A vehicle reinforcement beam is roll formed from a metal sheet to provide a multi-tubular reinforcement beam that includes two adjacent tubular sections that share a common center wall. The outer sections the metal sheet extend from opposing ends of the common center wall and are formed to enclose the adjacent tubular sections. An edge portion of the metal sheet that is bent to have a bend radius of about 3-9 mm, where the edge portions attach in abutting and continuous contact with the common center wall to form crevices between the adjacent tubular sections along the first and second faces. A weld is formed in each of the crevices to define crevice ribs in general alignment with and at each of the opposing first and second ends of the common center wall that are configured to improve bending strength and torsional strength of the reinforcement beam.

A method for producing a flat spiral spring formed as an annular disk-shaped segment, wherein a strip-shaped material is supplied in a tangential alignment to the lateral surface of the drum such that a lateral wall which determines the thickness of the strip-shaped material rests against some sections of a contact surface on the lateral surface of the drum. The contact surface of the drum has a radius which substantially corresponds to an internal radius of the strip-shaped material, and at least one deflecting device is aligned at a distance to the drum such that the strip-shaped material is guided in a forced manner between the drum and the deflecting device, and the strip-shaped material is bent so as to follow the drum by means of the deflecting device.

Forming roll units included in an apparatus for manufacturing a roll-formed component each include a roll pair. The roll pair includes a receiving roll part and a first bending roll part that face each other. A plate member passing area is formed below the first bending roll part, the plate member passing area allowing a roll formed member excluding its side edge portions to pass through. The roll pair is configured to make, during bending, sliding movement in a width direction of the roll formed member and rotational movement about a normal direction to the roll formed member as a rotational center.

Forming roll units included in an apparatus for manufacturing a roll-formed component each include a roll pair. The roll pair includes a receiving roll part and a first bending roll part that face each other. A plate member passing area is formed below the first bending roll part, the plate member passing area allowing a roll formed member excluding its side edge portions to pass through. The roll pair is configured to make, during bending, sliding movement in a width direction of the roll formed member and rotational movement about a normal direction to the roll formed member as a rotational center.

A hydraulic roll bending machine includes a frame and a hydraulic cylinder supporting a bending roll such that extension or retraction of the rod changes a height of the bending roll relative to the frame. A hydraulic system includes a valve disposed to provide pressurized hydraulic fluid on at least one side of the hydraulic cylinder, and a controller operates to provide a command signal to a valve channeling hydraulic fluid from the hydraulic system to the cylinder. A sensor is integrated with the hydraulic cylinder, within the bore of the housing, and is disposed to sense a distance of the plunger relative to one end of the housing and provide a signal indicative of the distance to the controller.

A hydraulic roll bending machine includes a frame and a hydraulic cylinder supporting a bending roll such that extension or retraction of the rod changes a height of the bending roll relative to the frame. A hydraulic system includes a valve disposed to provide pressurized hydraulic fluid on at least one side of the hydraulic cylinder, and a controller operates to provide a command signal to a valve channeling hydraulic fluid from the hydraulic system to the cylinder. A sensor is integrated with the hydraulic cylinder, within the bore of the housing, and is disposed to sense a distance of the plunger relative to one end of the housing and provide a signal indicative of the distance to the controller.

A method of aligning a flat or profiled metal sheet with preformed notches on the two sides of the metal sheet when the sheet enters into a bender or folding machine directly from a roll forming machine linked or joined to the folder. The metal sheet has to be effectively aligned on the folder before folding to avoid potential damages to the metal sheet of not being properly squared or angled on bending while reducing the times to produce the folded products. Moreover, this method according to the invention allows the metal sheet to feed directly into the folder from the rollformer without having to pass through an intermediary transfer table or aligning device/machine before entering the folder for folding or manual alignment in the folder.

A method of aligning a flat or profiled metal sheet with preformed notches on the two sides of the metal sheet when the sheet enters into a bender or folding machine directly from a roll forming machine linked or joined to the folder. The metal sheet has to be effectively aligned on the folder before folding to avoid potential damages to the metal sheet of not being properly squared or angled on bending while reducing the times to produce the folded products. Moreover, this method according to the invention allows the metal sheet to feed directly into the folder from the rollformer without having to pass through an intermediary transfer table or aligning device/machine before entering the folder for folding or manual alignment in the folder.

A device for guiding and directing a metal sheet in a bending machine to form continuously a conical structure, in particular a frustoconical structure, comprises: resting and contrasting arrangement extending along a closed path, and suitable for restingly receiving a longitudinal edge of the metal sheet and contrasting a movement of the edge in a direction that is transverse to a preset advancement trajectory of the metal sheet; a supporting body for the resting and contrasting arrangement, having at least one oblong lateral portion that is suitable for facing the edge and configured for conforming the resting and contrasting arrangement to the longitudinal profile of the edge so as to obtain an extended zone of contact with said edge and impose resting and contrasting pressure distributed along the edge; the resting and contrasting arrangement is movable around the supporting body along the closed path to accompany the edge of the metal sheet by a distributed contact devoid of relative sliding and rolling, so as to impose on the metal sheet the advancement along the desired advancement trajectory to and through the bending machine. The corresponding method is also provided.

A device for guiding and directing a metal sheet in a bending machine to form continuously a conical structure, in particular a frustoconical structure, comprises: resting and contrasting arrangement extending along a closed path, and suitable for restingly receiving a longitudinal edge of the metal sheet and contrasting a movement of the edge in a direction that is transverse to a preset advancement trajectory of the metal sheet; a supporting body for the resting and contrasting arrangement, having at least one oblong lateral portion that is suitable for facing the edge and configured for conforming the resting and contrasting arrangement to the longitudinal profile of the edge so as to obtain an extended zone of contact with said edge and impose resting and contrasting pressure distributed along the edge; the resting and contrasting arrangement is movable around the supporting body along the closed path to accompany the edge of the metal sheet by a distributed contact devoid of relative sliding and rolling, so as to impose on the metal sheet the advancement along the desired advancement trajectory to and through the bending machine. The corresponding method is also provided.