Systems and Methods for Making Panels from Sheet Material Using Adaptive Control

Abstract

A system for forming a building panel of a desired shape includes a shaping machine comprising multiple rollers, wherein the shaping machine is configured to provide a desired shape to a building panel, and wherein the building panel is made from sheet material. A drive system moves the building panel longitudinally along the shaping machine, and a power source provides power to the drive system. As the building panel is moved along the shaping machine, a load sensor detects a load placed on the power source, and an optional speed sensor detects a speed of the building panel. A control system controls the drive system in response to a signal from the load sensor so as to control the load on the power source as the building panel moves along the shaping machine.

1 . A system for forming a building panel of a desired shape, the system comprising:
 a shaping machine comprising multiple rollers, the shaping machine configured to provide a desired shape to a building panel, the building panel being made from sheet material,   a drive system for moving the building panel longitudinally along the shaping machine;   a power source for providing power to the drive system;   a load sensor for detecting a load placed on the power source as the building panel is moved along the shaping machine; and   a control system for controlling the drive system in response to a signal from the load sensor so as to control the load placed on the power source as the panel moves along the shaping machine.   
     
     
         2 . The system of  claim 1 , further comprising a speed sensor for detecting a speed of the building panel as the building panel moves along the shaping machine, wherein the control system is configured to further control the drive system in response to a signal from the speed sensor. 
     
     
         3 . The system of  claim 1 , wherein the control system controls the drive system to reduce the load on the power source if the load on the power source exceeds a desired level. 
     
     
         4 . The system of  claim 1 , wherein the power source comprises a motor and wherein the load sensor comprises a rotational speed sensor for generating a signal indicative of a rotational speed of the motor. 
     
     
         5 . The system of  claim 1 , wherein the drive system comprises a hydraulic system, and wherein the load sensor comprises a flow-rate sensor for generating a signal indicative of a flow rate of hydraulic fluid. 
     
     
         6 . The system of  claim 1 , wherein the shaping machine comprises a curving apparatus comprising multiple rollers for contacting the building panel and for imparting a longitudinal curve to the building panel. 
     
     
         7 . The system of  claim 1 , wherein the shaping machine comprises a panel forming apparatus comprising multiple rollers for contacting the building panel and for imparting a desired cross-sectional shape to the building panel. 
     
     
         8 . The system of  claim 1 , wherein the drive system comprises a hydraulic system, the hydraulic system includes a pressure sensor to generate a signal indicative of the a pressure of hydraulic fluid, and the control system is configured to generate a warning signal if the pressure signal exceeds a predetermined value. 
     
     
         9 . The system of  claim 2 , wherein the control system is configured to make determinations of whether to decrease the speed of the building panel at a first rate and to make determinations of whether to increase the speed of the building panel at a second rate, wherein the first rate is greater than the second rate. 
     
     
         10 . The system of  claim 2 , wherein the control system is configured to control the drive system to increase the speed of the building panel as the panel moves along the shaping machine if the speed is less than a target value and if the load on the power source is less than a desired level. 
     
     
         11 . A method for shaping a building panel of a desired shape, comprising:
 providing power to a drive system using a power source;   moving a building panel longitudinally through a shaping machine using the drive system, the shaping machine comprising multiple rollers, the building panel being made from sheet material, the shaping machine configured to provide a desired shape to the building panel;   detecting a load placed on the power source with a load sensor as the building panel moves along the shaping machine; and   controlling the drive system in response to a signal from the load sensor so as to control the load placed on the power source as the panel moves along the shaping machine.   
     
     
         12 . The method of  claim 11 , further comprising:
 detecting a speed of the building panel with a speed sensor as the building panel moves along the shaping machine; and   controlling the drive system in response to a signal from the speed sensor.   
     
     
         13 . The method of  claim 11 , wherein controlling the drive system comprises controlling the drive system to reduce the load on the power source if the load on the power source exceeds a desired level. 
     
     
         14 . The method of  claim 11 , wherein detecting the load on the power source comprises detecting a rotational speed of a motor of the power source. 
     
     
         15 . The method of  claim 11 , wherein detecting the load on the power source comprises detecting a flow rate of hydraulic fluid of a hydraulic system coupled to the power source. 
     
     
         16 . The method of  claim 11 , wherein moving the building panel longitudinally through a shaping machine comprises moving the building panel through a curving apparatus comprising multiple rollers for contacting the building panel and for imparting a longitudinal curve to the building panel. 
     
     
         17 . The method of  claim 11 , wherein moving a building panel longitudinally through a shaping machine comprises moving the building panel through a panel forming apparatus comprising multiple rollers for contacting the building panel and for imparting a desired cross-sectional shape to the building panel. 
     
     
         18 . The method of  claim 11 , comprising detecting a pressure of hydraulic fluid of a hydraulic system coupled to the power source and generating a warning signal if the pressure exceeds a predetermined value. 
     
     
         19 . The method of  claim 12 , comprising making determinations of whether to decrease the speed of the building panel at a first rate and making determinations of whether to increase the speed of the building panel at a second rate, wherein the first rate is greater than the second rate. 
     
     
         20 . The method of  claim 12 , comprising controlling the drive system to increase the speed of the building panel as the panel moves along the shaping machine if the speed is less than a target value and if the load on the power source is less than a desired level. 
     
     
         21 . A method for controlling a system for shaping a building panel of a desired shape, the method comprising:
 receiving a first signal from a load sensor that detects a load placed on a power source, the power source configured provide power to a drive system, the drive system configured to move a building panel longitudinally along a shaping machine, the building panel being made from sheet material, the shaping machine configured to provide a desired shape to the building panel;   processing the first signal from the load sensor; and   controlling the drive system based on said processing to control the load placed on the power source as the building panel moves along the shaping machine.   
     
     
         22 . The method of  claim 21 , further comprising:
 receiving a second signal from a speed sensor that detects a speed at which the building panel moves along the shaping machine;   processing the second signal from the speed sensor; and   controlling the drive system based on the processing of the second signal.   
     
     
         23 . The method of  claim 21 , wherein controlling the drive system comprises controlling the drive system to reduce the load on the power source if the load on the power source exceeds a desired level. 
     
     
         24 . The method of  claim 21 , wherein the first signal from load sensor is indicative of a rotational speed of a motor of the power source. 
     
     
         25 . The method of  claim 21 , wherein the first signal from load sensor is indicative of a flow rate of hydraulic fluid of a hydraulic system coupled to the power source. 
     
     
         26 . The method of  claim 21 , comprising receiving a signal indicative of pressure of hydraulic fluid of a hydraulic system coupled to the power source and generating a warning signal if the pressure exceeds a predetermined value. 
     
     
         27 . The method of  claim 22 , comprising making determinations of whether to decrease the speed of the building panel at a first rate and making determinations of whether to increase the speed of the building panel at a second rate, wherein the first rate is greater than the second rate. 
     
     
         28 . The method of  claim 22 , wherein controlling the drive system comprises controlling the drive system to increase the speed of the building panel as the panel moves along the shaping machine if the speed is less than a target value and if the load on the power source is less than a desired level. 
     
     
         29 . A control system for controlling a panel shaping machine for shaping a building panel, the control system comprising:
 a processing system; and   a memory coupled to the processing system,   wherein the processing system is configured to execute steps comprising:   receiving a first signal from a load sensor that detects a load placed on a power source, the power source configured provide power to a drive system, the drive system configured to move a building panel longitudinally along a shaping machine, the shaping machine configured to provide a desired shape to the building panel;   processing the first signal from the load sensor; and   controlling the drive system based on said processing to control the load placed on the power source as the building panel moves along the shaping machine.   
     
     
         30 . The control system of  claim 29 , the processing system being configured to execute steps comprising:
 receiving a second signal from a speed sensor that detects a speed at which the building panel moves along the shaping machine;   processing the second signal from the speed sensor; and   controlling the drive system based on the processing of the second signal.   
     
     
         31 . The control system of  claim 29 , wherein controlling the drive system comprises controlling the drive system to reduce the load on the power source if the load on the power source exceeds a desired level. 
     
     
         32 . The control system of  claim 29 , wherein the first signal from load sensor is indicative of a rotational speed of a motor of the power source. 
     
     
         33 . The control system of  claim 29 , wherein the first signal from load sensor is indicative of a flow rate of hydraulic fluid of a hydraulic system coupled to the power source. 
     
     
         34 . The control system of  claim 29 , the processing system being configured for receiving a signal indicative of pressure of hydraulic fluid of a hydraulic system coupled to the power source and generating a warning signal if the pressure exceeds a predetermined value. 
     
     
         35 . The control system of  claim 30 , the processing system being configured for making determinations of whether to decrease the speed of the building panel at a first rate and making determinations of whether to increase the speed of the building panel at a second rate, wherein the first rate is greater than the second rate. 
     
     
         36 . The control system of  claim 30 , the processing system being configured for increasing the speed of the building panel as the panel moves along the shaping machine if the speed is less than a target value and if the load on the power source is less than a desired level. 
     
     
         37 . An article of manufacture comprising a non-transitory computer-readable medium comprising programming instructions for the control of a system for shaping a building panel of a desired shape, the programming instructions when executed causing a processing system to carry out steps comprising:
 receiving a first signal from a load sensor that detects a load placed on a power source, the power source configured provide power to a drive system, the drive system configured to move a building panel longitudinally along a shaping machine, the shaping machine configured to provide a desired shape to the building panel;   processing the first signal from the load sensor; and   controlling the drive system based on the first signal to control a speed at which the building panel moves along the shaping machine.   
     
     
         38 . The article of manufacture of  claim 37 , the programming instructions when executed causing the processing system to execute steps comprising:
 receiving a second signal from a speed sensor that detects a speed at which the building panel moves along the shaping machine;   processing the second signal from the speed sensor; and   controlling the drive system based on the processing of the second signal.   
     
     
         39 . The article of manufacture of  claim 37 , wherein controlling the drive system comprises controlling the drive system to reduce the load on the power source if the load on the power source exceeds a desired level. 
     
     
         40 . The article of manufacture of  claim 37 , wherein the first signal from load sensor is indicative of a rotational speed of a motor of the power source. 
     
     
         41 . The article of manufacture of  claim 37 , wherein the first signal from load sensor is indicative of a flow rate of hydraulic fluid of a hydraulic system coupled to the power source. 
     
     
         42 . The article of manufacture of  claim 37 , the programming instructions when executed causing the processing system to execute steps comprising receiving a signal indicative of pressure of hydraulic fluid of a hydraulic system coupled to the power source and generating a warning signal if the pressure exceeds a predetermined value. 
     
     
         43 . The article of manufacture of  claim 38 , the programming instructions when executed causing the processing system to execute steps comprising making determinations of whether to decrease the speed of the building panel at a first rate and making determinations of whether to increase the speed of the building panel at a second rate, wherein the first rate is greater than the second rate. 
     
     
         44 . The article of manufacture of  claim 38 , the programming instructions when executed causing the processing system to control the drive system to increase the speed of the building panel as the panel moves along the shaping machine if the speed is less than a target value and if the load on the power source is less than a desired level.