig. 43, F6F) with subsequent separation of the curved part and the straight part. The carriage will then introduce the second pair of rollers into the tube (Fig. 43, f6g. ) which will bend the edge (Fig. 43, f6h) and then the other pairs of rollers which at the end of the stroke (fig. 27, x2), will have done the job called "crimping". Another important function carried out by the carriage is shearing and turning the edge of the sheet by the inside of the machine. It redefines the profile that will be turned since if the series of rollers finds only a flap, only cutting, bending and crushing will usually be carried out (fig. 43, f6h) . A profiler carriage can also be defined, which slides along the outer side of the flap (Fig. 27, x2 ) . In order to obtain closed completed tubes, the machine in question can be equipped with a dilator device (Fig 1, xz) , (Fig. 44, xz) , driven by geared motors adapted to carry out the movement and press the rotary motion of the tools (fig. 44, F7L) , to dilate the diameter of the tube (fig. 45, f7n) , for a length sufficient to allow the other end (fig. 45, f7o) , to penetrate the dilated part (fig.45, F7P) , in order to assemble multiple segments in the longer pipes from the press-calendering machine in question. All movements are driven by a continuous numeric controller (CNC) , with hydraulic and electrical actuators, with speed and position feedback loop control. The management program (software) is open-ended, structured among various screens that list the moving parts set depending upon the activated movement cycles. Each axis of motion has command string assigned to it with the name of the movement, which is called according to the machining to be performed. The program is thus assembled in cycles to build in countless combinations as a function of the product to be created. An example is shown in figures 42,43,44,45,46, where the end result is a double open channel with a double curve, bend and counter-bend with a flat surface on the central part. The first command will be to close the grippers, followed by support roller z2 forward- support roller z3 forward - closing prism - flap ql forward - support roller z4 forward - take roll holder z4 - ql flap rotation - take flap ql rotation share - pliers forward - take gripper - calender v2 roller rotation - calender v3 roller rotation - calendar v4 roller rotation. Once the quotas have been reached, the machine will perform the first curve (fig. 42) and the program will continue executing all set cycles in sequence. This is a summary of the machine operation and programming possibility, with the ability to store almost an infinite number of programs which can be recalled from memory whenever necessary. It is a multifunction machine, a centre for permanently machining any sheet metal, and able to create products with curves and mixed folds in multiple combinations.