Folding Machine for Flat Materials

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The present inventive relates to a machine used to fold flat materials, and more particularly, a machine used to fold flat metal materials along extended fold lines and the method of folding such flat metal materials.

This section is intended to introduce various aspects of the art, which may be associated with exemplary embodiments of the present disclosure. This discussion is believed to assist in providing a framework to facilitate a better understanding of particular aspects of the present disclosure. Accordingly, it should be understood that this section should be read in this light, and not necessarily as admissions of prior art.

Metal parts are oftentimes formed by bending or folding a length of flat material or sheet. The metal sheet may be folded multiple times in order to produce the finished product.

Machines that fold the flat metal material have been designed and produced to perform this task. A typical folding machine is shown in U.S. Pat. No. 11,541,442 B2, which is incorporated herein by reference in its entirety. These folding machines include a top clamp head or upper machine frame part and a bottom clamp head or lower machine frame part. The top clamp head and bottom clamp head moves relative to each other between a loading position when feeding the metal material and a working position when processing the metal material. The top clamp head has an upper bending beam or working tool. Similarly, the bottom clamp head has a lower bending beam or working tool. These working tools move to form the bend or fold in the material. A side insertion unit or beam extends between the top clamp head and the bottom clamp head. The side insertion unit includes a shuttle having pneumatic suction cups which hold the metal material and moves back and forth along the side insertion unit to position the metal material within the machine.

A problem with these machines is that they can only position and process one piece of metal material at a time. As such, the sequential processing of multiple pieces of metal material can be very time consuming.

A folding machine has been devised that bends several pieces of metal material at the same time. These machines multiple pieces of metal material into the machine prior to processing. However, the machine must still completely process the metal material before it moves the next series of metal material into the machine. Thus, there is still a significant stalling of the machine during each folding process.

Accordingly, it is seen that a need therefore exists for an improved folding machine which can process multiple pieces of metal material simultaneously. It is the provision of such therefore that the present invention is primarily directed.

A folding machine for folding sheet metal material, the folding machine comprises a frame, at least one bottom clamp head coupled to the frame, at least one top clamp head pivotally coupled to the at least one bottom clamp head, a bottom clamp coupled to the at least one bottom clamp head, a top clamp coupled to the at least one top clamp head, a bottom folding apron coupled to the bottom clamp, a top folding apron coupled to the top clamp, a material working surface configured to support a sheet metal material, the material working surface being positioned adjacent the bottom clamp, at least one back gauge reciprocally movable between a first position distal the bottom clamp and a second position adjacent the bottom clamp, wherein the at least one back gauge is configured to engage a trailing edge of the sheet metal material, at least one lifting tray assembly configured to support the sheet metal material thereon, the at least one lifting tray assembly being reciprocally movable between a lower position and a raised position elevating the sheet metal material to a position above the material working surface allowing for the passage of the at least one back gauge beneath the sheet metal material as the back gauge moves from the second position to the first position, and a side loader assembly positioned between the bottom clamp head and the top clamp head, the side loader assembly including an elongated transfer shuttle beam and a transfer shuttle movable along the transfer shuttle beam between a loading position and an unloading position.

A method of operating a folding machine for folding a plurality of sheet metal materials comprising the steps of (A) loading a first sheet metal material into a folding machine, (B) indexing the first sheet metal material into a position for folding operation, (C) commencing the folding operation on the first sheet metal material, (D) loading a second sheet metal material into the folding machine while simultaneously continuing the folding operation of the first sheet metal material, (E) completing the folding operation of the first sheet metal material, (F) indexing the second sheet metal material into a position for folding operation, and (G) commencing the folding operation of the second sheet metal material.

With reference next to the drawings, there is a shown a folding machinefor folding flat sheet metal material M embodying principles of the invention in a preferred form.

The folding machineincludes a base or frameupon which is mounted a series of bottom clamp heads or lower machine frame parts. A top surface of the bottom clam headsform a generally co-planar material working surface. A series of top clamp heads or upper machine frame partsis pivotally coupled to the bottom clamp headsfor movement between an open, material loading position and a closed, material working position. The top clamp headsare moved through conventionally know pneumatic devices, hydraulic devices, or other mechanical means.

An elongated bottom clampis coupled to a distal end of the bottom clamp heads. Similarly, an elongated top clampis coupled to a distal end of the top claim heads. The bottom and top clampsandare configured to hold a piece of sheet metal material M therebetween when the top clamp headsare in their closed position.

A bottom folding apron, lower bending beam, or working toolis mounted to the bottom clampfor pivotal movement relative to the bottom clamp. A top folding apron, lower bending beam, or working toolis mounted to the top clampfor pivotal movement relative to the top clamp. The relative movement between the top and bottom folding apronsandand their adjoining top and bottom clampsandcreates the fold in the sheet metal material M held by the top and bottom clampsand. The top and bottom folding apronsandare coupled to and moved through conventionally know pneumatic devices, hydraulic devices, or other mechanical means.

The folding machinealso includes a side loader assembly or side insertion unitmounted to the bottom clamp head. The side loader assemblyhas a transfer shuttle beam or central railextending between the top clamp headand the bottom clamp head. The transfer shuttle beamis mounted to the bottom clamp headfor back and forth or reciprocal, vertical movement between a lower engaging position and an upper transfer position. Alternatively, the transfer shuttle beammay be mounted to the top clamp head, frame, be independent, self-supporting structure, or other mounting configurations. The side loader assemblyalso includes a transfer shuttlecoupled to the transfer shuttle beamfor back and forth, or reciprocal horizontal movement along the longitudinal length of the transfer shuttle beambetween a loading position proximal an entry end of the folding machineand an unloading position distal the entry end of the folding machine. The transfer shuttleis of conventional design having pneumatic suction cupswhich releasably hold the sheet metal material M. The suction cupsare coupled to a pneumatically operated vacuum source to create a negative air pressure associated with each suction cup. The transfer shuttleis moved along the transfer shuttle beamthrough a servo motor coupled to a linear timing belt system, although other means may also be used to create similar movements of the transfer shuttle. An infeed rolleris mounted to the bottom clamp headassociated with an entry end of the folding machine to help guide the sheet metal material M into the folding machineduring the in feeding process of the sheet metal material M, as best shown in. The construction of the folding machine thus far is similar to that shown in U.S. Pat. No. 11,541,442 B2 which is incorporated herein by reference in its entirety.

The folding machinealso includes a series of lifting tray assemblieswherein the first two lifting tray assembliesinclude a central lifting trayand two oppositely disposed side lifting trays, while the last three lifting tray assembliesinclude two dual lifting trays. Each central lifting tray, side lifting tray, and dual lifting trayincludes pneumatic devices, hydraulic devices, or other mechanical means, for vertically reciprocating the lifting trays,andin a vertical direction between a raised position above the material working surfaceand a lowered position generally co-planar with the material working surface. Each lifting tray assemblymay include an attachment base or plateand a pneumatic cylindercoupled between the attachment baseand the corresponding central lifting tray, side lifting tray, or dual lifting trayfor vertical movement of the corresponding lifting trays.

The folding machine also includes conventionally known reciprocating back gaugesthat abut, grasp and hold the rearward edge of the sheet metal material M when positioned upon the material working surface. The back gaugesincrementally move the sheet metal material M forwardly prior to and during the folding process with each incremental movement being associated with a fold of the sheet metal material M. The back gaugesare configured so as to have a height that allows the back gaugesto move beneath the sheet metal material M positioned upon the lifting tray assemblies while in the raised position. Thus, the back gaugesreciprocate, or move back and forth in a lateral direction relative to the transfer shuttle beambetween a forward position and a rearward position. Again, the back gaugesmove through the actuation of pneumatic devices, hydraulic devices, or other mechanical means.

The actuation of the pneumatics, hydraulics, or other mechanical means for movement of the top clamp head, top folding apron, bottom folding apron, transfer shuttle beam, transfer shuttle, transfer shuttle suction cups, lifting tray assemblies, and back gaugesare all conventionally controlled by a computer or processorthat automates and coordinates the actuation of each component.

The folding machineis intended to be utilized in conjunction with a supply table ST configured to support a vertical stack of sheet metal material M to be processed by the folding machine. The supply table ST is positioned adjacent the entrance end of the folding machine, as shown in.

In use, a stack of sheet metal material M is placed upon a supply table ST positioned adjacent the entry end of the folding machine. The folding machineis then actuated to commence the folding process of each sheet of the sheet metal material M.

As shown in, with the top clamp headin its closed position, the lifting tray assembliestheir lowered position, the back gaugesin their rearward position, and the transfer shuttlein its loading position, the side loader assemblyis actuated so that the transfer shuttle beamis moved to its lower engaging position. With the transfer shuttle beamlowered, the suction cupsof the transfer shuttlecontact and engage the top surface of the topmost sheet metal material M of the stack of sheet metal materials so that the sheet metal material M releasably adheres to the suction cupsby means of the downstream suction of negative air pressure located within the suction cups.

As shown in, the side loader assemblyis then actuated so that the transfer shuttle beamis raised to its upper transfer position, thereby lifting a first end of the sheet metal material M from the remaining stack of sheet metal materials. The lifting tray assembliesare also moved to their raised position.

As shown in, the transfer shuttleis then moved along the longitudinal length of the transfer shuttle beamto its unloading position. The vacuum associated with the suction cupsis then stopped so that the sheet metal material M is released from the suction cups. The sheet metal material M is now resting upon or is positioned upon the raised lifting tray assemblies, specifically the central lifting tray, side lifting trays, and dual lifting traysof each lifting tray assembly.

As shown in, the transfer shuttle is then moved back along the longitudinal length of the transfer shuttle beamso that is returns to its loading position.

As shown in, with the lifting tray assembliesstill in their raised position, the back gaugesare moved back to their rearward position. The back gaugespass beneath or below the raised sheet metal material M supported upon the raised lifting tray assemblies, i.e., the lifting tray assembliesprovide clearance beneath the raised sheet metal material M for return passage or movement of the back gauges. The lifting tray assembliesare then moved downwardly to their lowered position whereby the sheet metal material M is now supported upon the material working surfaceof the bottom clamp heads, as shown in. The sheet metal material M may also be partially supported on the lowered lifting tray assemblies. The top clamp headsare also pivoted to their open loading position to create a space between the bottom clampand the top clampfor subsequent passage of the sheet metal material M.

With the sheet metal material M resting upon the material working surfacethe back gaugesare moved forwardly so that they contact and grip the rearward or trailing edge of the sheet metal material M. The back gaugesare then moved or indexed forwardly until the sheet metal material M is properly positioned for its first fold wherein the top clamp headsare pivoted to their closed or working position so that the bottom clampand top clampcontact and hold the sheet metal material M therebetween. The bottom folding apronand/or top folding apronmay then be actuated to create a first fold upon the sheet metal material M. The back gaugesmay continually and incrementally move or index the sheet metal material M forwardly while the top clamp headpivots slightly upwardly to temporarily or momentarily release the sheet metal material M to reposition the sheet metal material M for subsequent folds through actuation of the bottom folding apronand/or top folding apron.

During the continuous folding actions of the bottom folding apronand/or top folding apron, the lifting tray assembliesare returned to their raised position, the vacuum upon the suction cupsis actuated, and the side loader assemblyis actuated to lower the transfer shuttle beamto its lower engaging position in order to hold a second sheet metal material M now positioned at the top of the stack of sheet metal materials M. The entire sequencing of movements then reoccurs as previously described. Thus, while one piece of sheet metal material M is located along the front of the folding machineassociated with the bottom and top clampsand, a second piece of sheet metal material M may be grasped and moved into an initial loaded position upon the raised lifting tray assemblies within the folding machine for processing.

Thus, one sheet metal material M is being processed through multiple folding operations by the folding machine, the folding machineis also simultaneously loading another sheet metal material M within the folding machine. This is achieved through the raising of the material through the lifting tray assembliesabove the level of the material working surfaceso that the back gaugescan move under and past the loaded sheet metal material to their rearward positions. As such, it is no longer necessary to complete the entire folding sequence of the first sheet metal material M prior to loading a second sheet metal material into the folding machine. This ability to both work and simultaneously load multiple sheets decreases the time associated with processing each sheet of sheet metal material M. Thus, the folding machinemay produce more finished products from the sheet metal materials M during a given time period, thereby reducing costs and increasing production.

It should be understood that the initial positions of the folding machine components, such as the top clamp heads, back gauges, lifting trays, transfer shuttle, shuttle beam, and other items have been described in a preferred method. However, these positions may be changed or altered without departing from the present invention. An important factor is that the lifting traysraise the sheet metal material M so that the back gaugesmay move beneath the sheet metal material M so that the second piece of sheet metal material may be loaded into the folding machine while the first piece of sheet metal material is being processed or folded. Obviously, these positions are also dependent upon where the components are located when the folding machine restarts or commences the folding machine after a pause.

It will be appreciated that the inventions are susceptible to modification, variation and change without departing from the spirit thereof.