Angle Plate Insertion Machine for Irregular Duct Flanges
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Solution Overview
Problem
Existing apparatus for automatically inserting angle plates into duct flanges, such as CORNERMATIC® and CORNER CADET®, are unable to handle irregularly shaped duct fittings and require manual insertion, leading to increased time and potential damage to the flanges, and the loading of angle plates is inefficient due to the need for manual handling and obstruction by the angle plate supply hopper.
Innovation Solution
A new machine design with clamping members that pull and straighten duct flanges, a feed member that positions angle plates below the work area, and a supply hopper system that allows for efficient loading of angle plates, enabling automatic insertion into irregularly shaped duct fittings and improving workflow efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If existing automatic angle plate insertion machines (CORNERMATIC® and CORNER CADET®) are used, then automatic insertion capability is achieved for regular ducts, but irregularly shaped duct fittings cannot be processed requiring manual insertion
Solution Approach 1:
The machine incorporates adjustable and movable components including the angle plate supply hopper that can be repositioned, and clamping members that can adapt to different fitting geometries. The press member and feed mechanism are designed with degrees of freedom to accommodate irregular shapes while maintaining automatic operation.
Solution Approach 2:
The apparatus is designed to handle both regular and irregularly shaped duct fittings through universal clamping mechanisms and adjustable positioning systems. The machine can process multiple fitting types without requiring complete reconfiguration, achieving multi-functionality while maintaining automatic insertion capability.
2Adaptability or versatility
If manual insertion of angle plates is used for irregular fittings, then adaptability to all fitting shapes is achieved, but insertion time increases and flange damage risk increases
Solution Approach 1:
The machine performs self-positioning and self-alignment through automated feed mechanisms and positioning systems. The angle plates are automatically fed, positioned, inserted, and crimped without requiring manual intervention, thereby maintaining high productivity while handling irregular fittings through adaptive automation rather than manual operations.
3Ease of manufacture
If angle plate supply hopper is positioned above the work area, then gravity feed is simplified, but the hopper obstructs the work area and prevents processing of certain fittings
Solution Approach 1:
The angle plate supply hopper is repositioned from a vertical arrangement above the work area to a horizontal arrangement along the side of the machine. This dimensional change eliminates obstruction of the work area while maintaining efficient angle plate supply through the feed mechanism, allowing full access to irregularly shaped fittings.
4Adaptability or versatility
If duct flanges are not precisely fabricated or are bent, then manufacturing flexibility is maintained, but automatic angle plate insertion becomes difficult or impossible
Solution Approach 1:
The machine incorporates adjustable parameters including clamping force, press member position and force, and feed mechanism settings that can be modified to accommodate variations in flange geometry. This allows the automatic insertion system to adapt to imprecise or bent flanges while maintaining operational capability.
Solution Approach 2:
The clamping members are designed to preliminarily position and stabilize the duct fitting before angle plate insertion. This preliminary action compensates for manufacturing imperfections by establishing proper alignment and securing the fitting in place, enabling subsequent automatic insertion to proceed successfully.
Data Source
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AI summary
An apparatus and method are described for inserting angle plates in transverse duct flanges. The apparatus is especially useful in inserting angle plates into transverse duct flanges of duct fittings. Packages for holding angle plates are also described.