HUE031350T2 - Ablakelem profil továbbítása - Google Patents

Description

(12) EUROPEAN PATENT SPECIFICATION (45) Date of publication and mention (51) Int Cl.: of the grant of the patent: E06B 31673<200601> B21D 53174 <2006 01) 04.01.2017 Bulletin 2017/01 (21) Application number: 05108723.7 (22) Date of filing: 21.09.2005 (54) Window component stock transferring

Vorratsbeförderung von Fensterkomponent Transport d’élément de fenétre embobiné (84) Designated Contracting States: (72) Inventors: AT BE BG CH CY CZ DE DK EE ES Fl FR GB GR · JAMES, Brian G. HU IE IS IT LI LT LU LV MC NL PL PT RO SE Sl 44060, Mentor (US) SK TR · KHALFOUN, Mohamed 44118, Cleveland Heights (US) (30) Priority: 29.09.2004 US 614454 P · MCGLINCHY, Timothy B. 21.03.2005 US 084929 44087, Twinsburg (US) (43) Date of publication of application: (74) Representative: Tomkins &amp; Co 05.04.2006 Bulletin 2006/14 5 Dartmouth Road

Dublin 6 (IE) (73) Proprietor: GED Integrated Solutions, Inc.

Twinsburg, Ohio 44087 (US) (56) References cited: EP-A1-0 585 534 US-A1-2002 170 159 US-A1- 2004 037 985

Note: Within nine months of the publication of the mention of the grant of the European patent in the European Patent Bulletin, any person may give notice to the European Patent Office of opposition to that patent, in accordance with the Implementing Regulations. Notice of opposition shall not be deemed to have been filed until the opposition fee has been paid. (Art. 99(1) European Patent Convention).

Description inserted between adjacent frame element ends to form the corners. In some constructions the corner keys were Field of the Invention foldable so that the sealant could be extruded onto the frame sides as the frame moved linearly past a sealant [0001] The present invention relates to insulating glass 5 extrusion station. The frame was then folded to a rectan- units and more particularly to a method and apparatus gular configuration with the sealant in place on the op-for transferring elongated window component stock from posite sides. The spacer assembly thus formed was one station to another station in an elongated window placed between glass lites and the IGU assembly corn-component production line. pleted. 10 [0007] IGUs have failed because atmospheric water

Background of the Invention vapor infiltrated the sealant barrier. Infiltration tended to occur at the frame corners because the opposite frame [0002] Insulating glass units (IGUs) are used in win- sides were at least partly discontinuous there. For exam- dows to reduce heat loss from building interiors during pie, frames where the corners were formed by cutting cold weather. IGUs are typically formed by a spacer as- 15 "V" shaped notches at corner locations in a single long sembly sandwiched between glass lites. A spacer as- tube. The notches enabled bending the tube to form mi-sembly usually comprises a frame structure extending tered corner joints; but afterwards potential infiltration peripherally about the unit, a sealant material adhered paths extended along the corner parting lines substan-both to the glass lites and the frame structure, and a tially across the opposite frame faces at each corner, desiccant for absorbing atmospheric moisture within the 20 [0008] Likewise in IGUs employing corner keys, poten- unit.Themarginsortheglasslitesareflushwithorextend tial infiltration paths were formed by the junctures of the slightlyoutwardlyfromthespacerassembly.Thesealant keys and frame elements. Furthermore, when such extends continuously about the frame structure periphery frames were folded into their final forms with sealant ap- and its opposite sides so that the space within the IGUs plied, the amount of sealant at the frame corners tended is hermetic. 25 to be less than the amount deposited along the frame [0003] There have been numerous proposals for con- sides. Reduced sealant at the frame corners tended to structing IGUs. One type of IGU was constructed from cause vapor leakage paths. an elongated corrugated sheet metal strip-like frame em- [0009] In all these proposals the frame elements had bedded in a body of hot melt sealant material. Desiccant to be cut to length in one way or another and, in the case was also embedded in the sealant. The resulting com- 30 of frames connected together by corner keys, the keys posite spacer was packaged for transport and storage were installed before applying the sealant. These were by coiling it into drum-like containers. When fabricating all manual operations which limited production rates. Ac- an IGU the composite spacer was partially uncoiled and cordingly, fabricating IGUs from these frames entailed cut to length. The spacer was then bent into a rectangular generating appreciable amounts of scrap and performing shape and sandwiched between conforming glass lites. 35 inefficient manual operations.

[0004] Perhaps the most successful IGU construction [0010] In spacer frame constructions where the roll has employed tubular, roll formed aluminum or steel forming occurred immediately before the spacer assem-frame elements connected at their ends to form a square bly was completed, sawing, desiccant filling and frame or rectangular spacer frame. The frame sides and cor- element end plugging operations had to be performed ners were covered with sealant (e.g., a hot melt material) 40 by hand which greatly slowed production of units. for securing the frame to the glass lites. Thesealant pro- [0011] U.S. patent number 5,361,476 to Leopold dis-vided a barrier between atmospheric air and the IGU in- closes a method and apparatus for making IGUs accord-terior which blocked entry of atmospheric water vapor. ing to the preambles of claims 11 and 1 respectively, Particulate desiccant deposited inside the tubular frame wherein a thin flat strip of sheet material is continuously elements communicated with air trapped in the IGU in- 45 formed into a channel shaped spacer frame having cor-teriorto remove the entrapped airborne water vapor and nerstructures and end structures, the spacerthus formed thus preclude its condensation within the unit. Thus after is cut ofF, sealant and desiccant are applied and the as-the water vapor entrapped in the IGU was removed in- semblage is bent to form a spacer assembly, ternal condensation only occurred when the unit failed.

[0005] In some cases the sheet metal was roll formed so Summary into a continuous tube, with desiccant inserted, and fed to cutting stations where "V" shaped notches were cut in [0012] The present application concerns a method ac-the tube at corner locations. The tube was then cut to cording to claim 11 and apparatus according to claim 1 length and bent into an appropriate frame shape. The for transferring elongated window component stock from continuous spacer frame, with an appropriate sealant in 55 one station to another station in an elongated window place, was then assembled in an IGU. component production line.

[0006] Alternatively, individual roll formed spacer [0013] In one embodiment, the stamping station and frame tubes were cut to length and "corner keys" were the roll forming station are controlled by the controller to create slack in the stock between the stamping station presently disclosed system allows rapid changeover and the roll forming station that causes the stock to droop from one width strip to a next so that repair units for ex- a predetermined distance. In one embodiment, the con- ample can be built as needed to replace damaged win- troller monitors a width of elongated sheet stock supplied dow units as they occur. The system produces less work by a stock supply station and automatically adjusts the 5 in process and real time response to customer orders in stamping station to accept sheet stock of the monitored a way that increases total manufacturing throughput, width and adjusts the roll forming station to accept sheet [0019] Further features and advantages will become stock of the monitored width. apparent from the following detailed description with ref- [0014] The transfer mechanism of the apparatus of the erence to the accompanying drawings, present invention comprises a pair of gripping members to and a conveyorfor moving the pair of gripping members Brief Description of the Drawings from a first position where the gripping members grip an end portion of the elongated sheet stock to a second [0020] position where the gripping members provide the end portion to the feed mechanism. In one embodiment, the 15 Figure 1 is perspective view of an insulating glass transfer mechanism comprisesa bridge that supports the unit; stock material as the stock material is transferred to the Figure2isacrosssectionalviewseenapproximately feed mechanism and allows the stock to droop once the from the plane indicated by the line 2--2 of Figure 1; stock is engaged by the feed mechanism. In one embod- Figure 3 is a fragmentary plan view of a spacer frame imént, the transfer mechanism defines a path of travel 20 element before the element has had sealant applied between the stamping station and the roll forming station and in an unfolded condition; that includes a droop. Figure 4 is a fragmentary elevational view of the el- [0015] In one embodiment, the feed mechanism com- ement of Figure 3; prises a pair of drive rollers positioned at an entrance to Figure 5 is an enlarged elevational view seen ap- the roll forming station that are selectively moveable be- 25 proximately from the plane indicated by the line 5— tween a disengaged position and an engaged position. 5 of Figure 4; [0016] The disclosed system has significant advantag- Figure 6 is afragmentary elevational view of a spacer es over the the system disclosed in US Patent no. frame forming part of the unit of Figure 1 which is 5,361,476 to Leopold. In that system an entire first spacer illustrated in a partially constructed condition; frame unit was scrapped each time a new roll was thread- 30 Figure 7 is an elevational view of a spacer assembly ed into the system. That first frame was only scrapped, production line constructed according to the inven- however, after dessicant and adhesive were applied to tion; the frame resulting in waste in both time and materials. Figure 8 is a plan view of the production line of Figure

The disclosed system avoids excess waste by use of a 7; short piece of scrap frame material that is removed from 35 Figure 9 is a perspective view of a stock supply sta- the system conveyor prior to the dessicant application tion; station. Figure 10 is aside elevational view of a stock supply [0017] The ’476 patent has a single supply of strip station; mounted at the beginning of the frame fabrication system. Figure 11 is a front elevational view of a stock supply

The present system utilizes an automated strip change- 40 station; over system. Whereas the prior system might take up to Figure 12 is a top plan view of a stock supply station; 15 minutes to switch in a new roll of strip material once Figure 12A is a top plan view of an alternate stock a preceding strip has been exhausted, the present sys- supply station; tern achieves changeover in less than one minute. Ad- Figure 13A is an enlarged view as indicated by ref- ditionally the reliance on operators for changeover in- 45 erence FIG. 13 in Figure 10; creased the possibility in operator error in set up that is Figure 13B is an enlarged view as indicated by ref- avoided by the disclosed system. erence FIG. 13 in Figure 10; [0018] The rapid changeover from one roll of strip ma- Figure 14 is an enlarged view as indicated by refer- terial to a next roll and the ability to rapidly switch to dif- ence FIG. 14 in Figure 10; ferent width strip material has resulted in efficiencies not so Figure 15 is an enlarged view as indicated by refer- achievable in the prior art. In the prior art, the fact that a ence FIG. 15 in Figure 10; whole roll of spacer material was used before a change Figure 16 is a view taken along lines 16--16 in Figure meant that window construction was dependent on re- 15; ceipt of a large batch of frames of a given width. This Figure 17 is a perspective view of the clamping placed constraints on subsequent manufacturing proc- 55 mechanism shown in Figure 16; esses that could be performed and these constraints Figure 18isaperspectiveviewofastampingstation; were not necessarily convenient or compatible with a de- Figure 19 is a perspective view of a stamping station; sire to most efficiently fill customer orders. Use of the Figure 20 is a perspective view of a stamping station entrance; Figure 48 is a partial perspective view of a conveyor

Figure 21 is a side elevational view of a portion of a showing an alternate scrap removal apparatus; stamping station; Figure 49 is an enlarged perspective view of the al-

Figure 22 is a view taken along the plane indicated ternate scrap removal apparatus of Figure 48; and by lines 22—22 in Figure 21; 5 Figure 50 is an enlarged perspective view of the al-

Figure 23 is a side elevational view of a transfer tenrat scrap removal apparatus of Figure 48 with a mechanism that transfers sheet stock from a stamp- pusher mechanism actuated for removing scrap ing station to a roll forming station; from the conveyor.

Figure 24 is a side elevational view of sheet stock extending from a stamping station to a roll forming 10 Detailed Description station;

Figure 25 is a perspective view of a transfer mech- [0021] The drawing Figures and following specification anism; disclose a method and apparatus for producing elongat-

Figure 26 is a side elevational view of a transfer ed window components 8 used in insulating glass units, mechanism; 15 Examples of elongated window components include

Figure27 isatopplanviewofatransfermechanism; spacer assemblies 12 and muntin bars 130 that form

Figure 28 is an illustration of a transfer mechanism parts of insulating glass units. The new method and ap- of an alternate embodiment; paratus are embodied in a production line which forms

Figure 29 is an illustration of a transfer mechanism sheet metal ribbon-like stock material into muntin bars of an alternate embodiment; 20 and/or spacers carrying sealant and desiccant for com-

Figure 30 is a perspective view of a roll forming sta- pleting the construction of insulating glass units. While tion; the elongated window components illustrated as being

Figure 31 is a side elevational view of a roll forming produced by the disclosed method and apparatus are station; spacers, the claimed method and apparatus may be used

Figure 32 is a side elevational view of a roll forming 25 to produce any type of elongated window component, station; including muntin bars.

Figure 32A is an enlarged perspective view of the

Figure 30 roll forming station depicting a chain ten- THE INSULATING GLASS UNIT sioner;

Figure 33 is a top plan view of a roll forming station; 30 [0022] An insulating glass unit 10 constructed using

Figure 34 is a perspective view of a swedging and the method and apparatus of the present invention is cutoff station; illustrated by Figures 1-6 as comprising a spacerassem-

Figure 35 is a view taken along lines 35—35 in Figure bly 12 sandwiched between glass sheets, or lites, 14. 34; The assembly 12 comprises a frame structure 16, sealant

Figure 36 is a view taken along lines 36—36 in Figure 35 material 18 for hermetically joining the frame to the lites 35; to form a closed space 20 within the unit 10 and a body

Figures 36A, 36B and 36C are enlarged perspective 22 of desiccant in the space 20. See Figure The unit 10 views of portions of the swedging station with parts is illustrated in Figure 1 as in condition for final assembly removed for ease of illustration; into a window or door frame, not illustrated, for ultimate

Figure 37 is a view taken along lines 37—37 in Figure 40 installation in a building. The unit 10 illustrated in Figure 36; 1 includes muntin bars 130 that provide the appearance

Figure 38 is aside elevational view of a cutofF station; of individual window panes.

Figure 39 is a partial perspective view of a conveyor; [0023] The assembly 12 maintains the lites 14 spaced

Figure 40 is a partial top plan view of the conveyor apart from each other to produce the hermetic insulating shown in Figure 39; 45 "insulating air space" 20 between them. The frame 16

Figure 41 is a partial side elevational view of the con- and the sealant body 18 co-act to provide a structure veyor shown in Figure 39; which maintains the lites 14 properly assembled with the

Figure 42 is a perspective view of a conveyor; space 20 sealed from atmospheric moisture over long

Figure 43 is a partial perspective view of a conveyor time periods during which the unit 10 is subjected to fre- showing a scrap removal apparatus; 50 quent significant thermal stresses. The desiccant body

Figure 44 is a partial side elevational view of a con- 22 removes water vapor from air, or other volatiles, en- veyor showing a scrap removal apparatus; trapped in the space 20 during construction of the unit 10.

Figure 45 is a schematic representation of a scrap [0024] The sealant body 18 both structurally adheres removal apparatus; the lites 14 to the spacer assembly 12 and hermetically

Figure 46 is a schematic representation of a scrap 55 closes the space 20 against infiltration of airborne water removal apparatus; vapor from the atmosphere surrounding the unit 10. The

Figure 47 is a schematic representation of a scrap illustrated body 18 is formed from a "hot melt" material removal apparatus; which is attached to the frame sides and outer periphery to form a U-shaped cross section. each other to form a telescopic joint 72. See Figure 6.

[0025] The structural elements ofthe frame 16 are pro- When assembled, the telescopic joint 72 maintains the duced by the method and apparatus of the present in- frame in its final polygonal configuration priorto assembly vention. The frame 16 extends about the unit periphery ofthe unit 10. to provide a structurally strong, stable spacer for main- 5 [0029] In the illustrated embodiment the connector taining thelites aligned and spaced while minimizing heat structure 34 further comprises a fastener arrangement conduction between the litesviatheframe. The preferred 85 for both connecting the opposite frame ends together frame 16 comprises a plurality of spacerframe segments, and providing a temporary vent for the space 20 while or members, 30a-d connected to form a planar, polygonal the unit 10 is being fabricated. The illustrated fastener frame shape, element juncture forming frame corner n> arrangement (see FIGS. 3 and 6) is formed by connector structures 32a-d, and connecting structure 34 for joining holes 84, 82 located, respectively, in the tongue 66 and opposite frame element ends to complete the closed the frame end 64, and a rivet 86 extending through the frame shape. connector holes 82, 84 for clinching the tongue 66 and [0026] Each frame member 30 is elongated and has a frame end 64 together. The connector holes are aligned channel shaped cross section defining a peripheral wall 15 when the frame ends are properly telescoped together 40 and first and second lateral walls 42, 44. See Figure and provide a gas passage before the rivet is installed. 2. The peripheral wall 40 extends continuously about the [0030] In some circumstances it may be desirable to unit 10 except where the connecting structure 34 joins provide two gas passages in the unit 10 so the inert gas the frame member ends. The lateral walls 42, 44 are in- flooding the space 20 can flow into the space 20 through tegral with respective opposite peripheral wall edges. 20 one passage displacing residual air from the space The lateral walls extend inwardly from the peripheral wall through the second passage. The drawings show such 40 in a direction parallel to the planes ofthe lites and the a unit. See FIGS. 3 and 6. The second passage 87 is frame. The illustrated frame 16 has stiffening flanges 46 formed by a punched hole in the frame wall 40 spaced formed along the inwardly projecting lateral wall edges. along the common frame member from the connector

The lateral walls 42, 44 add rigidity the frame member 25 hole 84. The sealant body 18 and the desiccant body 22 30 so it resists flexure and bending in a direction trans- each defines an opening surrounding the hole 84 so that verse to its longitudinal extent. The flanges 46 stiffen the air venting from the space 20 is not impeded. The second walls42,44 so they resist bending and flexure transverse passage 87 is closed by a blind rivet 90 identical to the to their longitudinal extents. rivet 86. The rivets 86, 90 are installed at the same time [0027] The frame is initially formed as a continuous 30 and each is covered with sealant material so that the seal straight channel constructed from a thin ribbon of stain- provided by each rivet is augmented by the sealant ma- less steel material (e.g., 304 stainless steel having a terial. thickness of 0.006-0.010 inches). Other materials, such

as galvanized, tin plated steel, or aluminum, may also be THE ELONGATED WINDOW COMPONENT PRODUC-used to construct the channel. The corner structures 32 35 TION LINE are made to facilitate bending the frame channel to the final, polygonal frame configuration in the unit 10 while [0031] As indicated previously the spacer assemblies assuring an effective vapor seal at the frame corners as 12 and muntin bars 130 are elongated window compo- seen in FIGS. 3-5. The sealant body 18 is applied and nents 8 that may be fabricated by using the method and adhered to the channel before the corners are bent. The 40 apparatus of the present invention. Elongated window corner structures 32 initially comprise notches 50 and components are formed at high rates of production. The weakened zones 52 formed in the walls 42, 44 at frame operation by which elongated window components are corner locations. See FIGS. 3-6. The notches 50 extend fashioned is schematically illustrated by Figures 7 and 8 into the walls 42, 44 from the respective lateral wall edg- as a production line 100 through which a thin, relatively es. The lateral walls 42, 44 extend continuously along 45 narrow ribbon of sheet metal stock is fed endwise from the frame 16 from one end to the other. The walls 42, 44 a coil into one end ofthe assembly line and substantially are weakened at the corner locations because the notch- completed elongated window components 8 emerge es reduce the amount of lateral wall material and elimi- from the other end ofthe line 100. nate the stiffening flanges 46 and because the walls are [0032] The line 100 comprises a stock supply station stamped to weaken them at the corners. 50 102, a first forming station 104, a transfer mechanism [0028] The connecting structure 34 secures the oppo- 105, a second forming station 110, a conveyor 113, a site frame ends 62, 64 together when the frame has been scrap removal apparatus 111, third and fourth forming bent to its final configuration. The illustrated connecting stations 114, 116, respectively, where partially formed structure comprises a connecting tongue structure 66 spacer members are separated from the leading end of continuous with and projecting from the frame structure 55 the stock and frame corner locations are deformed preend 62 and a tongue receiving structure 70 at the other paratory to being folded into their final configurations, a frame end 64. The preferred tongue and tongue receiving desiccant application station 119 where desiccant is ap- structures 66, 70 are constructed and sized relative to plied to an interior region of the spacer frame member, and an extrusion station 120 where sealant is applied to 164. The angular member 168 is sized and shaped to the yet to be folded frame member. A scheduler/motion co-act with the grooves 140 in the front wheels 136. The controller unit 122 (Figure 8) interacts with the stations angular member 168 and the front wheels 136 form a and loop feed sensors to govern the spacer stock size, guide that limits movement of the carriage to be in the spacer assembly size, the stock feeding speeds in the 5 direction of axis A. Itshould bereadilyapparentthatmany line, and other parameters involved in production. A pre- other types of guides could be employed without depart- ferred controller unit 122 is commercially available from ing from the scope of the claimed invention.

Delta Tau, 21314 Lassen St, Chatsworth, CA 91311 as [0037] The illustrated track 162 is supported by legs part number UMAC. 172. A stop 174 is included at each end of the track. The to stops 174 prevent the carriage 132 from moving off the THE SUPPLY STATION 102 end of the track 162. Asensor 176 is included near each end of the track. The sensors 176 are coupled to the [0033] The stock supply station 102 is illustrated by controller 122. The sensors are used to detect when the

Figures 9-17. The station 102 comprises a plurality of carriage is approaching a stop 174 and to detect the po- rotatable sheet stock coils 124, an indexing mechanism i5 sition of the carriage on the frame to allow the controller 126, and an uncoiling mechanism 128 (Figure 10). The to establish a "home" position when the stock supply sta-indexing mechanism 126 is coupled to the sheet stock tion 102 is initialized. coils 124 for indexing a selected one of the sheet stock [0038] Referring to Figure 14, the illustrated drive coils to an uncoiling position Ρα. When a sheet stock coil mechanism 133 is controlled by the controller 122 and 124 is located at the uncoiling position Py, a sheet stock 20 coupled to the carriage 132. The controller 122 controls end 130 is positioned to be drawn into the first forming the drive mechanism 133 to move the carriage 132 to station 104 as will be described in detail below. The un- position a selected one of the coils 124 at the uncoiling coiling mechanism 128 selectively uncoils sheet stock position Pj. The illustrated drive mechanism 133 in- 125 from a sheet stock coil 124 indexed to the uncoiling eludes the gear rack 156 attached to the carriage, a motor position Pu to thereby provide sheet stock to the down- 25 178, a drive gear 180, and an engagement actuator 182. stream processing stations. The drive gear 180 is coupled to the motor 178 and is [0034] In the illustrated embodiment, the indexing positioned by the engagement actuator 182. The control- mechanism 126 includes a carriage 132 and a drive ler 122 controls the engagement actuator to selectively mechanism 133 (Figure 10). The carriage 132 supports move the drive gear 180 between an engaged position the sheet stock coils, such that the sheet stock coils are 30 (shown in phantom in Figure 14) and a disengaged po-individually rotatable about a common axis A. The illus- sition (shown as solid in Figure 14). In the engaged potrated carriage 132 includes a frame 134 supported by a sition, teeth of the drive gear 180 mesh with the teeth of pair of front wheels 136 and a pair of rear wheels 138. the gear rack 156. The motor 178 is controlled by the The wheels 136, 138 are secured to the frame 134 such controller 122 to position the carriage. The motor 178 is that the carriage is moveable in the direction of axis A. 35 a servo drive motor that can be precisely controlled by The illustrated front wheels 136 each include an annular the controller 122 to position an appropriate one of the groove 140. The illustrated annular groove are substan- plurality of sheet stock coils 124 at the uncoiling position tially "v" shaped, but it should be readily apparent that P(j. Controlled energization of the motor 178 positions any groove configuration could be employed. An elon- the carriage 132 is position for threading a corresponding gated gear rack 156 is mounted to the frame 134. In the 40 sheet into the forming station 104 In the disengaged po-illustrated embodiment, the gear rack 156 extends across sition, an operator is able to manually move the carriage the length of the carriage 132. 132 on the track 162. In an alternate embodiment, the [0035] Referring to Figure 12, the frame 134 includes engagement actuator is omitted and the drive gear 180 a plurality of spaced members 142 that extend from a is positioned in the in the engaged position. In this em-front 144 of the frame 134 to a rear 146 of the frame. A 45 bodiment, an operator is not able to manually move the coil support post 148 extends upward from each member carriage 132 on the track without manually removing the 142. Individual coil support shafts 150 are removably drive gear 180 from engagement with the gear rack 156. supported between each pair of adjacent coil support [0039] Referring to Figures 11 and 12, each sheet posts 148. The individually removable shafts 150 allow stock coil 124 is mounted to a rotatable disk 184. In the individual sheet stock coils 124 to be installed on the 50 illustrated embodiment, each sheet stock coil 124 is se-carriage and removed from the carriage. A pair of loop cured between the rotatable disk 184 and a plate 186. defining supports 152 extend from the outer coil support The coil support shaft 150 extends through and supports posts. A coil end support member 154 extends between the sheet stock coil 124, the rotatable disk 184, and the the pair of loop defining supports 152. plate 186, such that the sheet stock coil 124, the rotatable [0036] In the illustrated embodiment, the carriage 132 55 disk 184, and the plate 186 are rotatable about axis A. rides on a track 162. The track 162 includes a front rail Rotation of the disk 184 as indicated by arrow 188 Figure 164 and a rear rail 166. An elongated angular member 13B causes sheet stock 125 to be unwound off of the coil 168 is secured to an upper surface 170 of the front rail 124.

[0040] Referring to Figures 13A and 13B, a brake as- disk 184 to uncoil the sheet stock 125. sembly 190 is connected to the carriage 132 at each ro- [0043] In the illustrated embodiment, a plurality of tatable disk location. The brake assembly 190 prevents clamping mechanisms 212 position the end portion 130 the sheet stock from inadvertently unwinding from the of each of the sheet stock coils 124 such that the end coil 124. The brake assembly includes a pivotable arm 5 portion of a coil indexed to the uncoiling position UP is 192, a brake pad 194 mounted at one end of the pivotable located at an entrance of the first forming station 104. In arm, an engagement wheel 196 mounted at another end the illustrated embodiment, the clamping mechanisms of the pivotable arm, and a biasing member 198, such 212 are connected to the coil end support member 154. as a spring, that biases the pivotable arm to a braking In the exemplary embodiment, the motor202 is controlled position (Figure 13A). The pivotable arm 192 is pivotably 10 to define a loop 213 (See Figure 10) or droop between mounted to the carriage 132. In the braking position, the each sheet stock coil 124 and its associated clamping brake pad 194 engages the rotatable disk and prevents mechanism 212. The illustrated clamping mechanisms the coil 124 from inadvertently unwinding. In a disen- 212 each include a support 215, a pair of guide rollers gaged position (Figure 13B), the brake pad is not in en- 216, 217, a clamping roller 218, and a biasing member gagement with the disk 184 and the coil 124 may be 15 220, such as a spring. The guide rollers 216, 217 limit unwound. lateral movement of the sheet stock and thereby guide [0041] A wide variety of sheet stock widths can be load- the sheet stock 125 into the first forming station 104. The ed on the stock supply station. For example, a window guide rollers 216, 217 are rotatably mounted to the sup- manufacturer that makes one size of elongated window port 215, such that an axis of rotation of each guide roller component could load all of the disks with one size of 20 216, 217 is perpendicular to an upper surface 222 of the sheet stock. This may allow the line to run for an entire support. In the illustrated embodiment, the position of the shift or more, without the need for an operator to load a guide roller 216 is fixed and the position of the guide roller new coil onto the stock supply station. A window manu- 217 is adjustable to accommodate different sizes of sheet facturer that makes a variety of different widths of elon- stock 125. The adjustable guide roller 217 includes a gated window components would load the stock supply 25 release handle 223 that allows the roller to be selectively station with sheet stock coils have a variety of different moved toward or away from the fixed guide roller 216. widths and have multiple coils for commonly used sizes. The clamping roller 218 is positioned such that its axis [0042] Referring to Figures 12, 13A and 13B, the un- of rotation is parallel to the upper surface 222 of the sup- coiling mechanism 128 is positioned to individually drive port 215. The biasing member 220 is coupled to the each of the rotatable sheet stock coils 124 when posi- 30 clampingroller218andthesupport215byabracket224 tioned at the uncoiling position Py to individually uncoil such that the clamping roller 218 is biased toward the the sheet stock 123 from each of the coils. In the illus- upper surface 222. The clamping roller presses the sheet trated embodiment, the position of the uncoiling mecha- stock 125 againstthe upper surface 222 to thereby guide nism 128 is fixed with respect to the track 162. The un- the sheet stock 125 into the first forming station 104. coiling mechanism 128 is controlled by the controller 122 35 [0044] The width and depth of the frames 16 being proto selectively engage and drive a radially outer surface duced may be changed from time to time as desired by 200 of the rotatable disk indexed to the uncoiling position passing wider or narrower sheet stock through the pro- P(j to provide sheet stock to the processing station. In duction line. In addition, sheet stock coils eventually run the illustrated embodiment, the uncoiling mechanism 128 out of stock and need to be replaced. When it is necessary includes a motor 202, a drive wheel 204, an engagement 40 to change coils, the controller 122 simply indexes the actuator 206, and a brake plate 208. The motor 202, nextselectedsheetstockcoil124totheuncoilingposition brake plate 208, and the drive wheel 204 are mounted PU, to position the sheet stock end 130 at the entrance to a frame 210. The motor 202 is controlled by the con- to the first forming station 104. trailer 122 and is coupled to the drive wheel 204. The [0045] In the illustrated embodiment, a loop feed sen- frame 210 is pivotably connected to the rear of the track 45 sor 230 is included at the supply station. The loop feed 162. The engagement actuator 206 is controlled by the sensor230 (Figures 10 and 12) co-acts with the controller controller 122 and is coupled to the frame 210 and the unit 122 to control the motor 202 for preventing paying track 162. The actuator 206 selectively pivots the frame out excessive stock while assuring a sufficiently high 210 between a disengaged position (Figure 13A) and an feeding rate through the production line. The loop feed engaged position (Figure 13B) as dictated by the con- 50 sensor 230 is schematically illustrated as positioned trailer 122. In the disengaged position, the sheet stock above the sheet stock 125 at the uncoiling position P(j coil 124 at the uncoiling position Py is prevented from that extends from the sheet stock coil 124 to its associ- uncoiling by the brake assembly 190. In the engaged atedclampingmechanism212.Stockfedtotheclamping position, the brake plate 208 is in engagement with the mechanism 212 from the supply station 102 droops in a wheel 196 and the drive wheel 204 is in engagement with 55 caternary loop 232 (Figure 10). The depth of the loop 232 the disk 184. The engagement of the brake plate 208 is maintained between predetermined levels by the con- with the wheel 196 disengages the brake pad 194 from trailer 122. The illustrated loop feed sensor 230 is an the disk 184. Rotation of the drive wheel 204 rotates the ultrasonic loop detector which directs a beam of ultra- sound against the lowermost segment of the stock loop. the processing station by a clamping mechanism 212 The loop feed sensor 230 detects the loop location from that is located at the uncoiling position P^ The drive roll-reflected ultrasonic waves and signals the controller unit ers 256, 258 selectively feed the sheet stock positioned 122. A signal is output from the loop feed sensor 230 to at the entrance of the processing station 260 into the the controller unit 122. The controller 122 controls the 5 processing station 102. In the illustrated embodiment, motor 202 to control the feed rate of stock to the produc- drive roller 256 is selectively driven by a motor 262 that tion line. is controlled by the controller 122. The drive roller 258 is [0046] A sensor 175 senses the amount of sheet ma- pivotally connected to the framework 238. In the illustrat- terial left on a given stock coil 124. The preferred sensor ed embodiment, the roller 258 is an idler roller that press-includes a IR source positioined above the uncoil position 10 es the sheet stock 125 against the roller 256 when the Pu· When the coil 124 is full or only partially dispensed drive rollers are in the engaged position. An actuator 264 the radiation from the source 175 bounces off the sheet is connected to the framework 238 and the drive roller material and the sensor does not receive a return signal. 258.Theactuator264 is selectively controlled bythecon-When the strip nears an end of its payout, the radiation trailer 122 to engage sheet stock 125 positioned at the traverses a path to a reflector 175a and bounces back 15 entrance of the stamping station 104. The motor 262 is to a photodetector included in the sensor 175. This sig- controlled to feed the sheet stock 125 through the station nals the controller 122 that the coil at the uncoil position 104 to the stock driving station 242. In the illustrated em-Pu has been dispensed and anothercoil should be moved bodiment, a sensor 266 is positioned along the path of into position for unwinding. travel P, near the stock feed mechanism. Thesensor266 [0047] Figure 12A depicts an alternate supply station 20 is used to verify that stock 125 is being fed by the stock 102’ that includes a plurality of rotatable sheet stock coils feed mechanism 240 and to determine when the stock 124 that are mounted to a carriage 132’. The carriage is feed mechanism can be disengaged, because the stock similar to a turntable that is drive by an indexing system 125 has reached the stock driving system. The controller having a servo motor (not shown) that precisely rotates 122 is in communication with the supply station 102 and one of the coils 124 to a uncoil position Pu. The supply 25 the stockfeed mechanism. The controller moves the pair station 102’ includes a single stationary uncoiling mech- of drive rollers to the disengaged, spaced apart position anism 128 similar to the mechanism described above. and indexes the selected sheet stock coil to the uncoiling The carriage 132’also supports a plurality of brake mech- position. At the uncoiling position, the corresponding anisms (not shown) and clamping mechanisms 212. Un- clamping mechanism 212 positions the sheet stock end der control of the controller 122, the servo motor rotates 30 portion 130 between the pair of drive rollers 256, 258. a particular one of the coils 124 to the uncoil position Pu The controller 122 moves the pair of drive rollers to the (or orientation) such that an associated clamping mech- engagement position to engage the coil end portion, and anism is juxtaposed in relation to the forming station 104 rotates the drive rollers to feed the sheet stock into the for feeding stock material 125 from the coil into the form- processing station and to the stock driving mechanism ing station for subsequent processing described below. 35 242.

[0050] In one embodiment, the stockfeed mechanism THE FORMING STATION 104 240 is also used to withdraw stock from the stamping station 104 when sizes are changed as will be described [0048] The forming station 104 (Figures 18-22) with- in further detail below. The sensor 266 is used by the draws the stock from the clamping mechanism 212 po- 40 controller to determine the when the feeding mechanism sitionedatthe uncoiling position Pj and performs a series 240 stops withdrawing stock from the stamping station, of stamping operations on the stock passing through it. [0051] Referring to Figures 18 and 19, the stock driving The station 104 comprises a supporting framework 238 system 242 engages the stock provided by the stock fixed to the factory floor adjacent the loop sensor, a stock feeding mechanism 240. The stock feeding mechanism feed mechanism 240 that feeds the sheet stock end 130 45 240 then disengages. The stock driving system 242 com- (FigurelO)intotheformingstation,astockdrivingsystem prises a stock driving roll set 268 secured to the frame- 242 which moves the stock through the station, and work 238 along the stock path of travel P at the exit end stamping units 244, 246, 248, 250, 252, 254 where indi- of the station 104, a motor 270 (Figure 19) is operated vidual stamping operations are carried out on the stock. by the controller unit 122 for precisely driving the roll set [0049] Referring to Figure20, the illustrated stockfeed 50 268, and a positive drive transmission 272 couples the mechanism 240 comprises a pair of drive rollers 256,258 motor 270 and the roll set 268. secured to the framework 238 along a stock path of travel [0052] The preferred roll set comprises a pair of drive P at a processing station entrance 260. The pair of drive rolls rigidly supported by bearings secured to the frame- rollers 256,258 are selectively moveable between a dis- work 268. The rolls define a nip for securely gripping the engaged position (shown in phantom in Figure 20) where 55 stock and pulling it through the station 104 past the the drive rollers are spaced apart and an engaged posi- stamping units 244, 246, 248, 250, 252, 254. In the illus-tion (shown in solid in Figure 20) where the drive rollers trated embodiment, the rolls grip the stock so tightly that engage a coil end portion positioned at the entrance of there is no stock slippage relative to either roll as the stock advances. the driving system 242 and stopped with predetermined [0053] The illustrated motor 270 is an electric servo- stock locations precisely aligned in the stamping station motor of the type constructed and arranged to start and 252. The punches are actuated by the ram 286a so that stop with precision. Accordingly, stock passes through the connector holes 82, 84 are punched on the stock the station 104 at precisely controlled speeds and stops 5 midline, or longitudinal axis. When the punches are with-precisely at predetermined locations, all depending on drawn, the stock feed resumes. signals from the controller unit 122 to the motor 270. [0059] Referring to Figure 22, the stamping unit 248

While a servo motor is disclosed in the production line forms the frame corner structures 32b-d but not the cor- 100, it may be possible to use other kinds of motors or nerstructure 32a adjacent the frame tongue 66. Referring different stock feeding mechanisms. 10 to Figures 21 and 22, the unit 248 comprises a die as- [0054] The drive transmission 272 is illustrated as a sembly 280b operated by a ram assembly 284b. The die timing belt reeved around sheaves 274, 276 respectively assembly 280b punches material from respective stock secured to the motor shaft and a shaft of the lower roll. edges to form the corner notches 50. The die assembly

The upper roll being coupled to the lower roll by gears 280b also stamps the stock at the corner locations to 278 (Figure 18). The timing belt has toothlike lugs which 15 define the weakened zones 52 which facilitate folding the positively engage each sheave so that the motor and roll spacer frame member at the corner locations. The ram shafts are all driven together without any slippage. Con- assembly 284b preferably comprises a pair of rams consequently, the motor shaft movement is faithfully trans- nected to the upper die 288b. mitted to the roll set 268 by the timing belt so stock motion [0060] Each weakened zone 52 is illustrated as formed is controlled as desired in the station 104. As an alterna- 20 by a score line (more than one score line may be included) tive, the roll set 268 may be driven by gears connected radiating from a corner bend line location on the stock to the motor shaft. toward the adjacent stock edge formed by the corner [0055] Referring to Figure 21, each stamping unit 244, notch 50. The score line is formed by a sharp edged ridge 246, 248, 250, 252, 254 comprises a die assembly 280 on the anvil 286b. In the illustrated embodiment, the and a die actuatorassembly, orram assembly, 284. Each 25 frame members produced by the production line 100 die assembly comprises a die set having a lower die, or have common side wall depths even though the frame anvil, 286 beneath the stock travel path and an upper width varies. Therefore, the score line on the anvil 286b die, or hammer, 288 above the travel path. The stock are effective to form the corner structures for all the frame passes between the dies as it moves through the station members made by the line 100. 104. Each hammer 288 is coupled to its respective ram 30 [0061] Referring to Figures 21 and 22, the stamping assembly 284. Each ram assembly forces its associated unit 250 configures the leading and trailing ends 62, 64 dies together with the stock between them to perform a of each spacer frame member. The unit 250 comprises particular stamping operation on the stock. For conven- a die assembly 280c operated by a ram assembly 284c. ience, the die assemblies and ram assemblies of sue- The die assembly is configured to punch out the profile cessive stamping units are identified by common refer- 35 ofthe frame member leading end 62as well as the profile ence numerals having different respective suffix letters. ofthe adjoining frame member trailing end 64 with a sin- [0056] Each ram assembly 284 is securely mounted gle stroke. The leading frame end 62 is formed by the atop the framework 238 and connected to a source (not tongue 66 and the associated corner structure 32a. A shown) of high pressure operating air via suitable con- trailing frame end 64 associated with the preceding frame duits (not shown). Each ram assembly 284 is operated 40 member is immediately adjacent the tongue 66 and re-from the controller 122 which outputs a control signal to mains connected to the tongue 66 when the stock passes a suitable or conventional ram controlling valve arrange- from the unit 250. The ram assembly 284c comprises a ment (not shown) when the stock has been positioned pair of rams each connected to the hammer 288c. appropriately for stamping. [0062] The corner structure 32a is generally similar to [0057] Referring to Figure 22, the stamping unit 252 45 the corner structures 32b-d except the notches 50 asso- punches the connector holes 82, 84 in the stock at the dated with the corner 32a differ due to their juncture with leading and trailing end locations of each frame member. the tongue 66. The die assembly therefore comprises a

When included, the passage 87 is also punched in the score line forming a ridge like the die set forming the stock by the unit 252. In the illustrated embodiment, the remaining frame corners 32b-d. die set anvil 286a defines a pair of cylindrical openings 50 [0063] In the illustrated embodiment the stamping unit disposed on the stock centerline a precise distance apart 246 forms muntin bar clip mounting notches in the stock, along the stock path of travel P. The hammer 288a is The muntin bar mounting structures include small rec- formed in part by corresponding cylindrical punches each tangular notches. The unit 246 comprises a ram assem- aligned with a respective anvil opening and dimensioned bly 284d coupled to the notching die assembly 280d. The to just fit within the aligned opening. The ram 284a is 55 anvil 286d and hammer 288d ofthe notching die assem-actuated to drive the punches downwardly through the bly are configured to punch a pair of small square corner stock and into their respective receiving openings. notches 289 on each edge ofthe stock. Accordingly the [0058] The stock is fed into the stamping unit 252 by ram assembly 284d comprises a single ram which is suf- ficient to power this stamping operation. A single stroke mechanism 240 to move to the engaged position. The of the ram actuates the die set to form the opposed notch- controller then actuates the motor 262 to pull the stock es simultaneously and in alignment with each other along 125 out of the stamping station 104 and position the stock the opposite stock edges. end 130attheentrancetothestampingstation.Thestock [0064] Referring to Figure 22, the stamping station 104 5 that forms the last spacer frame member in the series is defines a scrap piece 294 followed by a connected first driven outofthe machine by the stock driving mechanism spacerframe defining length 296 of stock in a given series 242. The controller then moves the stock feed mecha- 297 of spacer frames. In one embodiment, the scrap nism 240 to the disengaged position to release the stock piece 294 is defined by the stamping station 104 when- end 130. The stock end remains secured by its clamping ever a different coil is indexed to the uncoiling station and 10 mechanism 212. The controller may then index the next fed into the forming station 104. This prevents the first selected coil to the uncoiling position Pu and thereby spacerframe member in a series of spacer frame mem- place its end 130 between the rollers 256, 258. The con- bers made from the indexed coil from being scrapped. trailer 122 then controls the stock feed mechanism 240

Instead, only the scrap piece 294 is scrapped. A first to start the next series of spacer frame units, spacerframe member in a series of spacerframe mem- 15 [0068] In order to accommodate wider or narrower bers may otherwise need to be scrapped for a variety of stock passing through the station 102 die assemblies reasons. For exam pie, the leading end 130 of the material 280b-e are split. In the illustrated embodiment, one side initially fed into the station may not be cut to define the of each die assemblies is fixed and the opposite side leading edge of a spacerframe, the leading edge may each splitdie assembly is adjustably movable towardand be bent, and/or the first spacer frame member may not 20 away from the corresponding fixed die assembly to form be properly formed by the second forming station 110. different width spacer frames. Thus, each anvil 286b-e

In the illustrated embodiment, the scrap defining length is split into two parts and each hammer 288b-e is likewise 296 is substantially shorter (1/2 as long or shorter for a split. To maintain die assembly 280a in the center of the typical frame) than the length of stock needed to form a path of travel P, die assembly 280a is also moveable, typical elongated window component. The resulting 25 [0069] Referring to Figure 21, the moveable opposed scrap sheet stock 125 is thereby reduced. hammer and anvil parts are linked by vertically extending [0065] Referring to Figures 21 and 22, the stamping guide rods 302. The guide rods 302 are fixed in the ham- unit 244 configures the leading edge 298 of the scrap mer parts and slidably extend through bushings in the piece 294 and trailing end 64 of the last spacer frame opposed anvil parts. The guide rods 302 both guide the member in a series of spacer frame members formed 30 hammers into engagement with their respective anvils from the indexed coil 124. The trailing edge 297 of the and link the hammers and respective anvils so that all scrap unit is formed by the stamping unit 250 when the the hammers and anvils are adjusted laterally together, leading edge ofthe first spacer in the next series of spac- [0070] Referring to Figures 19 and 22, the moveable ers formed from this particular sheet stock coil is hammer and anvil parts of each die assembly are mov- stamped. The unit 244 comprises a die assembly 280e 35 able laterally towards and away from the fixed hammer operated by a ram assembly 284e. The die assembly is and anvil parts by an actuating system 304 to desired configured to punch out the profile of the scrap piece adjusted positions for working on stock of different leading end 298 as well as the profile of the end 64 of widths. The system 304 firmly fixes the die assembly the last frame member in the series of spacerframe mem- parts at their laterally adjusted locations for further frame bers with a single stroke. The ram assembly 284e com- 40 production. Referring to Figure 21, the anvil parts of each prises a pair of rams each connected to the hammer die assembly 280a-e are respectively supported in ways 288e. 309 attached to the stamping unit frame 238. The ham- [0066] Referring to Figure 22, at the end of a series of mer parts of each die assembly are each supported in spacerframe members, the stamping unit 244 forms the ways 311 fixed its respective die actuator, or ram 284a- trailing end ofthe last spacerframe member in the series 45 e. The ways 309, 311 extend transversely of the travel and the leading end 298 ofthe scrap piece. The stock is path P and the actuating system 304 shifts the hammer then indexed to stamping unit 254 where the connection parts and the anvil parts simultaneously along the re-between the end of the last spacer frame member and spective ways between adjusted positions. the leading end 298 ofthe scrap piece 294 is severed. [0071] The illustrated actuating system is controlled by The unit 254 comprises a die assembly 280f operated so the controller 122 to automatically adjust the station 104 by a ram assembly 284f. The die assembly 280f punches for the stock width provided at the entrance ofthe station, the material that spans the respective stock edges to The width ofthe stock provided to the station 104 may sever the stock. The ram assembly 284f preferably com- be detected and the controller automatically adjusts the prises a ram connected to the upper die 288f. station 104 to accommodate the detected width. Refer- [0067] Referring to Figure 19, a sensor 300 detects the 55 ring to Figures 19 and 22, the illustrated actuating system end of the last spacer frame in a series of spacer frame 304 provides positive and accurate moveable die assem- members. Upon detection ofthe severed end ofthe last bly section placement relative to the stock path of travel spacer frame, the controller 122 causes the stock feed P. The system 304 comprises a plurality of drivescrews 316, a drive transmission 318 coupled to thedrivescrews, to stamp all the muntin bar connection locations as well and die assembly driving members 319, 320, 321, 322, as the remaining stamping operations. The average rate 323, 325 driven by the drivescrews 326 and rigidly linking of stock feed in this case is low because of all the stops, the drivescrews to the anvil parts.

[0072] The drivescrews 316 are disposed on parallel 5 TRANSFER MECHANISM 105 axes 324 and mounted in bearing assemblies connected to lateral side frame members 330. Each drivescrew is [0077] Referring to Figure 23, the transfer mechanism threaded into its respectivedie assembly driving member 105 automatically feeds the elongated sheet stock 125 319,320,321,322,323,325. Thus when thedrivescrews from the stamping station 104 into a down stream station, rotate in one direction the driving members 319, 320, 10 such as a roll forming station 110 in the window compo- 321,322, 323, 325 force their associated die sections to nent production line 100. The transfer mechanism is po-shift laterally away from the fixed die sections. Drive- sitioned between the stamping station 104 and the roll screwrotation intheotherdirectionshiftsthediesections forming station 110. In the illustrated embodiment, the toward the fixed die sections. The threads on the drive- transfer mechanism 105 provides the stamped sheet screws are precisely cut so that the extent of lateral die 45 stock to a feed mechanism 360 positioned at an entrance section movement is precisely related to the angular dis- to the roll forming station 110. The controller 122 is in placement of the drivescrews creating the movement. communication with the stamping station 104, the trans- [0073] The ham mer sections of the die assemblies are fer mechanism 105, and the feed mechanism 360. The adjustably moved by the anvil sections. The guide rods controller 122 causes the transfer mechanism to engage 302 extending between confronting anvil and hammer 20 stock material 125thatextendsfromthestampingstation die sections are structurally strong and stiff and serve to 104 and transfer the stock material paid out by the stamp-shift the hammer sections of the die assemblies laterally ing station to the feed mechanism. The controller 122 with the anvil sections. The hammer sections are rela- then drives the feed mechanism to feed the elongated tively easily moved along the upper platen ways 311. sheet stock into the roll forming station 110. In the illus- [0074] In the illustrated embodiment, the drive trans- 25 trated embodiment, the stamping station 104 and the roll mission 318 is driven by a motor 317 that is controlled forming station 110 are controlled by the controller 122 by controller 122. The illustrated transmission 318 com- to create a caternary loop 362 (Figure 24) between the prises a timing belt 332 and conforming pulleys 334 on stamping station and the roll forming station. the drivescrews and motor 317 around which the belt is [0078] Referring to Figures 25-27, one acceptable reeved. In the illustrated embodiment, the pulley 334 that 30 transfer mechanism 105 comprises a pair of gripping drives the die assembly 252 is larger, since the move- members 364, a conveyor 366, and a conveyor support ment of the die assembly 252 is half that of the movement frame 368 (Figures 23 and 24). The controller selectively of the other die assemblies. This keeps the gas holes causes the conveyor 366 to move the pair of gripping centered on the path of travel of P. The angular position members 364 between the exit of the stamping station of the screws is measured and provided to the controller 35 104 to an entrance of the feed mechanism. It should be 122. In one embodiment, the station width that corre- readily apparent that the transfer could take a variety of sponds to the measured angular position is displayed on other forms without departing from the scope of the a controller screen 123 where it can be read by the op- claimed invention. For example, Figure 28 illustrates an erator. In one embodiment a digital encoder (not illustrat- automatic transfer mechanism that comprises a bridge ed) is associated with one of thejackscrews. The encoder 40 370 that supports the stock material as the stock material is coupled, via the scheduler/motion controller unit 122. is transferred to the feed mechanism 360 and allows the Precise movement of the jackscrews is accomplished stock to droop once the stock is engaged by the feed using the motor 317 linked to and controlled by motion mechanism. Figure 29 illustrates a transfer mechanism control unit 122. that defines a path of travel 361 between the stamping [0075] The stock moves through the forming station 45 station and the roll forming station that includes a droop. 104 intermittently, stopping completely at each location [0079] In the illustrated embodiment, the gripping where it is stamped. The average rate of stock feed can members 364a, 364b are positioned next to the conveyor vary widely from one frame member to the next. For in- 366. A moveable gripping member 364b is coupled to a stance, if the station 104 forms a spacer frame member pneumatic actuator 372. A pressurized air source, cou- for ultimate use in a large "picture" window having no 50 pled to the pneumatic actuator 372, is controlled by the muntin bars, the rate of stock feed is relatively high be- controller 122 to selectively move the gripping member causethestockisstoppedonlytostampthecornerstruc- 364b between an engaged position (shown in solid in tures, the frame ends and to punch holes. The stock Figures 25 and 26) and a disengaged position (shown in moves continuously (and may move rapidly) through the phantom in Figures 25 and 26). The illustrated conveyor station between corner structure locations. 55 366 includes a carriage 374, a rail 376, and an actuator [0076] If the immediately succeeding spacer frame is 378 that moves the carriage along the rail under the con-intended for use in a relatively small window having a trol of the controller 122. The pneumatic actuator 372 is number of muntin bars the stock feed must be stopped mounted to a carriage 374. The controller 122 controls the actuator 378 to move the gripping members between station 104, it falls from the exit of the stamping station the stamping station 104 and the roll forming station 110. and is pulled into the roll forming station. In an alternate embodiment, the transfer mechanism captures the end FEED MECHANISM 360 and transfers it to the roll forming station. 5 [0080] Referring to Figures 30-32, the illustrated feed THE FORMING STATION 110 mechanism 360 comprises a pair of drive rollers 379,380 positioned along the stock path oftravel Pat a processing [0082] Referring to Figures 31-33, the forming station station entrance 382. The pair of drive rollers 379, 380 110 is preferably a rolling mill comprising a supportframe are selectively moveable between a disengaged position 10 structure 442, roll assemblies 444-452 carried by the where the drive rollers are spaced apart and an engaged frame structure, a roll assembly drive motor 454, a drive position where the drive rollers engage a coil end portion transmission 456 (Figure 32) coupling the drive motor positioned at the entrance of the roll forming station 110 454 to the roll assemblies, and an actuating system 458 by the transfer mechanism 105. The drive rollers 379, (Figure 32) for enabling the station 110 to roll form stock 380 selectively feed the sheet stock positioned at the is having different widths. entrance 382 into the processing station 110. In the illus- [0083] The support frame structure 442 comprises a trated embodiment, drive roller 379 is selectively driven base 460 fixed to the floor and a roll supporting frame by a motor 384 that is controlled by the controller 122. assembly 462 adjustably mounted atop the base 460. The drive roller 379 and the motor 384 are pivotally con- The base 460 is positioned in line with the stock path of nected to the station 110. In the illustrated embodiment, 20 travel P immediately adjacent the transfer mechanism the roller 380 is an idler roller that presses the sheet stock 105, such that a fixed stock side location of the stamping 125 against the roller 379 when the drive rollers are in station is aligned with a fixed stock side location of the the engaged position. An actuator 386 is connected to roll forming station. The roll supporting frame assembly the station 110 and the drive roller 380. The actuator 386 462 extends along opposite sides of the stock path of is selectively controlled by the controller 122 to engage 25 travel P. sheet stock 125 positioned at the entrance of the roll form- [0084] Referring to Figure 33, the roll supporting frame ing station 110 by the transfer mechanism. The motor assembly 462 comprises a fixed roll support units 480 384 is controlled to feed the sheet stock 125 into the and a moveable roll support unit 482 respectively dis-station 110. In the illustrated embodiment, a sensor is posed on opposite sides of the path of travel P. The units positioned along the path oftravel P, near the stock feed 30 480,482 are essentially mirror images, with the exception mechanism. The sensor is used to verify that stock 125 that unit 482 is moveable and unit 480 is fixed so only is being fed by the stock feed mechanism 360. the unit 482 is described in detail with corresponding [0081] The controller 122 is in communication with the parts of the units being indicated by like reference char stamping station 104, the gripping member actuator 372, acters. Components that allow unit 482 to move are not the drive roller actuator 386, and the conveyor 366. When 35 included in unit 480. Referring to Figure 33, the top plate stock 125 that defines a series of units is paid out by the 482 comprises a lower support beam 484 extending the stamping station 104, the controller 122 pivots the grip- full length of the mill, a series of spaced apart vertical ping member 364b to the spaced apart, disengaged po- upwardly extending stanchions 486 fixed to the beam sition and positions the gripping members 364a, 364b 484, one pair of vertically aligned mill rolls received be- (check drawings) at the exit of the stamping station 104. 40 tween each successive pair of the stanchions 486, and

This positions the stock material end portion 130 between an upper support bar 488 fixed to the upper ends of the the gripping members 364. The controller then moves stanchions. the gripping member 364b to the engaged or gripping [0085] Each mill roll pair extends between a respective position togriptheend portion. The controller 122 moves pair of stanchions 486 so that the stanchions provide the pair of drive rollers 379, 380 to the disengaged posi- 45 support against relative mill roll movement in the direction tion and moves the gripping members 364 and the end of extent of the path of travel P as well as securing the portion to the roll forming station entrance 382 where the rolls together for assuring adequate engagement presend portion 130 is disposed between the drive rollers. In sure between rolls and the stock passing through the roll one embodiment, the movementofthegripping members nips. The support beam 484 carries three spaced apart from the stamping station 104 to the roll forming station so linear bearing assemblies 489 on its lower side. Each 110 is incremental, with stops that correspond to stops linear bearing is aligned with and engages a respective required to stamp the material in the stamping station. trackway 474 so that the beam 484 may move laterally The controller 122 moves the pair of drive rollers 379, toward and away from the stock path oftravel P on the 380 to the engaged position to engage the end portion trackways 474. In the illustrated embodiment, the oppo-130. The controller 122 rotates the drive rollers 379, 380 55 site unit 480 is fixed . to feed the elongated sheet stock into the roll forming [0086] Each roll assembly 444-452 is formed by two station. When the end of the stock that forms the series roll pairs aligned with each other on the path of stock of spacer frame members is paid out of the stamping travel to define a single "pass" of the rolling mill. That is to say, the rolls of each pair have parallel axes disposed ing the stock without distorting it. in a common vertical plane and with the upper rolls of [0092] The disclosed roll forming station 110 has an each pair and the lower rolls of each pair being coaxial. automatic chain tensionerfor assuring adequate tension

The rolls of each pair project laterally towards the path in the drive chain 518. In a prior art roll forming system of stock travel from their respective support units 480, 5 the drive chain would require periodic chain tension ad- 482. The projecting roll pair ends are adjacent each other justment with resultant down time of the system. The with each pair of rolls constructed to perform the same presently disclosed roll forming station includes a ten- operation on opposite edges of the ribbon stock. The nip sioning sprocket 520 rotatably supported by a movable of each roll pair is spaced laterally away from the center mounting block 521. In accordance with a presently pre line of the travel path. The roll pairs of each assembly n> ferred system atthe conclusion of each strip, the control-are thus laterally separated along the path of travel. ler 122 activates a drive cylinder 522 that has a output [0087] Each roll comprises a bearing housing 490, a shaft coupled to the mounting block 521. This drives the roll shaft 492 extending through a bearing in the housing mounting block down thereby driving the sprocket 520 490, a stock forming roll 494 on the inwardly projecting down and tensions the drive chain 518. end of the shaft and a drive pulley 496 on the opposite 15 [0093] A preferred drive cylinder is air actuated and is end of the shaft which projects laterally outwardly from commercially available as Festő part number KPE-16 or the support unit. The housings 490 are captured between 178467. The air applied to the drive cylinder delivers a adjacent stanchions as described above. uniform tensioning force to the mounting block 521. Prior [0088] The upper support bar 488 carries a nut and to this force being applied by a valving system coupled screw force adjuster combination 500 associated with 20 to the controller, the controller 122 releases a clamp 523 each upper mill roll for adjustably changing the engage- which frees the output shaft for movment. Once the ment pressure exerted on the stock at the roll nip. The sprocket 520 is properly tensioned, the controller applies adjuster 500 comprises a screw 502 threaded into the air through coupling 525 to a brake 524 which clamps upper roll bearing housing 490 and lock nuts for locking the shaft and maintains tension until a next subsequent the screw 502 in adjusted positions. The adjusting screw 25 chain tensioning is performed by the controller 122. is thus rotated to positively adjust the upper roll position [0094] In the exemplary embodiment, the actuating relative to the lower roll. The beam 484 fixedly supports system 458 is driven by the controller to automatically the lower mill roll of each pair. The adjusters 490 enable adapt the roll forming station 110 to the width of sheet the vertically adjustable mill rolls to be moved towards or stock to be presented to roll forming station 110. Refer- away from the fixed mill rolls to increase or decrease the 30 ring to Figure 32, the actuating system 458 shifts the force with which the roll assemblies engage the stock moveable roll laterally towards and away from the fixed passing between them. roll of each roll assembly so that the stock passing [0089] The drive motor 454 is preferably an electric through the rolling mill can be formed into spacer frame servomotor driven from the controller unit 122. As such members having different widths. Referring to Figure 33, the motor speed can be continuously varied through a 35 the actuating system 458 comprises a pair of threaded wide range of speeds without appreciable torque varia- drivescrews 530, a motor 531 that is controlled by the tions. controller 122, and a drive transmission 532 that couples [0090] Referring to Figure 32" the transmission 456 the motor 531 to the drivescrews 530. The drivescrew is couples the motor 454 to the roll assemblies 444- 452 mounted in a bearing fixed to the rails 472. The support so that the roll assemblies are positively driven whenever 40 beam 484 on the moveable side is threaded onto the the servomotor is operated. The transmission 456 com- drivescrew thread so that when the drivescrew is rotated prises a motor output shaft and sprocket arrangement in one direction the moveable beam and its rolls are 512, a drive shaft 514 disposed laterally across the end moved laterally toward the fixed rolls while drivescrew of the rolling mill, a drive chain 516 coupling the motor rotation in the opposite sense moves the moveable rolls shaft to the drive shaft, and drive chains 518 coupling 45 awayfrom thefixed rolls. The moveable beam 484 moves the drive shaft 514 to the respective roll pairs on each alongthetrackways474withtheaidofthelinearbearings opposite side of the rolling mill. The drive chains 518 are 489 during its position adjustment. reeved around the drive shaft sprocket and around [0095] The drive transmission 532 is preferably a tim- sprockets on each roll shaft 492 on each side of the ma- ing belt reeved around sheaves on the drivescrews. The chine. so actuating system 458 is substantially like the actuating [0091] Whenever the motor 454 is driven, the rolls of system 200 described above. Further details concerning each roll assembly are positively driven in unison at pre- the construction of the actuating system 458 can there- cisely the same angular velocity. The roll sprockets of fore be obtained from the foregoing disclosure of the sys- successive roll pairs are identical and there is no slip in tern 200. Details of another suitable roll forming station the chains so that the angular velocity of each roll in the 55 that can be used in accordance with the present invention rolling mill is the same as that of each of the others. The can be found in U.S. patent number 5,361,476 to slight difference in roll diameter provides for the differ- Leopold, which is incorporated herein by reference in its ences in roll surface speed referred to above for tension- entirety.

[0096] Referring to Figures 23 and 24, an upper loop [0100] The swedging body 572 comprises a plate-like feed sensor 550 and a lower loop feed sensor 552 func- base 580 adjacent one lateral side of the frame member tion to ensure that the stock advancing rates of the station path of travel P, a swedge mount member fixed to the 104 and the forming station 110 does not place undue base 580 adjacent the path of travel, and an upstanding stress on the stock 125. The loop feed sensors 550, 552 5 stop member which projects away from the base toward co-act with the controller 122 to control the stock feed the actuator system for limiting the travel of the actuator through the stations 104 and 110. In one embodiment, system as the frame tongue is swedged. the speed of the roll forming station 110 is increased if [0101] The moveable base 580 is supported on the the lower loop feed sensor 552 senses that the caternary bed 570 by way of forming members (see Figure 37) so stock loop is below the lower stock feed sensor. This will 10 the base position is adjustable laterally toward and away reduce the caternary loop 362 (i.e. reduce the amount of from the fixed base 580. The base 580 defines a frame stock between the stations). The controller 122 will stop guide portion 588 extending under the side of a frame the roll forming station 110 or reduce the speed of the member moving along the path of travel P through the roll forming station if the upper sensor 550 senses that swedging station. The guide portion 588 supports the the caternary stock loop 362 is above the upper sensor. 15 frame member on the travel path during swedging. The This will increase the caternary loop 362 (i.e. increase the base member position adjustment shifts the guide portion

amount of stock between the stations). 588 to accommodate different width frame members. A corresponding fixed guide portion 588’ is aligned with the TFIE FORMING STATIONS 114,116 fixed stock edge locations defined by the stamping unit 20 1 04 and the roll forming unit 110.

[0097] Referring to Figures 34-37, the forming stations [0102] The swedge mount member is rigidly fixed to 114,116aredisposedtogetheronacommon supporting the base 580 and projects upwardly. The member sup-unit 550. The controller 122 controls the stations 114, ports the anvil assembly for vertical movement to and 116 to subject the frame members to a swedging oper- away from a frame member being swedged and supports ation at the station 114 and a cut off operation at the 25 the swedging tool assembly 576 for horizontal motion station 116. The swedging operation produces the nar- into and away from engagement with the frame member, rowed frame membertongue section which is just narrow [0103] The anvil assembly 574 is positioned to support enough to be telescoped into the opposite frame end and engage the tongue side wall at the conclusion of the when the spacer frame is being fabricated. The cut off swedging operation to define the tongue side wall shape, operation is performed between the tip of each frame 30 The anvil assembly 574 comprises an elongated anvil tongue section and the adjacent trailing end of the pre- member 590 and a pair of actuator rod assemblies 592 ceding frame member. The tongue and trailing end are supported by the body 572 for transmitting movement joined by a short rectangular tang of the stock material from the actuator system 566 to the anvil member, which is sheared by the cut off operation. [0104] The anvil member 590 has an elongated blade- [0098] The swedging station 114comprisesasupport- 35 likeprojectingelement596extendingdownwardlyforen- ing framework 560, first and second swedging units 562, gagement with the frame member. The lengths of the 564 disposed along opposite sides of the stock path of anvil member 590 and blade portion 596 correspond to travel P and an actuator system 566 for the swedging the length of the frame member tongue wall so that the units. The framework 560 is mounted on top of the sup- element 596 coextends with the tongue and for support- porting unit 550 and is comprised of structural members 40 ingthetonguewallthroughoutitslengthduringswedging. welded together to form an actuator supporting super- [0105] The actuator rod assemblies 592 force the structure above the path of stock travel P and a work blade portion 596 of the anvil member 590 into engage- station bed 570. The bed 570 extends beneath and sup- ment with the frame member during swedging and with- ports the structural members of the superstructure. draw the anvil member from the frame member when [0099] The swedging units 562, 564 are essentially 45 swedging is completed. The rod assemblies 592 are mirror images of each other, with the exception that unit spaced apart with each projecting through a bore in the 562 is laterally adjustable and unit 564 is fixed, and there- swedging member 572. The rod assemblies are identical fore only the moveable unit 562 is described in detail. and therefore only one is illustrated and described. Some parts of the laterally adjustable unit 562 may not [0106] The swedging tool assembly 576 comprises an be required on the fixed unit 564. The swedging unit 562 50 elongated tool body 610 extending through a horizontal engages and deforms one frame member tongue side guide opening in the swedge mount member, a hardened wall to reduce the span of the tongue. This enables the swedging nose element 612 fixed to the end of the body frame ends to be telescoped into engagement when the 610 adjacent the travel path P and an actuating cam el-frame is being assembled. The unit 562 comprises a ement 614 adjacent the opposite end of the body 610. swedging body 572 stationed on the bed 570, an anvil 55 [0107] The cam element 614 has a wedge-like face assembly 574 carried by the body 572 and a swedging which is engaged by a complementary wedge face 615 toolassembly 576 supported by the body 572 for coaction of the actuator system to force the tool assembly to with the anvil assembly 574. swedge the frame tongue. The actuating force serves to move the nose element 612 into engagement with the placement ofthedrivescrew creating the movement. The frame side wall. moveable actuating cam assemblies are moved by the [0108] The nose element 612 is constructed to match swedging unit assemblies via the guide rods 636 (Figure the length of the anvil blade-like element 596 so that the 37) when the lateral positions are adjusted, swedging procedure is completed with the nose element 5 [0114] The angular position of the jackscrew is meas- and the blade-like element confronting along their lengths ured and used by the controller to control the width of the with the frame side wall clenched between them. After station 114. In the exemplary embodiment, the station swedging, the nose element 612 projects slightly from width is automatically set by the controller based on the the swedge mount member to provide a lateral guide for width of the elongated spacer frame 16 formed by the frame members passing along the path P. 10 roll forming station to be provided to the station 114. In [0109] The actuator system comprises a pair of pneu- one embodiment a digital encoder (not illustrated) is as-matic rams 620 attached to the framework 560 above sociated with the jackscrew. In the illustrated embodi-the cut off and swedging stations, an actuator platen 622 ment, the fixed swedging and actuator parts are fixed fixed to the rams for vertical reciprocating motion when such that the fixed reference of the station 114 is aligned the rams are operated, and actuating cam assemblies 15 with the fixed references of stations 104 and 110. 624 supported by the platen for operating the swedging [0115] Referring to Figure 38, the cut-off unit 116 is station. located axially adjacent the swedging unit in the direction [0110] The cam assembly 624 operates the swedging of frame member travel along the path P. The cut-off unit unit 562. The cam assembly 624 includes a camming comprises an elongated cut-off blade 680 extending in a member 634. The lower end of the camming member 20 plane transverse to the direction of the travel path P and defines a wedge face 615 which coacts with the wedge- a pair of blade supporting rods 682 fixed to the platen like face on the cam element 614. The downward travel 622 at their upper ends and fixed to the blade 680 at their of the camming member 634 is the same regardless of lower ends. The blade 680 is laterally wider than the wid-how wide the frame member in the swedging unit might est frame member passing through the unit and extends be. 25 into vertically oriented slots formed in the swedge mount [0111] One of the sets of swedging and actuator parts members 582 on opposite sides of the path P. The are laterally fixed and the other set of swedging and ac- swedge mount member slots are sufficiently wide that tuator parts are movable laterally towards and away from they accommodate and guide the blade 680 regardless the fixed set by an actuating system 650 to desired ad- of the adjusted swedge mount member positions relative justed positions for working on stock of different widths. 30 to the centerline of the path P.

The system 650 firmly fixes the laterally adjustable parts [0116] The actuator system operates the swedging at their laterally adjusted locations for further frame pro- unit at the same time the cut-off unit is operated. Accord- duction. As noted, the laterally moveable parts are sup- ingly, when thetongueatthe leading end ofaframe mem- ported in ways extending transverse to the direction of ber is being swedged the preceding frame member is extent of the travel path P. The actuating system 650 35 cut-offfrom the stock and is free to move from the forming shifts the laterally moveable parts simultaneously along stations 114,116 to the extrusion station 120. Additional the respective ways between adjusted positions. In the details and embodiments of acceptable swedging and exemplary embodiment, the actuating system 650 is driv- forming stations 114, 116 are disclosed in U.S. patent en by the controller. In the exemplary embodiment, the number 5,361,476, which is incorporated herein by ref-width of station 114 is automatically adjusted by the con- 40 erence in its entirety. trailer based on the width of formed spacer frame stock [0117] In one embodiment the forming stations 114, received from the roll forming station. 116 perform their operations without requiring that the [0112] The preferred and illustrated actuating system stock moving along the travel path P be stopped or 650, like the system 200 described above, provides ex- slowed down. This may be accomplished by reciprocat- tremely accurate information regarding placement rela- 45 ing the bed 570 carrying the stations 114,116 relative to tive to the stock path of travel P. The system 650 com- the supporting unit 550 in the direction of the path of travel prises a single threaded drivescrew 652 and a swedging so that the swedging and cut-off operations are per- unit drive member 656 driven by the drivescrew. formed on the stock moving along the path. Details of [0113] The drivescrew 652 is mounted in a bearing as- one acceptable reciprocating mechanism are disclosed sembly 658 connected to the framework 60. The drive- 50 in U.S. patent number 5,361,476 to Leopold, which is screw 652 is threaded into the swedging unit drive mem- incorporated herein by reference in its entirety. ber 656. When the drivescrew rotates in one direction the driving member 656 forces the moveable swedging CONVEYOR 113 units to shift laterally away from the fixed swedging units.

Drivescrew rotation in the other direction shifts the as- 55 [0118] The conveyor 113 transports the formed and semblies toward the fixed swedging units. The threads separatedelongatedspacerframes16fromstations114, on the drivescrew are precisely cut so that the extent of 116 to stations 119, 120 where desiccant 22 and adhe- lateral movement is precisely related to the angular dis- sive 18 are applied. The illustrated conveyor 113 includes vertical supports 800a, 800b, 800c, 800d, an elongated mission. The first output shaft 830 includes threads 850 support 802 that extends along the path of travel, rollers that are threaded into threads in the coupling 834. Rota- 804, 805, a belt 806 disposed around the elongated sup- tion of the shaft by the motor 822 applies force to the cam port and rollers, a motor 808, and a guide 810. The ver- mechanism in the direction of the path of travel, which tical supports 800 position the elongated support 802 5 causes the cam members 840 and the attached guide along the path of travel P. The motor 808 drives roller member to move toward or away from the fixed guide 804 to drive the belt 806. The motor 808 is controlled by member. The motor 122 is controlled by the controller to the controller 122. The belt 806 delivers the elongated control the spacing between the fixed guide member 812 spacerframefrom stations 114,116 to stations 119,120. and the moveable guide member814.

The guide 810 keeps the elongated spacer frames on to [0121] The vertical support 800a is coupled to the elon-the path of travel P. The guide 810 is adjustable to ac- gated support 802 by the conveyor end drive 828 of the commodate spacer frame members of varying widths. adjustment mechanism 820. The conveyor end drive 828 [0119] In the illustrated embodiment, the guide 808 in- adjusts the lateral position of the elongated support 802 eludes a fixed guide member 812 and a laterally adjust- with respect to the vertical support to align the centerline able guide member 814. The fixed guide member 808 is 15 of the conveyor 113 with the centerline of the stations aligned with the fixed reference of station 114. In one 119, 120. The second output shaft 832 is coupled to the embodiment, a pair of conveyor guides of stations 119, conveyor end drive 828. The conveyor end drive 828 120 are symmetrically adjustable with respect to the cent- comprises a coupling 860 secured to the elongated super of the path of travel P. In the illustrated embodiment, port802.Threadsontheoutputshaft832 engage threads the end 816 of the conveyor 113 is automatically posi- 20 jn the coupling 860. Rotation of the shaft by the motor tioned to align the center of the path of travel P defined 822 adjusts the lateral position of the elongated support by the fixed guide member 812 and adjustable guide 802 with respect to the vertical support. Referring to Fig-member 814 with the symmetrically adjustable conveyor ure 42, the elongated support 802 is connected to vertical guides of stations 119, 120. In the illustrated embodi- supports 800b, 800c such that the elongated support is ment, an adjustment mechanism 820 adjusts both the 25 laterally moveable with respect to the vertical supports position of the moveable guide member 814 and the po- 800b, 800c. The elongated support 802 is fixed to vertical sition of the end 816 of the conveyor. Use of a single support 800d. When the conveyor end drive moves the adjustment mechanism assures that the movement of conveyor end, the elongated support 802 moves with re-the moveable guide member 814 is coupled to the move- spect to the vertical supports 800b, 800c. The movement ment of the end 816. It should be readily apparent that 30 at the elongated support 802 is minimal and is accounted separate mechanisms could be used to position the for by flexing of the elongated support. The vertical sup- moveable guide member 814 and the end 816. port 800d acts as a pivot point. The centerline of the con- [0120] The mechanism 820 includes a motor 822, a veyor 113 is substantially maintained in alignment with transmission 824, a guide member drive 826, and a con- the centerline of the station 114 and the centerline of the veyor end drive 828. The motor 822 is controlled by the 35 stations 119, 120 when widths are adjusted. The motor controller. The transmission 824 is coupled to the motor 122 is controlled by the controller to automatically align 822. The transmission 824 includes first and second out- the conveyor. putshafts 830, 832. The first output shaft 830 iscoupled [0122] Intheillustratedembodiment.aseriesofwheels to the guide member drive 826. The guide member drive 803 are attached to the conveyor 113 above the belt. The 826 includes a coupling 834, cam mechanisms 836, and 40 wheels 803 help to maintain the elongated spacer frame linkages 838. Each cam mechanism 836 includes a first members 16 against the conveyor belt. The wheel 803’ member840thatissecuredtotheadjustableguidemem- that is adjacent to the cutoff station 116 is coupled to a ber814 and a second member 842 that is secured to the force application actuator 805 that is controlled by the elongated support 802. The cam members 840, 842 are controller. The actuator 805 selectively urges the wheel coupled together such that the cam member 840 moves 45 803’ toward the conveyor belt. This causes the wheel away from the fixed guide member 812 when force in 803’ to apply pressure to the elongated spacer member one direction along the path of travel is applied to the that is exiting stations 110, 114, 116. In effect, the actu- cam mechanism 836 and the cam member 840 moves ator 805 and wheel 803’ clamp the spacer frame against toward the fixed guide member 812 when force in the the conveyor belt. This allows the conveyor belt to pull opposite direction along the path of travel is applied to so the elongated spacer frame 16 out of the stations 110, the cam mechanism 836. For example, the cam mech- 114, 116. anism may be configured such that movement of 0.250 inches of the cam member 840 in a direction along the SCRAP REMOVAL APPARATUS 111 path of travel results in movement of 0.250 inches of the cam member 840 away from the fixed guide member 55 [0123] lntheillustratedembodiment,ascrappiece294 812. Each cam mechanism 836 is connected to the ad- is stamped at the stamping station 104, roll formed at jacent cam mechanism. The coupling 834 is fixed to the station 110, and separated from the first elongated spac-first cam mechanism 836 that is adjacent to the trans- er at the station 116 each time a new or different stock coil is initially fed into the station 104. This prevents the forms without departing from the scope of the claims. In first elongated unit in the series of elongated units from the example of Figures 45-47, the path of travel altering being scrapped. In one embodiment, the scrap piece 294 mechanism 870’ is in the form of a pair of capturing mem- is automatically removed from the conveyor 113 before bers 900 coupled to a capturing mechanism actuator 902. it reaches the desiccant and adhesive application station 5 The capturing mechanism actuator is controlled by the 120. controller 122 to selectively moving the pair of capturing [0124] Thescrapremovalapparatus111 automatically members 900 between a spaced apart position (Figure removes the leading scrap piece 294 from the conveyor 45) and a scrap engagement position (Figure 46). The 113. The scrap removal apparatus includes a path of translating mechanism 872’ is coupled to the capturing travel altering mechanism 870 and a translating mecha- 10 mechanism for moving the capturing mechanism from a nism 872. The path of travel altering mechanism 870 is capturing position to a discharge position. Referring to positioned along the path of travel P. The path of travel Figures 45 and 46, the controller 122 is in communication altering mechanism 870 selectively facilitates movement with the capturing member actuator 902, and the trans- of the scrap piece off the path of travel. The translating lating mechanism 872’. Referring to Figures 46 and 47, mechanism 872 is in communication with the pathoftrav- 15 the controller moves the capturing members between a el altering mechanism 870 for moving the scrap piece off spaced apart position and a capturing position based on of the path of travel. The controller 122 is in communica- a sensed position of a scrap piece 294 to capture the tion with the path of travel altering mechanism and the scrap piece and stop its movement along the path of trav- translating mechanism. The controller actuates the path el. The controller 122 drives the translating mechanism oftravel altering mechanism when a scrap elongated win- 20 872’ to move the capturing members to the discharge dow component stock is detected and actuates the trans- position and drives the capturing actuator 902 to move lating mechanism 872 to move the scrap elongated win- the capturing members to the spaced apart position to dow component off the path of travel. discharge the scrap piece.

[0125] In the embodiment illustrated by Figures 43 and [0128] Figure 48 illustrates an alternate scrap removal 44, the path oftravel altering mechanism 870 includes a 25 system 111’. In the embodiment illustrated by Figures 48 guide actuator 874 and a moveable guide portion 876. - 50, the translating mechanism includes two pushers

In the illustrated embodiment, the moveable guide por- 910, 912. The pushers 910, 912 have generally round tion 876 is a segment of the fixed guide member 812. contact surfaces 914, 916 facing the path oftravel of the

One guide actuator 874 is coupled to each end of the elongated window component. Two actuators 920, 922 moveable guide portion 876. Each guide actuator 874 is 30 coupled to the controller 122 simultaneously move their also coupled to the elongated conveyor support 802. The respective pusher outwardly away from the position actuators 874 are coupled to a source of fluid pressure shown in Figure 48. Figure 49 illustrates one pusher 912 that is controlled by the controller 122. The controller con- in greater detail. In Figure 49 the pusher 912 has its controls the guide actuators 874 to selectively move the tactsurfaceretractedawayfromthepathoftravelofelon- moveable guide portion 876 to a raised position (shown 35 gated window components as they move along the con- in Figure 44). In the raised position, the guide portion 876 veyor 113. In the position shown in Figure 50 the con- is far enough above the conveyor belt that the scrap seg- trailer 122 has caused the actuator 922 to extend the ment 294 can be moved off of the conveyor. pusher’s round contact surface 916 through the path of [0126] In the embodiment illustrated by Figures 43 and movement followed by the scrap. Simultaneously, the 44, the translating mechanism 872 is a blower. The blow- 40 controller 122 causes the other pusher 910 to engage er is coupled to a source offluid pressure that is controlled the scrap material. Each of the two actuators 920, 922 by the controller 122. The controller controls the blower is an air actuated and coupled to a source offluid pressure to selectively move the scrap piece past the moveable that is controlled by the controller 122. The controllercon- guide portion 876 in the raised position and off of the trols the two pushers to selectively move the scrap piece conveyor 113. In the illustrated embodiment, a sensor 45 beneath the moveable guide portion 876’which is raised 880 is coupled to the controller 122 for detecting the scrap from the position shown in Figures 48 and 49 to a raised piece 294 on the conveyor. The speed of the conveyor position (Figure 50) spaced above the path of travel of 113 is input to the controller by the conveyor 113. The the scrap piece on the conveyor 113. In the illustrated controller uses the speed of the conveyor 113 and input embodiment, a sensor 880 is coupled to the controller from thesensor880todetermine the timewhen the scrap 50 122 for detecting the scrap piece 294 on the conveyor, piece will pass the moveable guide portion 876. The con- The speed of the conveyor 113 is input to the controller trailer 122 then moves the guide portion to the raised by the conveyor 113. The controller uses the speed of position accordingly, and actuates the blower when the the conveyor 113 and input from the sensor 880 to descrap piece is at the moveable guide portion to discharge termine a time when the scrap piece will pass the move- the scrap piece. 55 able guide portion 876’.

[0127] It should be readily apparent to those skilled in [0129] The controller 122 activates two pneumaticly the art that the path of travel altering mechanism and the controlled cylinders 874’ spaced on either side of the translating mechanism could take a variety of different pushers 910, 912 to move the guide portion 876’ to the raised position shown in Figure 50 and actuates the two trol of the production line is closely monitored and exer-pushers 910, 912 when the scrap piece reaches an ap- cised by the controller unit 122. In this regard, it is noted propriate position to discharge the scrap piece 294 to the that the controller unit 122 is capable of directing a preside into a collecting container (not shown). duction run of randomly different length frame members 5 (in which a relatively long frame member can be followed DESSICANT STATION 119 immediately by a relatively short frame member) by con trolling the speed of operation of the various forming sta- [0130] The desiccant application station 119 is control- tions and the ribbon stock accumulations. The controller led by the controller 122 for dispensing of a desiccant 22 unit 122 is also capable of directing a production run of into an interior region of an elongated window spacer 16. 10 randomly different width frame members by controlling

The system automatically selects an appropriate desic- the width of the various forming stations and the coil that cant dispensing nozzle and/or automatically determines is indexed to the uncoiling position. The ability to quickly an appropriate distance D between the desiccant dis- and automatically change spacer frame widths greatly pensing nozzle and the elongated spacerframe member adds to the versatility of the line. The automatic changing 16 based on a property of the spacerframe member 16, is ofwidthallowsspacersforinsulatingglass units thatneed such as a width W of the spacer frame member. The to be remade to be easily inserted into the production station 119 applies desiccant 22 to the interior region of sequence of the line 100 without significant time delays the elongated window spacer 16. The desiccant 22 ap- in production. pliedtotheinteriorregionoftheelongatedwindowspacer [0134] In one embodiment, the controller 122 causes 16 captures any moisture that is trapped within an as- 20 the supply station to begin to change the stock size pro-sembled insulating glass unit. Details of one acceptable vided at the uncoiling position shortly after the desired desiccant application station 119 are disclosed in U.S. amount of stock is paid out, even though one or more patent application 10/922,745, filed on August 20, 2004 downstream processing stations are still processing this and assigned to the assignee of the present application. stock. Similarly, the controller causes each processing U.S. patent application 10/922,745 is incorporated herein 25 station to change to the next width as soon as the oper-by reference in its entirety. ations being performed on the current stock are complet ed, even though other downstream stations are still per-SEALANT/ADHESIVE STATION 120 forming operations on the current stock. This reduces the time required to change widths.

[0131] The extrusion station 120 receives cut off frame 30 [0135] In one method of changing elongated window members from the conveyor 113 and feeds them endwise component widths, a sheet stock coil with a first width is to a sealant applying nozzle location where sealant is automatically indexedtothe uncoiling position.Thesheet applied with the frame member in its unfolded "linear" stock having the first width is provided to one or more condition. After the sealant is applied the frame member downstream processing station(s). The sheet stock hav-isfoldedtoitsfinishedrectangularconfiguration.theends 35 ing the first width is processed at the downstream telescoped and the assembly completed as described. processing station(s). The sheet stock having the first [0132] The controller 122 controls the sealant station width is severed. A sheet stock coil with a second width 120 to dispense of an adhesive 18 Referring to Figure 2, is automatically indexed to the uncoiling position while the station 120 applies adhesive 18 to glass abutting the sheet stock having the first width is being processed walls 42,44 and an outer wall 40 of the elongated window 40 by the downstream processing station. Processing of the spacer 16. The adhesive 18 on the glass abutting walls sheet stock having the first width is completed at the facilitates attachment of glass lites 14 of an assembled downstream processing station. The downstream insulated glass unit. The adhesive on the outer wall 40 processing station is automatically adjusted for process-strengthens the elongated window spacer 16 and allows ing of the sheet stock having the second width. Thesheet for attachment of external structure. The station 120 in- 45 stock having the second width is then provided to the eludes an adhesive metering and dispensing assembly, downstream processing station where the sheet stock an adhesive bulk supply, and a conveyor 32. The pres- having the second width is processed. surized adhesive bulk supply supplies adhesive under [0136] In one method of changing elongated window pressure to the adhesive metering and dispensing as- component widths, sheet stock having afirstwidth is pro-sembly. Details of one acceptable sealant application so vided to a first processing station where it is processed, station 120 are disclosed in U.S. patent number Sheet stock having the first width is provided from the 6,630,029 to Briese et al., which is incorporated herein first processing station to the second processing station by reference in its entirety. where it is processed. The first processing station [0133] The frame members 16 proceed to the sealant processing station is automatically adjusted by the con-applying nozzles where the sealant body 18 is applied. 55 trailer for processing of the sheet stock having a second Afterward, the frame member is bent to its final rectan- width while the sheet stock having the first width is being gular shape and fabrication of the spacer assembly is processed by the second processing station. The second completed. It should be appreciated that operating con- processing station completes processing of the sheet stock having the first width and is then automatically ad- the stock having the first width. When the stock having justed for processing of the sheet stock having the sec- the first width leaves the dispensing stations 119, 120, ond width. the controller drives the dispensing stations to accom- [0137] In the illustrated embodiment, a sheet stock coil modate stock having the second width, with a first width is automatically indexed to the uncoiling 5 [0138] Although the present invention has been deposition. Thesheetstockhaving thefirstwidth is provided scribed with a degree of particularity, it is the intent that to the stamping station 104. The stamping station 104 the invention include all modifications and alterations fall- performs spacer defining stamping operations on the ing within the scope of the appended claims, stock. The transfer mechanism 105 provides the stock from the stamping station to the roll forming station 110. 10

The roll forming station 110 rollforms the sheet stock to Claims form elongated window component stock. The elongated window component stock is provided from the roll forming 1. An apparatus for automatic feeding of elongated station to the swaging and cutoff stations 114,116 where sheet stock (125) from a stamping station (104) into the elongated window component stock is swaged and 15 a roll forming station (110) in a window component severed to form individual elongated window compo- production line, characterized by: nents. The elongated window components are provided from the swaging and cutoff stations 114, 116 to the dis- a) a transfer mechanism (105) between the pensing stations 114,116. The dispensing stations apply stamping station and the roll forming station desiccant and sealant to the elongated window compo- 20 comprising two gripping members (364) for nent. When the stamping station finishes performing its grasping an end portion of the elongated sheet operations on the stock having the first width to define a stock extending from an outlet of the stamping series of spacers having the first width, the controller station and a conveyor(366) for moving the grip- causes the stamping station to sever the stock having ping members and the end portion toward the the first width. The stock driving mechanism 242 drives 25 roll forming station; the leading end of the stock having the first width out of b) a feed mechanism (360) positioned at an en- the stamping station 104. The stock feed mechanism 240 trance to the roll forming station for feeding the reverses to pullthesheetstockoutofthestamping station end portion of the sheet stock moved to an en- 104 and positions it in the clamping mechanism 212 for trance of the roll forming station by said transfer threading into the stamping station at a later time. Once 30 mechanism into the roll forming station; the sheet stock having the first width is removed from the c) a controller (122) in communication with the stamping station 104, the controller drives the stock sup- stamping station, the transfer mechanism and ply to index a sheet stock having a second width to the the feed mechanism for: uncoiling position, even though the downstream stations 110,114,116,119,120 may still be processing the stock 35 j) actuating one of said gripping members having the first width. The sheet stock having the second for engaging the end portion of the stock width is provided into the stamping station 104. The materialthatextendsfromthestampingsta- stamping station 104performsspacerdefiningstamping tion; operations on the sheet stock having the second width, ii) actuating the conveyor for moving the even though the downstream stations 110,114,116,119, 40 gripping members and accompanying stock 120 may still be processing the stock having the first material from the stamping station to a rewidth. When the stock having the first width is driven out gion of the feed mechanism; and of the roll forming station 110, the controller drives the iii) driving the feed mechanism to feed the roll forming station to accept the stock having the second elongated sheet stock into the roll forming width and/or begin processing the stock having the sec- 45 station, ond width, even though the downstream stations 114, 116, 119, 120 may still be processing the stock having 2. The apparatus of claim 1 wherein the stamping sta-the first width. When the stock having the first width is tion and the roll forming station are controlled by the pulled out of the stamping and severing stations 114, controller to create slack in the stock between the 116, the controller drives the stamping and severing sta- so stamping station and the roll forming station that tions 114, 116 to accept the stock having the second causes the stock to droop to allow downstream proc- width and/or begin processing the stock having the sec- esses to be performed independently, ond width, even though the downstream stations 119, 120 may still be processing the stock having the first 3. The apparatus of claim 1 wherein the transfer mech-width. When the stock having the first width leaves the S5 anism comprises a conveyor for moving the gripping conveyor 113, the controller drives the conveyor 113 to members from a first position where the gripping accept the stock having the second width, even though members grip an end portion of the elongated sheet the downstream stations 119,120 may still be processing stock to a second position where the gripping mem- bers provide the end portion to the feed mechanism. rollers positioned at an inlet of the roll forming station; and 4. The apparatus of claim 1 wherein the transfer mech- d) activating a driven one of the pair of drive anism comprises a bridge that supports the stock rollers to feed the elongated sheet stock into the material as the stock material is transferred to the 5 roll forming station. feed mechanism and allows the stock to droop once the stock is engaged by the feed mechanism. 12. The method of claim 11 further comprising monitor ing a width of elongated sheet stock supplied by a 5. The apparatus of claim 1 wherein the transfer mech- stock supply station and automatically adjusting the anism defines a path of travel between the stamping 10 stamping station to accept sheet stock of the moni- station and the roll forming station that includes a tored width and adjusting the roll forming station to droop. accept sheet stock of the monitored width. 6. The apparatus of claim 1 wherein the feed mecha- 13. The method of claim 11 further comprising synchronism comprises a pair of drive rollers positioned at 15 nizing movement of the sheet stock from the outlet an entrance to the roll forming station that are selec- of the stamping station to the roll forming station with tively moveable between a disengaged position and movement of the elongated sheet stock through the an engaged position. stamping station. 7. The apparatus of claim 1 wherein the controller mon- 20 14. The method of claim 11 further comprising coordi- itors a width of elongated sheet stock supplied by a nating movement of the elongated sheet stock stock supply station and automatically adjusts the through the roll forming station and the stamping sta- stamping station to accept sheet stock of the moni- tion such that the sheet stock droops a controlled tored width and adjusts the roll forming station to amount between the roll forming station and the accept sheet stock of the monitored width. 25 stamping station. 8. The apparatus of claim 1 wherein the controller co- 15. The method of claim 11 additionally comprising: ordinates movement of the elongated sheet stock through the roll forming station and the stamping sta- severing the sheet of stock material after a spec- tion such that the sheet stock droops between the 30 ified number of components have been fed into roll forming station and the stamping station. the roll former, retracting the stock material from the stamping 9. The apparatus of claim 1 further comprising a roll station; and former having a chain driven by a motor for driving threading an additional elongated sheet of stock rolls of the roll former and wherein the controller pe- 35 material through the stamping station until the riodically tensions the chain. leading edge of said stock material extends be yond an outlet of the stamping station. 10. The apparatus of claim 1 additionally comprising a cut off station for separating roll formed strip into in- 16. The method of claim 15 wherein the additional elon- dividual window component elements and further 40 gated sheet of stock material is dispensed from a comprising a conveyor for routing said elements supply that is moved into alignment for delivering to away from the cut off station. the stamping station. 11. A method of feeding elongated sheet stock from a stamping station into a roll forming station in a win- 45 Patentansprüche dow component production line, characterized by: 1. Vorrichtung zum automatischen Einspeisen eines a) moving an elongated sheet of stock material langgestreckten Blechrohteils bzw. Blechvorrates through a stamping station until a leading end (125) von einer Stanzstation (104) in eine Walzen- of stock material extends from an outlet of the so umformungsstation (110) in einer Fensterkompo-stamping station; nentenproduktionslinie, gekennzeichnet durch: b) clamping stock material that extends from the outlet of the stamping station with a transfer a) einen Transfermechanismus (105) zwischen mechanism comprising first and second grip- der Stanzstation und der Walzenumformungs- ping members; 55 station, der zwei Greifglieder (364) aufweist, um c) actuating a conveyor for moving the first and einen Endteil des langgestreckten Blechvorra- second gripping members to pull stock material tes zu ergreifen, der sich aus einem Auslass der paid out by the stamping station to a pairof drive Stanzstation erstreckt, und eine Fördervorrich- tung (366) zum Bewegen der Greifglieder und sungsmechanismus ein Paar von Antriebswalzen des Endteils zur Walzenumformungsstation; aufweist, die an einem Eingang der Walzenumfor- b) einen Einspeisungsmechanismus (360), der mungsstation positioniert sind, die selektiv zwischen an einem Eingang der Walzenumformungssta- einer ausgerückten Position und einer eingerückten tion positioniert ist, um den Endteil des Blech- 5 Position bewegbar sind.

Vorrates, der zu einem Eingang derWalzenum- formungsstation durch den Transfermechanis- 7. Vorrichtung nach Anspruch 1, wobei die Steuervor- mus bewegt worden ist, in die Walzenumfor- richtung eine Breite des langgestreckten Blechvor- mungsstation einzuspeisen; rates überwacht, dervon derVorratslieferstation ge- c) eine Steuervorrichtung (122) in Verbindung 10 liefert wird, und wobei sie automatisch die Stanzsta- mit der Stanzstation, dem Transfermechanis- tion einstellt, um einen Blechvorrat der überwachten mus und dem Einspeisungsmechanismus zum: bzw. erkannten Breite aufzunehmen, und wobei sie die Walzenumformungsstation einstellt, um einen i) Betätigen von einem der Greifglieder zum Blechvorrat der überwachten bzw. erkannten Breite

Erfassen des Endteils des Vorratsmateri- 15 aufzunehmen. als, welches sich aus der Stanzstation erstreckt; 8. Vorrichtung nach Anspruch 1, wobei die Steuervor- ii) Betätigen der Fördervorrichtung zum Be- richtung eine Bewegung des langgestreckten Blechwegen der Greifglieder und Begleiten des Vorrates durch die Walzenumformungsstation und

Vorratsmaterials von der Stanzstation zu ei- 20 die Stanzstation so koordiniert, dass der Blechvorrat nem Bereich des Einspeisungsmechanis- zwischen der Walzenumformungsstation und der mus; und Stanzstation durchhängt. iii) Antreiben des Einspeisungsmechanismus zum Einspeisen des langgestreckten 9. Vorrichtung nach Anspruch 1, die weiter eine Wal-

Blechvorrates in die Walzenumformungs- 25 zenumformungsvorrichtung aufweist, die eine Kette Station. hat, die von einem Motor zum Antrieb von Walzen der Walzenumformungsvorrichtung angetrieben 2. Vorrichtung nach Anspruch 1, wobei die Stanzstati- wird, und wobei die Steuervorrichtung periodisch die on und die Walzenumformungsstation durch die Kette spannt.

Steuervorrichtung gesteuert werden, um einen 30

Durchhang im Vorratzwischen der Stanzstation und 10. Vorrichtung nach Anspruch 1, die zusätzlich eine Ab- derWalzenumformungsstation zu erzeugen, der be- schneidestation aufweist, um einen durch Walzen wirkt, dass der Vorrat durchhängt, um zu gestatten, umgeformten Streifen in einzelne Fensterkompo- dass die nachgelagerten Prozesse unabhängig aus- nentenelemente zu trennen, und die weiter eine För- geführt werden. 35 dervorrichtung aufweist, um die Elemente von der

Abschneidestation weg zu leiten. 3. Vorrichtung nach Anspruch 1, wobei der Transfermechanismus eine Fördervorrichtung zum Bewe- 11. Verfahren zum Einspeisen eines langgestreckten gen der Greifglieder von einer ersten Position, wo Blechrohteils bzw. Blechvorrates von einer Stanz- die Greifglieder einen Endteil des langgestreckten 40 station in einer Walzenumformungsstation in einer

Blechvorrates ergreifen, zu einer zweiten Position Fensterkomponentenproduktionslinie, gekenn- zu bewegen, wo die Greifglieder den Endteil zum zeichnet durch:

Einspeisungsmechanismus liefern. a) Bewegen eines langgestreckten Bleches 4. Vorrichtung nach Anspruch 1, wobei der Transfer- 45 bzw. Flächenelementes eines Vorratsmaterials mechanismus eine Brücke aufweist, die das Vorrats- durch eine Stanzstation, bis ein vorderes Ende material trägt, wenn das Vorratsmaterial zu dem Ein- des Vorratsmaterials sich aus einem Auslass speisungsmechanismus übertragen wird, und ge- der Stanzstation erstreckt; stattet, dass der Vorrat durchhängt, sobald der Vor- b) Klemmen des Vorratsmaterials, welches sich rat von dem Einspeisungsmechanismus ergriffen 50 aus dem Auslass der Stanzstation erstreckt, mit wird. einem Transfermechanismus, der erste und zweite Greifglieder aufweist; 5. Vorrichtung nach Anspruch 1, wobei der Transfer- c) Betätigen einer Fördervorrichtung zum Bewe- mechanismus einen Laufpfad zwischen der Stanz- gen der ersten und zweiten Greifglieder zum station und derWalzenumformungsstation definiert, 55 Ziehen des Vorratsmaterials, welches von der der einen Durchhang aufweist. Stanzstation ausgegeben wurde, zu einem Paar von Antriebsrollen, die an einem Einlass der 6. Vorrichtung nach Anspruch 1, wobei der Einspei- Walzenumformungsstation positioniert sind; und fenéire, caractérisé par : d) Aktivieren von einer angetriebenen Walze des Paares von Antriebswalzen zum Einspeisen a) un mécanisme de transfert (105) entre la stades langgestreckten Blechvorrates in die Wal- tion de presse et la station de formage aux rou- zenumformungsstation. 5 leauxcomprenantdeuxélémentsde préhension (364) poursaisir une partié d’extrémitéde la tőle 12. Verfahren nach Anspruch 11, welches weiter eine allongée s’étendant ä partir d’une sortie de la Überwachung bzw. Erkennung einer Breite des station de presse et un transporter (366) pour langgestreckten Blechvorrates aufweist, der von ei- déplacer les éléments de préhension et la partié ner Vorratslieferstation geliefert wird, und das auto- 10 d’extrémité vers la station de formage aux matische Einstellen der Stanzstation, um den Blech- rouleaux ;

Vorrat mit der erkannten Breite aufzunehmen, und b) un mécanisme d’alimentation (360) position-

Einstellen der Walzenumformungsstation, um den né au niveau d’une entrée dans la station de

Blechvorrat mit der erkannten Breite aufzunehmen. formage aux rouleaux pour amener la partié 15 d’extrémité de la tőle déplacée vers une entrée 13. Verfahren nach Anspruch 11, welches weiter auf- de la station de formage aux rouleaux par ledit weist, eine Bewegung des Blechvorrates aus dem mécanisme de transfert dans la station de for-

Auslass der Stanzstation zur Walzenumformungs- mage aux rouleaux ;

Station mit einer Bewegung des langgestreckten c) un Organe de commande (122) en communi-

Blechvorrates durch die Stanzstation zu synchroni- 20 cation avec la station de presse, le mécanisme sieren. de transfert et le mécanisme d’alimentation pour: 14. Verfahren nach Anspruch 11, welches weiter aufweist, eine Bewegung des langgestreckten Blech- i) actionner l’un desdits éléments de pré- vorrates durch die Walzenumformungsstation und 25 hension pour mettre en prise la partié d’ex- die Stanzstation so zu koordinieren, dass der Blech- trémité de la tőle qui s’étend á partir de la

Vorrat um ein gesteuertes Ausmaß zwischen der station de presse ;

Walzenumformungsstation und der Stanzstation ii) actionner le transporteur pour déplacer durchhängt. les éléments de préhension et la tőle qui les 30 accompagne de la station de presse ä une 15. Verfahren nach Anspruch 11, welches weiter Fol- région du mécanisme d’alimentation ; et gendes aufweist: iii) entramer le mécanisme d’alimentation pour amener la tőle allongée dans la station

Abschneiden des Blechvorratsmaterials nach- de formage aux rouleaux, dem eine festgelegte Anzahl von Komponenten 35 in die Walzenumformungseinrichtung einge- 2. Appareil selon la revendication 1, dans lequel la sta-speist worden ist, tion de presse et la station de formage aux rouleaux

Zurückziehen des Vorratsmaterials aus der sont commandées par l’organe de commande afin

Stanzstation; und de créer du mou dans latöle entre la station de pres-

Einführen eines zusätzlichen langgestreckten 40 se et la station de formage aux rouleaux pour amener

Flächenelementes aus Vorratsmaterial durch la tőle ä s’affaisser pour permettre de réaliser indé- die Stanzstation, bis die vordere Kante des Vor- pendamment les procédés en aval, ratsmaterials sich über einen Auslass der Stanzstation hinaus erstreckt. 3. Appareil selon la revendication 1, dans lequel le mé- 45 canisme de transfert comprend un transporteur pour 16. Verfahren nach Anspruch 15, wobei das zusätzliche déplacer les éléments de préhension d’une premiére langgestreckte Blech bzw. Flächenelement des Vor- position dans laquelle les éléments de préhension ratsmaterials aus einem Vorrat ausgegeben wird, saisissent une partié d’extrémité de la tőle allongée derin Ausrichtung zur Lieferung zur Stanzstation be- ä une seconde position dans laquelle les éléments wegtwird. 50 de préhension fournissent la partié d’extrémité au mécanisme d’alimentation.

Revendications 4. Appareil selon la revendication 1, dans lequel le mé canisme de transfert comprend un pont qui Supporte 1. Appareil pour l’alimentation automatique de tőle al- 55 la tőle lorsque la tőle est transférée vers le mécanis- longée (125) ä partir d’une station de presse (104) me d’alimentation et permet á la tőle de s’affaisser dans une station de formage aux rouleaux (110) une fois que la tőle est mise en prise par le méca- dans une chaíne de production de composants de nisme d’alimentation. 5. Appareil selon la revendication 1, dans lequel le mé- une paire de rouleaux d’entraTnement position- canisme de transfert définit une trajectoire de dépla- nés au niveau d’une entrée de la station de forcement entre la station de presse et la station de mage aux rouleaux ; et formage aux rouleaux qui comprend un affaisse- d) activerun rouleau entraíné de la paire de rou- ment. 5 leaux d’entraTnement pour alimenter la tőle al- longée dans la station de formage aux rouleaux. 6. Appareil selon la revendication 1, dans lequel le mé- canisme d’alimentation comprend une paire de rou- 12. Procédé selon la revendication 11, comprenant en leaux d’entraTnement positionnés au niveau d’une outre l’étape consistant á surveiller une largeur de entrée dans la station de formage aux rouleaux, qui 10 la tőle allongéefournie par une station d’alimentation sont sélectivement mobiles entre une position déga- de tőle et ajusterautomatiquement la station de pres- gée et une position mise en prise. se pour accepter la tőle de la largeur surveillée et ajuster la station de formage aux rouleaux pour ac- 7. Appareil selon la revendication 1, dans lequel l’or- cepter la tőle de la largeur surveillée. gane de commande surveille une largeur de la tőle 15 en feuille allongée fournie par la station d’alimenta- 13. Procédé selon la revendication 11, comprenant en tion de tőle et ajuste automatiquement la station de outre l’étape consistant ä synchroniser le mouve- presse pour accepter la tőle de la largeur surveillée ment de la tőle de la sortie de station de presse jus- et ajuste la station de formage aux rouleaux pour qu’á la station deformage aux rouleaux avec le mou- accepter la tőle de la largeur surveillée. 20 vement de la tőle allongée ä travers la station de presse. 8. Appareil selon la revendication 1, dans lequel l’or- gane de commande coordonne le mouvement de la 14. Procédé selon la revendication 11, comprenant en tőle allongée ä travers la station de formage aux rou- outre l’étape consistant á coordonner le mouvement leaux et la station de presse de sorté que la tőle 25 de la tőle allongée ä travers la station de formage s’affaisse entre la station de formage aux rouleaux aux rouleaux et la station de presse de sorté que la et la station de presse. tőle s’affaisse selon une quantité contrölée entre la station deformage aux rouleaux et la station de pres- 9. Appareil selon la revendication 1, comprenant en se. outre un formeur á rouleaux ayant une chaTne en- 30 traTnée par un moteur pour entraíner les rouleaux du 15. Procédé selon la revendication 11, comprenant de formeur du rouleau et dans lequel l’organe de com- plus les étapes consistant a : mande tend la chaTne de maniére périodique. couper lafeuille de tőle aprés qu’un nombre spé- 10. Appareil selon la revendication 1, comprenant de 35 cifié de composants ont été ámené dans le dis- plus une station de coupe pour séparer la bande positif de formage aux rouleaux, formée par le rouleau en éléments de composant de rétracter la tőle de la station de presse ; et fenétre individuels et comprenant en outre un trans- enfiler une feuille allongée supplémentaire de porteur pour acheminer lesdits éléments á distance tőle ä travers la station de presse jusqu’ä ce que de la station de coupe. 40 le bord d’attaque de ladite tőle s’étende au-delä d’une sortie de la station de presse. 11. Procédé pour alimenter une tőle allongée ä partir d’une station de presse dans une station de formage 16. Procédé selon la revendication 15, dans lequel la aux rouleaux sur une chaTne de production de com- feuille allongée supplémentaire de tőle est distribuée posants de fenétre, caractérisé par les étapes con- 45 ä partir d’une alimentation qui est déplacée en ali-sistant á : gnement pour la distribution ä la station de presse. a) déplacer une tőle allongée ä travers une station de presse jusqu’ä ce qu’une extrémité d’attaque de la tőle s’étende á partir d’une sortie de 50 la station de presse ; b) serrer la tőle qui s’étend á partir de la sortie de la station de presse avec un mécanisme de transfert comprenantdes premier etsecond éléments de préhension ; 55 c) actionner un transporter pour déplacer les premier et second éléments de préhension pour tirer la tőle déroulée par la station de presse vers

REFERENCES CITED IN THE DESCRIPTION

This list of references cited by the applicant is for the reader's convenience only. It does not form part of the European patent document. Even though great care has been taken in compiling the references, errors or omissions cannot be excluded and the EPO disclaims all liability in this regard.

Patent documents cited in the description • US5361476A, Leopold [0011] [0016] [0095] [0116] · US 922745 A [0130] [0117] · US 6630029 B, Briese [0132] • US 92274504 A [0130]

Claims (5)

1. ABLAKUL» fRÖFSL T<3pI|lTip: SZABADALMI IG&amp;WÖNTOK 1 Barend ezes hosszúkás booma-mez profi! (1S5) automatikus adagQiásárs sajtóid munkáik iomáéföi <104) nayitö munkaaliomássa {1101 ablakgyártó gyártósoron, azzal ief/emezve hogy a) lüuáhbitö marhán izmussal {100; vas ellátva a sapló munkaállomás és a hajlító munkaállomás közöli, amely két megfog ősiemmel {364} van kialakítva, amely arra szolgál, hogy a hosszúkás finomlemez profil vegezakeszát megragadja, ahol s i nomlemsz prof» a sajtóié munkaállomás Kimenete és szállítószalag {3661 között húzódik annak érdekében hogy a ütő munkaállomás samuna mozgassa 0) adagoló mechanizmussal 1300} van dpya. aátaly .a najlltö ÄIÜÄ^# nál van annak érdekábén hogy a hajlító mgnkastiömás bejárstihéz érkező: friöta-lenses profil végszakaszát a továbbító mechanizmussal a hajihó munkaállomásra juttassa·:; o} szabaiyotóegységet fi22), amely ósiió^tefásben varra sápié muhkaállömás^t ahol a továbbító mechanizmus és az adagoló mechanizmus mm szolgál, hogy 0 működtesse a msgfogóekmiék hogy ónnfkázésp lépjen a finpmfemez ριβ vliszakaszivai, amely kiéli a sápié munkaállé-másból· tíj működtesse a ézáliltószatagot annak érdekében, hogy a n-vegfogóelemekei mozgassa és a finomlemez profín éikísáp a aallölé mechanizmus tartományába; és hl) meghajtsa az adagoló mechanizmust annak: éc$ifc£b^Jfe$y· 'é:bóMiőKiS:· finomlemez profilt a hajlító munkaállomásra adagofä.
2. 2, Az 1 tpénvpom szer nfi berendezés ahol a sajtoló munkaállomást és a hajiho munkaállomást a szabálpáóetern vezérli annak érdekében, hogy hézagot hozzon léire shifKihÄii·&amp;Ä;köl-zóU a sajtoló állomás és a hajlító munkaállomás között, amelynek kovetkeitl^h^pÄ^t^i'eZili,.. hogy lehelévé tegye a következő eljárásuk független végrehajtását 3 Az 1 igénypont szer:ni. berendezés, ahol a továbbító mechanizmus tartalmaz egy szállító-szaiagot. amely a megfogóetemek mozgatására szolgái alsó helyzetükből, ahol a megfogöeiemek megragadják a hosszokás finomlemez profil végét egy második helyzetbe, ahol a roegfbgóeismek az adagold mechanizmus végét alkotják
3. 4. Az :. igénypont szerinti berendezés, ahol a továbbitó mechanizmus tartalmaz egy hidat, amely alátámasztja a finomlemez profilt anent a finomlemez profil továbbítódik az adagoló menha-nizmusiól anoak érdekében. hogy tehetővé tegye a profil belógását, ha a pmfsl érintkezésbe ifóp áh ad agoiö mecha n izmussal. δ. Az ι. berendezés, ahol a továbbad mecháf|zmüs továbbítást |>é^él ba- tirnzmeg a sáplö munka||tgmid és. a hajlító nwíÍ^|jKg$tg&amp; kősóit. %f*ßU belógást tartalmaz: 6. A?. 1 igénypont szennii berersdazés. ahoi az adagold mechanizmus tartalmaz agy pár mogh^^É idilli amelyek a hajlító munkaállomás bejáratánál vannak kiképezve, é$ amalyak ^lÄ fty mÉÖ|n moaietHatök agy távoli helyzetéé agy helyzet között ?. Az 1. igénypont szerinti berendezés, ghel a szabályozó egysig figyeli a hosszákp ßhomk igrgp profi ézlígssfg#, ameíyftagy profiladagoló munkaállomás továbbit, ás automatihgep szabá* fytvtza a sajtosé munkaállomást annak éfdakéöárk hogy elfogadja a megfigyelt széíesflgö finomlemez profilt ás szabályozza a hajlító munkaállomást annak árpákéban, bogy elfogadja a megfigyelt szelességé finomlemez prolim B Az 1 igénypont szerinti berendezik ghpi a szabályozd egység koordinálja a hosszúkás 0-nomlemez profil mozgását a bajlitá mnns-aáHomáson ás a sajtoló munkaállomáson át ágy. nogy a fl-notnlernez profn beióg a hajitto moráaatiomisés ä sájtoió munkaállomás kozott. 9 Az ; igénypont szerinti berendezési amely továbbá tartalmaz egy görgős hajfitőt amely·' nek lánca van. amelyet agy motdr bajt mag abbék érdekében, hogy a górgós hajlító megkap henger rest meghajts«, és ahol a pzaplyazö egységrpéööbikeMh megfeszíti a lábból
4. 10. Az 1. igénypont szerinti hárendezéei amely tárta imaz egy detiböié mártkaátlömást annak érdekében bogy szétválassza a hengerelt eleméket egyedi ablakaiémbkké^ tokibbé íedalmáz égy :széliitószalagot amely ama szolgál, hogy attevpílip az elemeket a daratW'^dbiüÜiÜMv'-
5. 11. Eljárás hosszúkás finomlemez profit adagplípra ssjtolö; monkséliomásieí bellfib mbhke-állomásig abiakelem gyártósoron, azzaljfeáemazve, begy; a) hosszúkás finomlemez proliit mpzgafpzfk aapió: dionkaállemásón Ä mibóaőöig, amíg a finomlemez gmfII eibíae vágszákasza kinyúlik a b) összekájxaoljuk a finomlemez prmiii amely kinyúlik a shield munkaállomás kimenetén egy tovibiflt mechanizmussal. amely első és második rnagfogdétetbekiáliélt: 4$ működtetőnk egy száilitészalsgot annak érdekÉiaén. jhőgy elmozdítsak az elé és második megfogóeiemeket azért, hogy elhúzzuk a finomlemez profilt., amely kibukkan a sajtoló munkaállomásból egy pár meghajtó hengerhez* amelyek a hapííő munkaállomás bemeneténél vannak rés d) aktiváljuk a meghajtó görgő pár egyikét annak érdekében, hogy ázlovihbiísa a hosz* szukás finomlemez profittá hajlító munkalliomáehoz. 12 Ä 11 igénypont szerinti eljárás, amelynek során továbbá megfigyeljük a hosszúkás ft.-flptemez profil szélességéi amelyet egy profiladagolő államáé edigel, és auiomankusan szabi-lózzuk a sápló munkaállomást annak érdekében, Hogy epgadja a megfigyelt szélességű finomie* mez profilt és szabályozzuk a hajlító munkaállomást §ηηΦ érdélben, hogy aibgadm a megfigyelt szélességű finomlemez profilt 13 A 11. igénypont szénné eljárás. amelynek során továbbá a finomlemez prtiia sejtolö munkaállomás kimenetétől » hajlító munkaállomásig á'.Íteszúkéá:%om^er^^i.i:^j^ói.hiu8ksák· iomáaon áj |p^ltt|:rni^iá|^i'.s^^i^^^e rnezgáleki 14 All. Igény pont szerinti ;á|árás. üMf i fÄ«is fifiomfemex prolii koordinált mosgésát » Miiéi mbbkaállomásbri és 'ilüp^- M ü$% hogy a finom-« •iámez profil szabályozott mértékbori béiég a hflílé;rtiPé1«ééBomá4 és é sájtbié rrmrikaálloméé késéit, 15 A 11 igénypont szennfi eltérés ampipéiéSOfán meg tovább lépésekbém domboljuk a énomtemés pmfik, miután $ρ fbághaiaroiíotf ssámn aikatré&amp;gf bésdé|öftoék é görgős hajiítéba. majd vissashuxzuk a bnomfemM ^öfá^éájtold'inüTika^fen^áí; és agy befűzünk ogy további hosszúkás hnomiomss prolié a sajtóié muokaaiiomásro rmndaddlg. amlf a lbérti|ém&amp;s profit eibisö vágsxakaszá tölnyiM a sajtaíé munkaállomás kimenetén*. 1β. A 15 igénypont számíts aljámé ahol a további hoaszuMa o flnömsOSúsz profit olyan ads-goíébéí adagoljuk. urnah egyvonasba mozdul annak érdekében, hogy a sajtoló munkaállomást ekés- SW·