Apparatus and method for forming duct flanges and duct work
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Solution Overview
Problem
Current methods for manufacturing small part duct fittings with TDF or TDC flanges are time-consuming, prone to part damage, and do not meet industry standards, particularly for small ducts where existing roll forming machines are inefficient and press brakes produce non-standard profiles.
Innovation Solution
An automated apparatus using a bending head assembly, drive roller, anvil, bending leaf, and roll form assembly to form TDF or TDC duct flanges from sheet metal, which includes a platen for bending, a pressure roll for clamping, and an electronic control unit for automated operation, reducing manual intervention and ensuring compliance with SMACNA standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If roll forming machines are used to manufacture small part duct fittings, then standardization is achieved, but the process becomes time-consuming and parts are prone to damage
Solution Approach 1:
The bending process is divided into multiple sequential operations (first bend, second bend, third bend) performed by separate bending stations. Each station performs a specific bending operation on the duct work, allowing the process to be completed in a single pass through the machine while maintaining precision and reducing cycle time.
Solution Approach 2:
The apparatus is designed to handle both small part duct fittings and larger ducts using the same bending mechanism and tooling. The universal bending heads and adjustable fixtures allow the machine to accommodate various duct sizes and flange types (TDF and TDC) without requiring separate specialized equipment.
2Productivity
If press brake is used to form duct channel, then manufacturing speed is improved, but the flange profile does not conform to SMACNA standards
Solution Approach 1:
The apparatus performs preliminary bending operations at dedicated bending stations before the final roll forming process. The first and second bending heads create pre-formed bends in the duct work, which are then finished by the roll forming section. This preliminary action ensures the final profile meets SMACNA standards while maintaining efficient production speed.
Solution Approach 2:
The roll forming section acts as an intermediary between the preliminary bending operations and the final flange formation. It takes the pre-bent duct work from the bending stations and completes the flange profiling, ensuring both speed and precision are achieved through the coordinated action of multiple process stages.
3Extent of automation
If multiple station roll forming machines are used, then automation is increased, but device complexity and operational difficulty increase
Solution Approach 1:
The apparatus combines multiple bending operations and roll forming into a single integrated machine structure. The bending stations are positioned in sequence along the duct path, with all operations occurring in one continuous pass through the machine. This merging of operations into a unified apparatus reduces the complexity that would result from multiple separate machines or overly complex single-machine configurations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The apparatus significantly reduces manufacturing time for small part duct fittings, increases productivity by forming TDF profiles in approximately nine seconds, and meets SMACNA standards, minimizing part damage and operational redundancy while being simpler, more cost-effective, and versatile.
Implementation Method 1
an apparatus and method for forming from a sheet metal blank a TDF or TDC duct flange for a duct
Implementation Method 2
a drive roller to move the sheet metal forward and backwards
Data Source
AI summary
An apparatus and method are disclosed for the automated manufacture of a duct flange profile to make small duct fittings, including a transverse duct flange duct flange profile. The duct flange profile is directed to small part duct fittings with section widths up to about 16 inches in 20 to 26 gauge metal. The apparatus includes a bending head assembly having a drive roller, a pressure roller, an anvil and a bending leaf and a roll form assembly.