US 20140196515A1

(19) United States

(12) Patent Application Publication (10) Pub. No.: US 2014/0196515 A1
Bloxham

(43) Pub. Date:

(54) APPARATUS AND METHOD FOR FORMING

(30)

J 11]. 17, 2014

Foreign Application Priority Data

A SCREW FLIGHT
Jul. 5,2011

(75) Inventor:

Gregory John Bloxham, Beecroft (AU)

(AU) .............................. .. 2011902667

Publication Classi?cation
(51)

(73) Assignee: ADVANCED SPIRAL

TECHNOLOGY PTY LIMITED,

Int. Cl.
BZID 11/14
(52) us CL

Castle Hill, New South Wales (AU)

CPC .................................... .. 3210 11/14 (2013.01)

USPC

72/67

14/130 837

(22)

PCT Filed.

JUL 5, 2012

This invention relates to an apparatus for forming a helical

screW ?ight from a ?ight blank. The apparatus includes a base

(86)

PCT NO"

PCT/AU2012/000803

mounted to the base and is con?gured to formineg engage the

Mar. 27, 2014

blank corresponding to a predetermined pitch of the ?ight.

............................................................ ..

1.N .:

21

(2006.01)

pp

ABSTRACT

and an engaging means. The engaging means is movably

371 (c)(1),

(2), (4) Date:

(57)

blank so as to form a tWist in at least a portion of the ?ight

Patent Application Publication

Jul. 17, 2014 Sheet 1 0f 17

US 2014/0196515 A1

Patent Application Publication

Jul. 17, 2014 Sheet 2 0f 17

US 2014/0196515 A1

OFILTLER
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con. FILTER \

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US 2014/0196515 A1

/|SOLATION SWITCH

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INTERFACE

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Patent Application Publication

GUIDE 1295

Jul. 17, 2014 Sheet 4 0f 17

I:5

US 2014/0196515 A1

GUIDE my
i

Patent Application Publication

Jul. 17, 2014 Sheet 5 0f 17

Inner Diameter "ID"

"Outer Diameter "OD"

FIGUREG

US 2014/0196515 A1

Patent Application Publication

Jul. 17, 2014 Sheet 6 0f 17

_ Flight Pitch "PT"

HGURE7

Flight Thickness "TH"

FIGUREB

US 2014/0196515 A1

Patent Application Publication

' BENDTINUTKREI'NCSEURTE

Jul. 17, 2014 Sheet 7 0f 17

US 2014/0196515 A1

Patent Application Publication

Jul. 17, 2014 Sheet 8 0f 17

US 2014/0196515 A1

3. MOVE THE RULE TO LINE-UP THE SCRIBE AND CENTRE

LINES THEN LOCK IN PLACE BY TIGHTENING BOLTS

4. LOOSEN BOLTS

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2. LOOSEN BOLTS

IF NO THEN FOLLOW POINTS 2 AND 3

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Patent Application Publication

Jul. 17, 2014 Sheet 9 0f 17

FIGURE 11

US 2014/0196515 A1

Patent Application Publication

Jul. 17, 2014 Sheet 10 0f 17

US 2014/0196515 A1

1. RULE GUIDE MUST BE FREE,

TO MOVE WITH IN CHANNEL

A
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3. SLIDE THE RULE ASSEMBLY UP

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FIGURE 12

Patent Application Publication

Jul. 17, 2014 Sheet 11 0f 17

US 2014/0196515 A1

1. LOCK RULE.

ASSEMBLY

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2. REMOVE RULE GUIDE

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Patent Application Publication

, ~

Jul. 17, 2014 Sheet 12 0f 17

4'

SELECT AND INSERT APPROPRIATEV

(DIE SIDE PLATE) AS PER (FLIGHT
DIE CONFIGURATION PROGRAM)
INTO BACK PLATE CHANNELS

HGURE14

US 2014/0196515 A1

Patent Application Publication

Jul. 17, 2014 Sheet 13 0f 17

3. LOCK (DIE SIDE PLATE) INTO POSITION

1. SLIDE
SDIE SIDE
PLATE TOWARDS RULE /

2. UNTIL CONTACT BETWEEN DIE

SIDE PLATE) AND RULE ED E

19"}
20

24

FIGURE .15

US 2014/0196515 A1

Patent Application Publication

Jul. 17, 2014 Sheet 14 0f 17

US 2014/0196515 A1

I. ADJUST THE DISTANCE BETWEEN SUPPORT BRACKET)

AND RULE EDGE ALONG (DIE SIDE LATE) TOP EDGE
TO MATCH THE (SUPPORT OFFSET) MEASUREMENT

\ 2. LOCK (SUPPORT BRACKET)

FIGURE 16

Patent Application Publication

Jul. 17, 2014 Sheet 15 0f 17

US 2014/0196515 A1

1. ADJUST THE DISTANCE BETWEEN SUPPORT BRACKET)

AND RULE EDGE ALONG (DIE SIDE LATE) TOP EDGE

TO MATCH THE (SUPPORT OFFSET) MEASUREMENT

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FIGURE 17

Patent Application Publication

Jul. 17, 2014 Sheet 16 0f 17

US 2014/0196515 A1

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Patent Application Publication

Jul. 17, 2014 Sheet 17 0f 17

US 2014/0196515 A1

\a\
SIDE PLATE ANGLE

LLSIDE PLATE LENGTH+_>

FIGURE 21

Jul. 17, 2014

US 2014/0196515 A1

APPARATUS AND METHOD FOR FORMING

A SCREW FLIGHT
FIELD OF THE INVENTION

[0001]

This invention relates generally to the ?eld of mate

rials handling equipment. More particularly, the present

invention relates to screw or auger ?ights (particularly sec

annular) wherein the annulus shapedblank has an inner diam

eter and an outer diameter. The engaging means is preferably
adapted to twist the portion of the annulus about a mean

radius line of the annulus. It will be appreciated by those

skilled in the art that, by twisting the blank about its mean
radius line, undesirable rounding or rolling across the cross

section of the blank is substantially avoided.

tional ?ights) and to an apparatus and method of forming such

[0014]

?ights.

sides of the blank such that forming movement of the engag

ing means forms a twist in at least a portion of the ?ight blank.
[0015] In some embodiments, the engaging means includes
primary engaging means for engaging the blank at at least two

BACKGROUND OF THE INVENTION

[0002] Any discussion of the prior art throughout the speci

?cation should in no way be considered as an admission that

such prior art is widely known or forms part of common

general knowledge in the ?eld.

[0003]

Screw or auger ?ights are typically used in bulk

handling industries for e?iciently moving ?uid, granular or

semi-solid material. Rotation of the ?ight causes the material
to be conveyed along the surface of a spiralled coil section.
[0004] The means and method of manufacturing conven
tional sectional screw ?ights involves pressing each section of
?ight between a set of appropriately shaped dies. Each section
of ?ight is then typically welded to a shaft in sequence to form

The engaging means preferably engages opposed

spaced apart positions, whereby the primary engaging means

is con?gured to cause relative movement between the at least
two engaged positions so as to form the twist in the blank.

[0016] In certain preferred embodiments, the primary

engaging means includes two pairs of (primary) side plates.
Each side plate is preferably a die formed plate having an
engaging portion such as, for example, an engaging edge or
surface for engaging the blank. Each side plate is preferably.
arranged so as to extend in a direction which is substantially
normal to the mean radius line of the blank.

a complete conveyor screw.

[0017] Preferably, each pair of side plates has a ?rst ?xed

plate and a second movable plate, the second plate being

[0005]

movable relative to the ?xed plate.

The conventional die pressing method has a number

of inherent disadvantages. These disadvantages include that,

[0018]

depending on the thickness of the blank material used, is it

often necessary to repeat the die pressing operation several
times in order to conform the shape of the annulus to the shape
of the dies between which the blank is pressed. The require
ment to repeat the pressing cycle necessarily adds to the costs
of production of screw ?ights produced via this method.

means includes secondary engaging means for engaging the

blank at at least one position in between the primary engaging
means. The secondary engaging means preferably engages

In some preferred embodiments, the engaging

the blank at a central or mid-point between the primary

engaging means. Preferably, the secondary engaging means

includes a pair of mid-plates. The mid-plates preferably

[0006] Furthermore, the blank typically undergoes plastic

include a ?xed mid-plate and a movable mid-plate, the mov

deformation during the pressing process which can lead to

inaccuracy in ?ight pro?les outside of desired manufacturing

able mid-plate being movable relative to the ?xed mid-plate.

[0019] The ?xed plates of both the primary and secondary

tolerances. Such variations away froth desired manufacturing

tolerances necessarily lead to inferior products and a resulting

engaging means are preferably mounted to a mounting means

such as a mounting frame connected to the base. Preferably,

reduction in product performance and lifespan.

the mounting means includes a receiving formation for

[0007]

receiving each ?xed plate. The receiving formation prefer

ably includes a pair of spaced apart channels, grooves, slots,

In addition, for each particular size and pitch for a

?ight, two sets of dies are needed if both left and right hand
?ights are to be produced, further adding to the costs of using
dies to form screw ?ights.
[0008] It is also di?icult to produce accurate dies which will

ridges, or other suitable formation for receiving the ?xed side

plates, and a central receiving formation (e.g. channel) for

receiving the ?xed mid-plate.

produce a ?ight of a particular size and pitch. Accordingly, it

[0020]

is typically necessary to use an iterative process of trial and

error whereby several sets of dies are produced, tested and

tion for mounting the plate in or on or otherwise to the receiv

modi?ed until the desired properties of a ?ight can be

achieved from the die set.
[0009] It is an object of the present invention to overcome
or ameliorate one or more of the disadvantages of the prior art,
or at least to provide a useful alternative.

SUMMARY OF THE INVENTION

[0010] According to a ?rst aspect of the invention, there is

provided an apparatus for forming a helical screw ?ight from

Preferably, each ?xed plate has a mounting forma

ing formation. The mounting formation of each plate is pref

erably complementary in shape to that of the receiving
formation. For example, the mounting formation and the
receiving formation may be con?gured as a tongue-and

groove type arrangement.

[0021] In certain embodiments, securing means is provided
for securing each ?xed side plate in position, relative to the
mounting means. The securing means preferably includes
one or more locking screws for holding the mounting forma

a ?ight blank, the apparatus including:

tion (e. g. tongue) in the associated channel. Preferably, each

receiving formation is con?gured to enable the associated

[0011]
[0012]

mined position along the length of the receiving formation.

a base; and
engaging means movably mounted to the base, the

engaging means being con?gured to formingly engage the

blank so as to form a twist in at least a portion of the ?ight

blank corresponding to a predetermined pitch of the ?ight.

[0013] Preferably, the ?ight blank is in the form of an
annulus, more preferably, an open ended annulus (e.g. a pen

?xed plate to be selectively mounted at a desired or predeter

For example, the ?xed plates can be slid along the associated
channel and then locked in the desired position.
[0022] Preferably, a locking means such as, for example, a

lock-bolt is provided for locking the ?xed mid-plate in posi

tion, relative to the mounting means.

Jul. 17, 2014

US 2014/0196515 A1

[0023]

The movable plates of the primary engaging means

and the secondary engaging means are preferably mounted to

a movable frame, the frame being movably mounted to the
base to enable relative movement between the ?xed plates and

the movable plates.

[0024] The movable frame preferably has a mounting for
mation for mounting the movable plates. Preferably, the
mounting formation of the movable frame corresponds to
(e. g. mirrors) the mounting formation of the ?xed mounting
frame such that the engaging portion of each pair of ?xed and
movable plates is substantially aligned. That is, the pairs of
side plates and the pair of mid-plates are preferably in engag

plates and the mid-plate in a counter-clockwise direction, or

vice versa. Again, it will be appreciated that side plates can be
mounted to achieve the desired direction of rotation for pro
ducing either a right-hand or left-hand twist in the blank.

[0030] Each side plate (?xed and movable) is generally

trapezoidal in shape, wherein its engaging edge is tapered
relative to its mounting formation. To achieve the desired
rotation of the blank at the point held between the side plates,

the ?rst pair of side plates are arranged such that the tapered
edges of the ?xed and movable plates in the ?rst pair are

ing alignment.

substantially parallel and extend at a negative angle (or posi

tive angle for opposite hand formation). Similarly, the second
pair of side plates are arranged such that the tapered edges of

[0025]

the ?xed and movable plates in the second pair are substan

The receiving formations are preferably arranged

such that the pairs of side plates are angled relative to one

another. Preferably, the side plates are con?gured such that

the relative angle therebetween is less than 180 degrees. In
certain preferred embodiments, the side plates are arranged to
have an angle of approximately 60 degrees therebetween. It
will be appreciated that the primary engaging members are
not limited to being angled at 60 degrees, but could, in other
embodiments, be angled at any suitable angle less than 180
degrees. For example, the side plates can be angled at
approximately 30, 45, 65, 75, 90, 105, 120, 135 or 145
degrees relative to each other.
[0026]

Preferably, a support means is associated with the

side plates for supporting the ?ight blank, in use. The support
means is preferably con?gured to support the outer diameter
of the blank. Preferably, the support means includes a ?rst
support bracket mountable to a ?xed side plate of a ?rst pair

tially parallel and extend at a positive angle (or negative angle

for opposite hand formation).
[0031]

It will therefore be appreciated that, due to the

tapered engaging edges of the side plates, the relative linear

movement between the ?xed and movable side plates results
in a rotation of the part of the blank between the plates about
the mean radius line to produce the desired twist in the blank.
[0032] In at least one preferred embodiment, the actuating
means is con?gured such that the apparatus operates with a
forming force in the range of 0 to 60 tonne at 200 bar (2,900
psi), and the forming speed is within the range of 0 to 80
mm/ s. Embodiments operating within these parameters can
be suitable for forming a helical screw from a blank having a
thickness in the range of 1 mm to 300 mm.

[0033]

According to a second aspect of the invention, there

is provided a method of forming a helical screw ?ight, the

of primary engaging side plates and a second support bracket

method including:

mountable to a movable side plate of a second pair of primary

[0034]

providing a ?ight blank of a predetermined size; and

engaging side plates. Each support bracket is preferably

selectively adjustably positionable relative to the associated

[0035]

formingly engaging the blank so as to form a twist in

side plate and secured thereto by a suitable locking means

such as one or more locking elements (e.g. screws). It will be

appreciated that the support brackets can be selectively

mounted to the desired side plates, depending on whether a
right-hand or left-hand helical screw ?ight is to be formed by

at least a portion of the ?ight blank, the twist substantially

corresponding to a predetermined pitch of the ?ight.
[0036] Preferably, the method includes twisting at least a
portion of the blank generally about a mean radius line of the
blank.

[0037]

Preferably, the method includes engaging the blank

the apparatus.
[0027] The moveable frame is preferably moved by an

with primary engaging means at at least two spaced apart

actuating means. The actuating means preferably includes a

to cause relative movement between the at least two engaged

positions so as to form the twist in the blank.

hydraulically driven cylinder, the hydraulic cylinder being

positions, whereby the primary engaging means is con?gured

selectively movable between an extended position and a

[0038]

retracted position for moving the movable frame and thus the

engaging means for engaging the blank at at least one position

movable plates of the primary and secondary engaging

in between the primary engaging means, whereby the

means. Preferably, the hydraulic cylinder has a cylinder rod

engaged portion of the blank on one side of the secondary

engaging means is twisted in a ?rst direction and the engaged
portion of the blank on the other side of the secondary engag
ing means is twisted in a second opposed direction.

which is con?gured to cause linear movement of the movable

frame when the cylinder rod extends or retracts.

[0028] To facilitate the forward and backwards linear

movement of the movable frame, the movable frame and base

[0039]

The method preferably includes using a secondary

Preferably, the method includes determining the

are preferably ?tted with guide means. Preferably, the guide

size of the blank from at least one of a desired pitch, outer

means includes at least one front guide bar and at least one

diameter, inner diameter, and thickness of the formed helical

rear guide bar extending from the movable frame. The at least
one front guide bar is arranged to pass through an aperture in
a front guide plate and the at least one rear guide bar is
arranged to pass through an aperture in a rear guide plate. In

screw ?ight.

one particularly preferred embodiment, there is provided two

front guide bars and two rear guide bars.

[0029] Preferably, a ?rst pair of side plates is con?gured to

rotate the portion of the blank between that pair of side plate

and the mid-plate (i.e. secondary engaging means) in a clock

wise direction, and a second pair of side plates is con?gured
to rotate the portion of the blank between that pair of side

[0040] According to a third aspect of the invention, there is

provided a screw (or auger) ?ight which has been manufac
tured in accordance with the method of the second aspect of
the invention.
[0041] According to a fourth aspect of the invention, there
is provided a method of setting up an apparatus for forming a
helical screw ?ight from a ?ight blank, the method including:
[0042] securing a central engaging means to the apparatus;
[0043] aligning a set up device with the central engaging
means;