Title: Numerically controlled pyramid roll forming machine

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Abstract: As a part to be contour formed passes through the rolls of a pyramid roll forming machine, the vertical position of the upper roll is continuously controlled. Specifically, upper roll position feedback signals are summed with position command signals and the resultant position error signals used to control hydraulic actuators. The hydraulic actuators, in turn, control the position of the upper roll. In an elongate pyramid roll forming machine (e.g. one designed to contour panels or plates) both ends of the upper roll are controlled such that the axis of the upper roll may be skewed with respect to the axes of the lower set of pyramid rolls, or lie parallel to the axes of the lower rolls. In such a machine the positions of the ends of the upper roll are continuously controllable as a part is being contour formed. In a narrow pyramid roll forming machine (e.g. one designed to contour structural parts) the vertical position of the upper roll alone is controlled, as opposed to controlling each end of the upper roll. In either case, synchronization is provided by controlling the rate of summation or comparison between position feedback signals and position command signals. Rate control is provided by sensing the rate of movement of the part through the pyramid roll forming machine and using the resultant rate information to control the rate of feedback and command position signal comparison. Part springback may be sensed and the resultant information used to modify the position errors signals prior to their being used to control the position of the upper roll.


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