Center shifted roll forming

Abstract

A roll forming machine capable of forming the corrugated metal web of a sinusoidal structural member is provided. The preferred embodiment includes a material feeding means, a material guiding means, and at least two forming cylinders. The material feeding means receives a sheet of material, and is in material communication with the material guiding means. The material guiding means receives the sheet of material, guiding the sheet of material into the forming cylinders and preventing significant movement or buckling of the sheet of material. The forming cylinders are a set of at least two substantially aligned and parallel cylinders, having a separation between sufficient to receive the sheet of material. The forming cylinders can alternately orbit one around the other, one forming cylinder axis being held substantially stationary while the other forming cylinder orbits the stationary cylinder, bending the sheet of material and forming the desired web geometry.

1 . A roll forming machine adapted to facilitate the formation of either a sinusoidal corrugation or a combination of planar and sinusoidal corrugation from a sheet of material comprising: 
 a material feeding means, having a material receiving means and a material exit; and    a material guiding means, having a first face and a second face, said first face being opposite of said second face, a gap being formed through said material guiding means from said first face to said second face, said gap being of sufficient size to accommodate said sheet of material; and    a first forming cylinder with a first central rotation axis and a first outer circumference; and    a second forming cylinder with a second central rotation axis and a second outer circumference, said second central rotation axis being substantially parallel and coplanar to said first central rotation axis, said first forming cylinder having a separation from said second forming cylinder, said separation being of sufficient size to accommodate said sheet of material;    wherein said sheet of material is received into said material receiving means, said material exit of said material feeding means being in material communication with said first face of said material guiding means and said material exit being substantially aligned with said gap of said material guiding means, said second face of said material guiding means being substantially aligned and in material communication with said separation between said first forming cylinder and said second forming cylinder when in an initial position;    and wherein said first forming cylinder and said second forming cylinder form a alternating orbital roll forming station, said first and second central rotation axes alternately orbit one around the other following said outer circumferences forming a sinusoidal pattern in said sheet of material.    
   
   
       2 . The roll forming machine of  claim 1  wherein said material feeding means is a plurality of opposing parallel cylinders.  
   
   
       3 . The material feeding means of  claim 2  wherein said opposing parallel cylinders having a gap between to allow simultaneous tangential contact with said sheet of material.  
   
   
       4 . The roll forming machine of  claim 1  wherein said material feeding means feeds said sheet of material in discrete incremental lengths corresponding to the length needed to form a first arc in said sinusoidal pattern.  
   
   
       5 . The roll forming machine of  claim 1  wherein said first forming cylinder and said second forming cylinder in said initial position, forming a planar length of said sheet of material.  
   
   
       6 . The roll forming machine of  claim 1  wherein said first forming cylinder and said second forming cylinder have a diameter corresponding to said sinusoidal corrugation wavelength.  
   
   
       7 . The roll forming machine of  claim 1  wherein said first forming cylinder and said second forming cylinder are interchangeable with a third and fourth forming cylinder having a different diameter.  
   
   
       8 . The roll forming machine of  claim 1  wherein said first forming cylinder orbits around said second circumference of stationary said second forming cylinder, forming an orbital path angle sufficient to form a required arc.  
   
   
       9 . The roll forming machine of  claim 1  wherein said second forming cylinder orbits around said first circumference of stationary said first forming cylinder, forming an orbital path angle sufficient to form a required arc.  
   
   
       10 . The roll forming machine of  claim 1  wherein said material guiding means is in sufficient proximity of said first forming cylinder and said second forming cylinder to insure proper formation of a required arc.  
   
   
       11 . The roll forming machine of  claim 1  wherein said material guiding means has sufficient clearance to allow said roll forming cylinders to complete alternating orbits.  
   
   
       12 . A roll forming machine adapted to facilitate the formation of either a sinusoidal corrugation or a combination of planar and sinusoidal corrugation from a sheet of material comprising: 
 a material feeding means, having a material receiving means and a material exit; and    a first forming cylinder with a first central rotation axis and a first outer circumference; and    a second forming cylinder with a second central rotation axis and a second outer circumference, said second central rotation axis being substantially parallel and coplanar to said first central rotation axis, said first forming cylinder having a separation from said second forming cylinder, said separation being of sufficient size to accommodate said sheet of material;    wherein said sheet of material is received into said material receiving means, said material exit of said material feeding means being in material communication with said separation between said first forming cylinder and said second forming cylinder when in an initial position; and wherein said first forming cylinder and said second forming cylinder form a alternating orbital roll forming station, said first and second central rotation axes alternately orbit one around the other following said outer circumferences forming a sinusoidal pattern in said sheet of material.