Title of Invention	BAR CORRUGATING MACHINE
Abstract	A corrugating machine to corrugate desired shapes and dimensions from metal strips or sections by cold or hot working process. Corrugated profiles are formed in single pass while strip or section is passing through rotation corrugating roller dies with the same pitch circle velocity.

Full Text

FIELD OF THE INVENTION This invention relates to a fabrication machines, particularly to a corrugating machine and more specifically to a corrugation machine for use in fabrication industry for uniformly corrugating metal or non-metal sections such as flat, round, square, or the like. BACKGROUND OF THE INVENTION Corrugating machines are known in the art They are generally used for the corrugation of plain metal sheets or Kraft paper or plastic of Asbestos sheets into one used as roofing sheets and for automobile body building and for making corrugated cartoon boxes. Further GB 631154 teaches a machine wherein the formation of corrugations progresses in steps from the centre of the sheets towards their ends, the sheets being acted upon from both sides by sectional dies, the die sections having continuous profiles and being successively brought into action on the sheets during one operation. In this manner, a plurality of corrugations is formed in each step and the sheets are gripped positively at either side during the whole operation. The method according to the invention is applicable to sheets both of tow and of high tensile strength. But the said machine in the prior art is a rigid, inflexible machine which cannot be employed to generate newer designs. It is also known from US 4875354 a machine for adjustable longitudinal corrugating of sheet materials, particularly of metal with step wise folding/bending over free-running rollers and counter rollers, so that alternating longitudinal convex and concave corrugations are formed. At each profiling step there are upward and downward forming rollers which can be individually adjusted laterally to the direction of the corrugation. Separate from the forming rollers there are atleast one set of drive rollers and counter rollers where both the drive rollers and the counter rollers can be adjusted laterally to the direction of corrugation. As in the earlier case this invention also is rigid and cannot be used for vertical corrugations. US2006083805A1 teaches a corrugating machine comprising a guide path along which a sheet of flexible material can be fed, a pair of rotatable members between which the guide path extends, and a plurality of elongate corrugating formers which can be engaged with and disengaged from the rotatable members. The rotatable members are spaced so that in use the elongate corrugating formers, when engaged with the rotatable members, cooperate to form corrugations in the flexible sheet as the flexible sheet passes between the rotatable members. The disclosed machine is very heavy and complex, which will increase the overall cost of operation. Therefore it is essential and a need to overcome the disadvantages of the prior art There is also a need to design a machine that is versatile. OBJECTS OF THE INVENTION The most important object of the present invention is to provide a corrugation machine that is not huge and heavy and employed to materials hard and soft It also another object of the invention to invent a machine that is versatile, which can be effectively used to make different designs and profiles. It is also another important object of the invention to design a machine that is cost-effective. SUMMARY OF THE INVENTION In one of the important embodiment a corrugating machine comprising of a first shaft and second shaft placed parallel to each other on a desired plane in a single stand to carry a power transmission means and a plurality of dies to corrugate the feed material into a desired shape, a handle to adjust the alter the position of the said first shaft relative to that of the said second shaft, a first guide at the first side of the machine to receive the said feed material and second guide at the second side of the machine to remove the corrugated material is described here. In another embodiment a method of corrugating a feed material on a machine comprising of a first shaft and second shaft placed parallel to each other on a desired plane in a single stand to carry a power transmission means and a plurality of dies to corrugate the feed material into a desired shape, a handle to adjust the alter the position of the said first shaft relative to that of the said second shaft, a first guide at the first side of the machine to receive the said feed material and second guide at the second side of the machine to remove the corrugated material is described here In yet another important embodiment a method of corrugating a feed material comprising the steps of: a. Cutting the said feed material to a required length b. Straightening the said feed material c. Feeding the feed material to the feed side of the said machine d. Adjusting the distance between the plurality of dies e. Removing the corrugated material at the output end of the machine is described herein. BRIEF DESCRIPTION OF THE DRAWINGS FIG 1 shows the side view of the section A-B of an embodiment FIG 2 shows a sectional view across the section A-B of an embodiment FIG 3 shows an embodiment of the corrugating machine when in use FIG 4 shows an embodiment of the corrugating machine when in use. FIG 5 shows a sectional view of another preferred embodiment FIG 6 shows a preferred embodiment in use FIG 7 shows some representative shapes FIG 8 snows some representative shapes FIG 9 shows some representative shapes FIG 10 shows a typical single die machine FIG 11 shows a multi-die machine. FIG 12 shows a representative design and shape of the final output made using one of the preferred embodiments FIG 13 shows a representative design and shape of the final output made using one of the preferred embodiments FIG 14 shows a representative design and shape of the final output made using one of the preferred embodiments FIG 15 shows a representative design and shape of the final output made using one of the preferred embodiments FIG 16 shows a representative design and shape of the final output made using one of the preferred embodiments FIG 17 shows a representative design and shape of the final output made using one of the preferred embodiments DETAILED DESCRIPTION A brief description of the major components used in the machine is given below for easy reference: BODY Its purpose is to support the whole system and gives sturdiness to the machine. The structure is fabricated out of metal plates or of mild steel channels or angles or the like. PLATE BODY:- Accurately machined and stress relived steel plate body gives sturdiness' to whole system and is incorporated into the structure. In this the tower and upper corrugating roller dies are fitted in flanges or bearing housings made in body. M. S. CHANNEL OR ANGLE BODY:- Required size of M. S. Channels or M.S. angle are cut into required lengths and are welded together to form the body to house the machines mechanisms. CORRUGATING ROLLER DIES:- Corrugating roller dies are the mam component of the machine and are designed perfect for forming of corrugated shapes and are made up of suitable cast iron or cast steel or alloy steel which are machined and surface hardened for long lasting accuracy and to with stand wear tear of the surface due to severe rubbing of the rotating dies with the stock. SHAFTS:- The shafts are made of hard metal. The shafts carry the gear wheels and the die. POWER TRANSMISSION MECHANISM: - The purpose is to transmit high torque to each roller to corrugate the feeding stock. Any of the following transmission system may be employed. CHAIN AND SPROCKET DEVICE Generally this type of device is preferred tor high output speed when the corrugating section is not heavy. SPUR OR HELICAL GEAR TRAIN Machine cut alloy steel gears are fitted to the shafts carrying the corrugating roller dies as shown in the figure and to facilitate the dies to roll without overrun or slippage. DRIVES This machine can be operated either manually by rotating a hand wheel or by employing a power drive like electric motor. Generally A/C Electric motor or gear box with separate electric motor or geared motor operation on 415 V mounted in a convenient place is provided. FEEDING AND GUIDING DEV1CES:- To feed the straightened and leveled stock in to the machines rotating corrugating dies more accurately, a stock feeding guide plates or meshing two rollers with grooves corresponding to the cross section of the stock are provided at the loading side of the machine and plate guides are provided on the unloading side of the machines to guide and prevent the corrugated section from any possible twists in the lateral and side wise directions while corrugation takes place in the running machine. The invention is better understood by going through the detailed description given herein with reference to the drawings. As the name suggests metal section corrugating machine forms corrugation of desired shapes and dimensions from metal strips or sections by cold or hot working process. Corrugated profiles are formed in single pass while strip or section is passing through rotation corrugating roller dies with the same pitch circle velocity. While comparing this process with other metal corrugating process, the roller forming gives maximum output speed at less energy consumption. It is a continuous process and the machine is price effective and gives maximum dimensional accuracy of corrugation than other process. Depending upon the requirements and convenience, these machines can be either horizontal or vertical. The two major embodiments along with accompanying embodiments are explained here. Referring to FIG 1, FIG 2 and FIG 3 and FIG 4, two main shafts(13,16) placed horizontally parallel to each other on the vertical plane carry the corrugating dies(14,l5) and external spur or helical gear pair(1,7) with the equal number of teeth keyed to the shafts(13,16). The main shafts (13,16) rotate in the opposite directions. The shafts (13, 16) are rotatably supported on anti-friction or bush bearings (21,22,25,26). The gears(l,7) make the corrugating dies(14,15) to rotate without any overrun or slippage as they are non-contactive to each other and are powered by rightly selected standard reduction gear box or geared motor (19). In the hand driven type a handle is used to rotate the die pairs (14, 15) through gear train. In the constant center distance type, the main shafts (13,16) center distance is fixed and in the variable center distance type, the main shafts (13, 16) center distance can be varied to get varied height of corrugation with same pitch distance. In another embodiment referring to FIG 5 and FIG 6 two main shafts (37,39) placed vertically parallel to each other on the vertical plane carry the corrugating dies(l4,l5) and external spur or helical gear pair (38, 40) with the equal number of teeth keyed to the shafts(37,39). The main shafts (37, 39) rotate in the opposite directions. The shafts (37, 39) are rotatabty supported on anti-friction or bush bearings (21, 22,25,26). The gears(38,40) make the corrugating dies(14,15) to rotate without any overrun or slippage as they are non-contative to each other and are powered by rightly selected standard reduction gear box or geared motor (19). In the hand driven type a handle is used to rotate the die pairs (14, 15) through gear train. In the constant center distance type, the main shafts (37, 39) center distance is fixed and in the variable center distance type, the main shafts (37, 39) center distance can be varied to get varied height of corrugation with same pitch distance. The corrugating dies (14,15) are made up of single piece and are accurately positioned on the main shafts(13,16,37,39) with keys. A number of corrugating dies of different shapes and sizes are keyed to the shafts or it can be keyed one pair at a time depending upon the profiles of corrugation. Separate dies are used for each corrugating profiles. Success and quality of the end product lie on design of corrugation forming dies. Design process is rather practical supported with technical theories. When the stock is fed in between the rotating corrugating roller dies and non-uniform velocity of the contact surface of dies with the stock produce severe rubbing of the stock with the roller peripheral surfaces which results in high wear and tear of the same and thus reduces the life of the costly dies. This could be greatly eliminated by adopting another version of series of hardened cylindrical steel rollers along the circumferential periphery of the corrugating rollers as shown in the figure. The rollers are made up of alloy steel which are perfectly machined and hardened for long lasting accuracy. The corrugating roller dies are meshed each other accurately with the clearance to accommodate the stock and thus there will not be any direct contact between the dies. The perfect rotation of the non contacting roller dies is made possible by the rotation of the main gears. The pitch velocity of the corrugating rollers is established in such a way that the complete corrugation is possible in one single pass. The great majority of up to date machines will have as their drive the three phase single speed induction motor in conjunction with the speed reduction gear box. The speed reduction gear box is housed in the machine stand. A typical gearing diagram of this machine shown in the figure 4 and a development through the speed gear box shafts is shown 1 & 2. The speed reduction gear box is driven through V belts from a single speed motor housed in the machine stand. In another embodiment, the speed gear box is arranged in a separate housing which is located outside of the stand. The output shaft of the gear box is linked to the drive shafts of the machine through V belts. This is known as a separate drive which provides smoother rotation. In another model the speed gear box is powered through V belts from a separate motor mounted on a bracket at the side of the machine. The belt tension is adjusted by moving the motor along the plate on which it is mounted. An adjustable center to center distance of the corrugating dies is employed to get different heights of corrugated figures while maintaining same pitch distance as shown in the figures. This is achieved through the movable bearing housings mounted on the upper die carrying shafts and is raised or lowered by a hand wheel attached to the threaded shafts which in turn is connected to the bearing housings. By doing so the center to center distance of the gear pair may get varied and at some point of time the gears go out of meshing and no rotation of the upper gear is possible from the lower gear. To solve this problem a pair of additional idle gears with the same number of teeth is made to mesh each one with the main gear pair. A proper supporting for these gears are made in the arms. By this mechanism the rotation of the driven gears are possible in the desired direction even these go out of contact The FIG 2 and FIG 5 clearly shows this mechanism. Thus by employing the dies with different pitch the adjustable center distance method gives many sizes and shapes of corrugation with different pitch and height in a single machine. Corrugated figures may be of single geometrical figures or the combination of two or more geometrical figures with constant or variable pitch and height of corrugation. Typical corrugated figures with different combination of geometrical figures are shown in the figures FIGs.7,8 & 9. FIG 10 shows a typical single die machine and FIG 11 shows a mutti die machine. In yet another embodiment, in a method of corrugating the metal plate the said machine is employed where the stock of ductile metal section such as mild steel fiat round, square or like available in the market are first cut to required length and are possibly having the manufacturing defects such as twists or bends are first removed by straightening manually by hammering or mechanically by suitable machines or devices. The cut and straightened stock is then fed into the running machine in between the rotating corrugating dies from one end i.e. the loading side of the machine. The stock trapped in between the rotating dies gets press bend and come out from the other side of the machine i.e. unloading side in corrugated form. Thus obtained corrugated sections may again have possible twists which can be removed again manually or mechanically. The sections thus obtained are made to small bundles for easy transportation to the users or the traders. For every corrugating shapes, separate dies are used. Examples of such designs, shapes are provided in the drawings. This corrugated sections could be combined together to get new designs as shown in FIG 8 and FIG 9 and are mainly used in fabrication industries for the fabrication of window, door or compound gate grills, and rolling grill shutters etc. The machines working model along with dies had been developed and tested and its performance are quite satisfactory. However further modifications are to be carried out for the development of its production as well as prototype model to establish its technical specifications. I claim, 1. A corrugating machine comprising of a first shaft and a second shaft placed parallel to each other on a desired plane in a single stand to carry a power transmission means and a plurality of dies to corrugate the feed material into a desired shape, a handle to adjust the alter the position of the said first shaft relative to that of the said second shaft, a first guide at the first side of the machine to receive the said feed material and second guide at the second side of the machine to remove the corrugated material. 2. A corrugating machine as claimed in any of the preceding claims wherein the said plane is a horizontal plane. 3. A corrugating machine as claimed in any of the preceding claims wherein the said plane is a vertical plane. 4. A corrugating machine as claimed in claim 1 wherein the said machine is operated by manual means. 5. A corrugating machine as claimed in any of the preceding claims wherein the said machine is operated by an electric motor. 6. A corrugating machine as claimed in any of the preceding claims wherein the said power transmission means is a gear train. 7. A corrugating machine as claimed in any of the preceding claims wherein the said power transmission means is a belt drive 8. A corrugating machine as claimed in any of the preceding claims wherein the said transmission means is a gear train, belt drive and the like. 9. A corrugating machine as claimed in any of the preceding claims wherein the said die can be of any desired shape and design. 10. A method of corrugating a feed material on a machine comprising of a first shaft and a second shaft placed parallel to each other on a desired planein a single stand to carry a power transmission means and a plurality of dies to corrugate the feed material into a desired shape, a handle to adjust the alter the position of the said first shaft relative to that of the said second shaft, a first guide at the first side of the machine to receive the said feed material and second guide at the second side of the machine to remove the corrugated material. 11. A method of corrugating a feed material comprising the steps of a. Cutting the said feed material to a required length b. Straigntening the said feed material c. Feeding the feed material to the feed side of the said machine d. Adjusting the distance between the plurality of dies e. Removing the corrugated material at the output end of the machine 12. A corrugating machine as herein described in the description and the accompanying drawings 13. A method of corrugating as herein described in the description and the accompanying drawings

Documents:

2361-CHE-2006 AMENDED PAGES OF SPECIFICATION 29-04-2011.pdf

2361-che-2006 amended claims 15-07-2011.pdf

2361-CHE-2006 AMENDED CLAIMS 29-04-2011.pdf

2361-CHE-2006 CORRESPONDENCE OTHERS 15-07-2011.pdf

2361-che-2006 form-1 15-07-2011.pdf

2361-che-2006 form-13 15-07-2011.pdf

2361-CHE-2006 EXAMINATION REPORT REPLY RECIEVED 29-04-2011.pdf

2361-CHE-2006 FORM-13 13-09-2010.pdf

2361-che-2006-abstract.pdf

2361-che-2006-claims.pdf

2361-che-2006-correspondnece-others.pdf

2361-che-2006-description(complete).pdf

2361-che-2006-drawings.pdf

2361-che-2006-form 1.pdf

2361-che-2006-form 26.pdf