metal folding apparatus

Abstract

An incremental metal folding apparatus may include a crank arm driving a folding mechanism in continuous reciprocating motion. The folding mechanism may be mechanically linked to a clamp arrangement such that motion of the folding mechanism causes movement of the clamp arrangement. The apparatus may be arranged to perform tangential folding operations.

1 . An incremental metal folding apparatus including:
 i. a folding mechanism configured to move so as to fold metal stock;   ii. a feed arrangement configured to move metal stock through the folding mechanism; and   iii. a clamp arrangement configured to hold metal stock while it is being folded;   wherein the folding mechanism, feed arrangement and clamp arrangement are arranged to work together to perform a plurality of spaced incremental folding operations so as to build up a fold from a plurality of incremental folds; and   wherein the folding mechanism and the clamp arrangement are mechanically linked, such that movement of the folding mechanism causes movement of the clamp arrangement.   
     
     
         2 . A folding apparatus as claimed in  claim 1  wherein movement of the folding mechanism causes release of the clamp arrangement. 
     
     
         3 . A folding apparatus as claimed in  claim 1 , wherein movement of the folding mechanism following completion of an incremental folding operation causes release of the clamp arrangement. 
     
     
         4 . A folding apparatus as claimed in  claim 1 , wherein the folding mechanism includes a contact surface configured to act against a cooperating surface of the clamp arrangement to cause movement of the clamp arrangement from a clamped position into an unclamped position. 
     
     
         5 . A folding apparatus as claimed in  claim 1 , including a crank mechanism arranged to convert circular drive motion into reciprocating motion of the folding mechanism. 
     
     
         6 . A folding apparatus as claimed in  claim 5  wherein the crank mechanism converts continuous circular drive motion into reciprocating motion of the folding mechanism to produce continuous oscillations of the folding mechanism. 
     
     
         7 . A folding apparatus as claimed in  claim 5  including an offset adjustment mechanism for adjusting the offset of the crank mechanism. 
     
     
         8 . A folding apparatus as claimed in  claim 7  wherein adjustment of the offset of the crank mechanism alters the final fold angle achieved by the folding mechanism. 
     
     
         9 . A folding apparatus as claimed in  claim 7  including an actuator configured to drive the offset adjustment mechanism. 
     
     
         10 . An incremental metal folding apparatus including:
 i. a folding mechanism configured to move so as to fold metal stock;   ii. a crank mechanism arranged to convert circular drive motion into reciprocating motion of the folding mechanism;   iii. a feed arrangement configured to move metal stock through the folding mechanism; and   iv. a clamp arrangement configured to hold the metal stock while it is being folded;   wherein the folding mechanism, feed arrangement and clamp arrangement are arranged to work together to perform a plurality of spaced incremental folding operations so as to build up a fold from a plurality of incremental folds.   
     
     
         11 . A folding apparatus as claimed in  claim 10  wherein the crank mechanism converts continuous circular drive motion into reciprocating motion of the folding mechanism to produce continuous oscillations of the folding mechanism. 
     
     
         12 . A folding apparatus as claimed in  claim 10  including an offset adjustment mechanism for adjusting the offset of the crank mechanism. 
     
     
         13 . A folding apparatus as claimed in  claim 12  wherein adjustment of the offset of the crank mechanism alters the final fold angle achieved by the folding mechanism. 
     
     
         14 . A folding apparatus as claimed in  claim 12  including an actuator configured to drive the offset adjustment mechanism. 
     
     
         15 . A folding apparatus as claimed in  claim 10 , wherein the folding mechanism includes a contact surface configured for reduction of damage to metal stock being folded. 
     
     
         16 . A folding apparatus as claimed in  claim 15  wherein the contact surface is a resilient, flexible or floating contact surface. 
     
     
         17 . A folding apparatus as claimed in  claim 15  wherein the contact surface is a floating surface and is biased to return to a starting position after each incremental folding operation. 
     
     
         18 . A folding apparatus as claimed in  claim 10 , wherein the clamp arrangement is biased towards a clamped position. 
     
     
         19 . A folding apparatus as claimed in  claim 18  wherein the clamp arrangement is biased by a spring or hydraulic or pneumatic cylinder. 
     
     
         20 . A folding apparatus as claimed in  claim 10 , further including a motor arranged to provide circular drive motion to the crank mechanism. 
     
     
         21 . A folding apparatus as claimed in  claim 10 , wherein the folding mechanism forms incremental folds at a rate of about 60 to 300 folds per minute. 
     
     
         22 . A folding apparatus as claimed in  claim 21  wherein the folding mechanism forms incremental folds at a rate of about 80 to 200 folds per minute. 
     
     
         23 . A folding apparatus as claimed in  claim 10 , wherein the feed arrangement is configured to feed metal stock through the apparatus in predetermined increments. 
     
     
         24 . A folding apparatus as claimed in  claim 23  wherein the increments are controllable so as to alter the spacing between incremental folding operations. 
     
     
         25 . A folding apparatus as claimed in  claim 24  wherein the increments and fold angle are such as to result in an overlap between adjacent incremental folds in the range 0 to 1 mm. 
     
     
         26 . A folding apparatus as claimed in  claim 10 , wherein the feed arrangement includes a vacuum holding system for gripping the metal stock. 
     
     
         27 . A folding apparatus as claimed in  claim 10 , wherein fold tooling located on the folding mechanism or opposing the folding mechanism is configured for a minimum required radius. 
     
     
         28 . A folding apparatus as claimed in  claim 10 , wherein fold tooling located on the folding mechanism or opposing the folding mechanism is configured for a specific required fold radius or specific required range of fold radii. 
     
     
         29 . A folding apparatus as claimed in  claim 10 , wherein each folding operation forms a fold with a fold angle in the range 1 to 20 degrees. 
     
     
         30 . A folding apparatus as claimed  claim 29  wherein each folding operation forms a fold with a fold angle in the range 5 to 15 degrees. 
     
     
         31 . A folding apparatus as claimed in  claim 30  wherein each folding operation forms a fold with a fold angle of around 12 degrees. 
     
     
         32 . A folding apparatus as claimed in  claim 10 , configured for tangential folding. 
     
     
         33 . A folding apparatus as claimed in  claim 10 , configured to fold sheet metal stock. 
     
     
         34 . A folding apparatus as claimed in  claim 10 , further including a controller arranged to control one or more of: fold angle and fold spacing. 
     
     
         35 . A folding apparatus as claimed in  claim 10 , further including a controller arranged to control one or more of: feed rate, drive rate and crank offset. 
     
     
         36 . A folding apparatus as claimed in  claim 35  wherein the controller is a programmable controller. 
     
     
         37 . An incremental metal folding apparatus including:
 i. a folding mechanism configured to move so as to tangentially fold metal stock;   ii. a feed arrangement configured to move metal stock through the folding mechanism; and   iii. a clamp arrangement configured to hold metal stock while it is being folded;   wherein the folding mechanism, feed arrangement and clamp arrangement are arranged to work together to perform a plurality of spaced incremental tangential folding operations so as to build up a fold from a plurality of incremental folds.   
     
     
         38 .- 39 . (canceled)