Duct Angle Plate Insertion and Seam Closing in One Pass
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Solution Overview
Problem
Current machinery requires separate machines for automatically inserting angle plates into ducts and closing seams, which is inefficient, costly, and occupies unnecessary space, as it typically involves closing the seam first and then inserting the plates, leading to difficulties in straightening and squaring the duct for seamless closure.
Innovation Solution
A dual-head apparatus that automatically inserts angle plates into ducts before closing the seam, featuring adjustable heads, clamping members, a feed mechanism, press members, and a crimper for inserting and securing angle plates, and a seam closing assembly with rollers to ensure seamless closure regardless of duct orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If separate machines are used for inserting angle plates and closing seams, then each machine can be optimized for its specific function, but the overall process becomes less efficient, more costly, and occupies more space
Solution Approach 1:
The patent combines two separate machines (angle plate inserter and seam closer) into a single integrated apparatus. The apparatus includes an angle plate inserter assembly with feed mechanism, press members, and crimpers, integrated with a seam closing assembly featuring rollers and bending members. This merging eliminates the need for separate machines, improving productivity while reducing space requirements and operational complexity.
Solution Approach 2:
The integrated apparatus performs multiple functions: inserting angle plates into duct flanges, crimping the flanges to secure plates, and closing seams regardless of duct orientation. The machine can handle both rectangular ducts and irregularly shaped fittings, making it a universal solution that replaces multiple specialized machines.
2Ease of manufacture
If the seam is closed first and then angle plates are inserted, then the seam closure process is simplified, but the duct cannot be properly straightened and squared, making seamless closure difficult
Solution Approach 1:
The apparatus performs preliminary actions by inserting angle plates and crimping flanges before closing the seam. The feed mechanism delivers angle plates to the duct flange, press members press the plates into position, and crimpers secure them. This preliminary preparation straightens and squares the duct, enabling precise seam closure that follows.
Solution Approach 2:
The apparatus segments the manufacturing process into distinct sequential operations: angle plate insertion, flange crimping, and seam closing. Each function is performed by dedicated components within the integrated machine, allowing precise control over duct straightening before seam closure, thereby achieving both ease of manufacture and manufacturing precision.
3Device complexity
If traditional separate machines are used, then each machine can be simpler in design, but labor costs and space requirements increase
Solution Approach 1:
By merging angle plate insertion and seam closing functions into one apparatus, the patent reduces the number of machines needed, decreasing space requirements and eliminating the time lost moving ducts between machines. The integrated design consolidates complexity into a single system rather than distributing it across multiple simpler machines.
Solution Approach 2:
The integrated apparatus enables continuous operation where angle plates are inserted, flanges are crimped, and seams are closed in seamless succession without removing the duct from the machine. This continuity eliminates idle time and handling operations, reducing labor costs and improving overall efficiency despite the increased complexity of the single apparatus.
Data Source
AI summary
An apparatus and method are described for automatically inserting angle plates into duct work and for seaming the duct work.