Channel letter machine and method thereof

1. A computer-implemented method of automatically bending a return of a channel letter comprises:

inputting a desired configuration for the return to be formed into a control computer;

feeding a stock under the control of the control computer along a feed path including an encoder, a flanging unit, a notching unit, and a bending unit that are arranged along the feed path for the stock, with the flanging unit being located downstream of the encoder and upstream of the notching unit and the bending unit along the feed path;

selectively forming a flange on the bottom of the stock at desired flange positions on the stock at the flanging unit under the control of the control computer;

notching the flange of the stock at locations corresponding to a position of bends at the notching unit under the control of the control computer; and

bending the stock at the positions of the bends into the desired configuration for the return at the bending unit under the control of the control computer.

2. The computer-implemented method of claim 1 , further comprising cutting the stock at a cutting unit.

3. The computer-implemented method of claim 1 , further comprising setting a height of at least one guide for controlling a depth of the flange, wherein the guide supports a bottom edge of the stock controlling a height of the stock relative to the flanging unit.

4. The computer-implemented method of claim 1 , wherein feeding the stock under the control of the control computer further comprises:

determining an amount of stock passing an encoder; and

performing at least one of the steps of forming the flange, notching the flange, and bending the stock according to the amount of stock passing the encoder.

5. The computer-implemented method of claim 1 , wherein forming the flange further comprises simultaneously cutting the flange.

6. A channel letter bending machine for automatically bending a return of a channel letter from a stock, comprising:

a control computer for receiving a desired configuration for the return of the channel letter;

a feeding unit controlled by the control computer disposed along a path of travel of the stock to be bent for feeding the stock, wherein the feeding unit comprises an encoder for determining an amount of stock passing through the feeding unit;

a flanging unit disposed along the path of travel for selectively forming a flange along one edge of the stock;

a notching unit disposed along the path of travel for notching the flange of the stock fed by the feeding mechanism along the path of travel; and

a bending unit disposed along the path of travel for bending the stock under the control of the computer control system into the desired configuration for the channel letter shape, wherein the flanging unit is disposed upstream of the notching unit.

7. The channel letter bending machine of claim 6 , wherein the bending unit further comprises a cutting unit for cutting the stock.

8. The channel letter bending machine of claim 6 , further comprising at least one guide for setting a depth of the flange, wherein the guide supports a bottom edge of the stock controlling a height of the stock relative to the flanging unit.

9. The channel letter bending machine of claim 8 , wherein a first guide is disposed upstream of the feeding unit.

10. The channel letter bending machine of claim 8 , wherein a first guide is disposed downstream of the feeding unit.

11. The channel letter bending machine of claim 8 , wherein the at least one guide is height adjustable for setting a depth of the flange.

12. The channel letter bending machine of claim 6 , wherein the control computer transmits commands to at least one of the feeding unit, the flanging unit, the notching unit, and the bending unit according to the amount of stock passing through the feeding unit.

13. The channel letter bending machine of claim 6 , wherein the notching unit and the flanging unit are disposed upstream of the bending unit.

14. The channel letter bending machine of claim 6 , wherein the flanging unit comprises a cutting tool for cutting the flange.

15. A channel letter bending machine for automatically bending a return of a channel letter from a stock, comprising:

a control computer for receiving a desired configuration for the return of the channel letter;

a feeding unit controlled by the control computer disposed along a path of travel of the stock to be bent for feeding the stock;

a flanging unit disposed along the path of travel for selectively forming a flange along an edge of the stock;

a notching unit disposed along the path of travel for notching the flange of the stock fed by the feeding mechanism along the path of travel; and

a bending unit disposed along the path of travel for bending the stock under the control of the computer control system into the desired configuration for the channel letter shape, wherein the flanging unit is disposed upstream of the notching unit.

16. The channel letter bending machine of claim 15 , wherein the flanging unit comprises a cutting tool for cutting the flange.

17. The channel letter bending machine of claim 15 , further comprising at least one guide for setting a depth of the flange, wherein the guide supports a bottom edge of the stock controlling a height of the stock relative to the flanging unit.

18. The channel letter bending machine of claim 15 , wherein a first guide is disposed upstream of the feeding unit.

19. The channel letter bending machine of claim 15 , wherein a first guide is disposed downstream of the feeding unit.

20. The channel letter bending machine of claim 15 , wherein the feeding unit comprises an encoder for determining an amount of stock passing through the feeding unit, wherein the control computer transmits commands to at least one of the feeding unit, the flanging unit, the notching unit, and the bending unit according to the amount of stock passing through the feeding unit.