Machine and method for forming arched roof vertical wall self supporting metal buildings

Abstract

A mobile metal building forming machine forms panels of predetermined length from a coil of flat metal and then the formed panels are continuously crimped on their side edges for strength and are selectively curved by crimping the bottom of the panel. The crimping and curvature are automatically controlled so that building panels with vertical walls and an arched roof may be formed. A moveable crimping roll is automatically portioned to control the curvature and the roll is chain driven so that it may be moved without affecting its rotational drive.

What is claimed is:  
     
       1. A machine for automatically and controllably forming sheet metal into panels for metal buildings having combined walls and roof panels, at least a portion of which are arched or curved; the machine comprising; 
       a) roll forming means for roll forming sheet metal material into a desired panel profile having a central bottom portion between upturned lateral edge portions;  
       b) shear means adjacent the roll forming means for shearing the roll formed panel;  
       c) crimping means for continuously crimping by bending small folds in the bottom portion of formed sheared panel lengths fed through the crimping means to provide a curvature of the formed panels, the depth of the folds establishing the curvature;  
       d) panel curvature measuring means for measuring the curvature of bottom crimped formed panels; and;  
       e) automatic digital control means for controlling the crimping means to vary the control the extent of curvature of the formed panels by varying the depth of the folds, the automatic digital control means being at least partially responsive to the measuring means and a control input setting of desired curvature.  
     
     
       2. A machine as defined in  claim 1  further comprising; means for automatically and controllably adjusting the crimping means only so that the sheared panel bottom portion is not crimped and a corresponding portion of the formed panel is straight. 
     
     
       3. A machine as defined in  claim 2  further comprising; additional crimping means for crimping the edge portions of the formed panels, and length measuring means connected to control means for continuously and automatically measuring the length of formed panels passing through the crimping means. 
     
     
       4. A machine as defined in  claim 1  wherein the crimping means includes a pair of crimping rolls sandwiching the bottom of the formed panel, a moveable block mounting at least one crimping roll so that the crimping rolls may be positioned toward or away from each other, means controlling movement of the block responsive to the control means. 
     
     
       5. A machine as defined in  claim 4  wherein the bottom crimping rolls are driven by chains. 
     
     
       6. A machine as defined in  claim 1  wherein the control means includes a control panel, a microprocessor and hydraulic and electrical circuits. 
     
     
       7. A machine as defined in  claim 6  wherein the control panel allows adjustment of the curvature length of curved portion, and length of straight portion of a formed panel. 
     
     
       8. A machine as defined in  claim 7  wherein the control panel includes automatic shut down means and a computer connection. 
     
     
       9. A machine as defined in  claim 1  wherein the machine is further mounted on a wheel vehicle for mobility. 
     
     
       10. A machine as defined in  claim 9  further comprising hydraulic activated shear means mounted on the vehicle for shearing desired length of the formed metal panel. 
     
     
       11. A method of making panels for a self-sustaining building formed of such panels seamed together side by side, the method comprising; 
       a) roll forming sheet metal from a roll of sheet metal into a desired cross-sectional configuration having side edges and a bottom;  
       b) shearing the formed configuration at a desired and predetermined length;  
       c) crimping by placing small indentations to the side edges of the predetermined length of formed configuration to add strength;  
       d) curving the sheared lengths of roll formed sheet metal by automatically and controllably crimping by placing small indentations to the bottom of the formed configuration to add strength and to provide a predetermined curvature for a portion of the predetermined length to provide a building panel having a curved roof portion and straight vertical wall portions on opposite sides of the roof portion, the depth of the indentations establishing the curvature; and  
       e) measuring the curvature and the predetermined length of the crimped panel and using such measuring and a predetermined setting of curvature for continuously and automatically controlling the depth of the indentations during crimping without removing the panel from the crimping step.  
     
     
       12. A machine for automatically and controllably forming sheet metal into panels for metal buildings having combined walls and roof panels, at least a portion of which are arched or curved, the machine comprising; 
         a )  a plurality of metal forming rolls arranged to form sheet metal material into a desired panel profile having a central bottom portion between upturned lateral edge portions;    
         b )  a movable shear blade adjacent said plurality of metal forming rolls, wherein said moveable shear blade cooperates with an other severing implement to cut said panel;    
         c )  crimping rollers for continuously crimping by bending small folds in the bottom portion of said cut panel lengths fed through said crimping rollers to provide a curvature to said formed panels, the depth of the folds establishing the curvature;    
         d )  a curvature gauge for measuring the curvature of bottom crimped formed panels, and;    
         e )  an automatic digital controller to control the crimping rollers to vary the depth of the folds produced by said crimping rollers to control the extent of curvature of the formed panels, the automatic digital controller being at least partially responsive to said curvature gauge and a control input setting of desired curvature.   
     
     
       13. A machine as defined in  claim 12  further comprising said digital controller automatically and controllably adjusts the crimping rollers so that a portion of the formed panel is straight. 
     
     
       14. A machine as defined in  claim 12  further comprising: 
       
         additional crimping rollers for crimping the edge portions of the formed panels, and length measurement devices connected to said digital controller for continuously and automatically measuring the length of the formed panels passing through the crimping rollers. 
       
     
     
       15. A machine as defined in  claim 12  wherein the crimping rollers include a pair of crimping rollers sandwiching the bottom of the formed panel, a moveable block mounting at least one crimping roller so that the crimping rollers may be positioned toward or away from each other, and a motor to control movement of the block in response to said digital controller. 
     
     
       16. A machine as defined in  claim 15  wherein the bottom crimping rollers are driven by chains. 
     
     
       17. A machine as defined in  claim 12  wherein the digital controller includes a control panel, a microprocessor and hydraulic and electrical circuits. 
     
     
       18. A machine as defined in  claim 17  wherein the control panel allows adjustment of the curvature length of curved portion, and length of straight portion of a formed panel. 
     
     
       19. A machine as defined in  claim 18  wherein the control panel includes automatic shut down means and a computer connection. 
     
     
       20. A machine as defined in  claim 12  wherein the machine is further mounted on a wheeled vehicle for mobility. 
     
     
       21. A machine as defined in  claim 20  further comprising hydraulic activated shear blades mounted on the vehicle for cutting a desired length of the formed metal panel. 
     
     
       22. A method of making panels for a self- sustaining building formed of such panels seemed together side by side, as in    claim 11   , wherein said side edge crimping is performed by at least two crimping rollers sandwiching at least one edge portion of said formed panels.   
     
     
       23. A method for making panels, as in  claim 11 , wherein said depth of the crimping indentations is controlled by a digital controller. 
     
     
       24. A method of making panels, as in  claim 11 , wherein said panels are formed by a machine mounted on a wheeled vehicle for mobility. 
     
     
       25. A method for making panels, as in  claim 23 , wherein the depth of said bottom crimping indentations is controlled independently of the depth of said edge crimping indentations. 
     
     
       26. A method for making panels, as in  claim 11 , wherein said bottom crimping indentations in a single formed panel have a plurality of depths. 
     
     
       27. A method for making panels, as in  claim 11 , wherein said roll forming, crimping and curving steps are performed on a machine mounted to a wheeled vehicle. 
     
     
       28. A machine as defined in  claim 12 , wherein said curvature gauge measures the radius of said panel.