Duct Blank Lock Seam Formation to Prevent Edge Separation
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Solution Overview
Problem
Existing ductmaking apparatuses are inefficient as they require manual alignment and reformation of free edges in the pre-formed seam during the manufacturing process, leading to separation issues during handling and final closure.
Innovation Solution
A ductmaking apparatus with a controller that automates the formation of a lock seam by using a fixed platen, movable platen, clamp beam, bed assembly, wiper, and sealant injector to bend metal web into a duct blank with a pre-formed lock seam, ensuring seamless alignment and closure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the seam is pre-formed by aligning and bending free edges in known apparatus, then the duct blank can be formed, but the free edges separate during removal from the apparatus requiring manual realignment and reformation
Solution Approach 1:
The lock seam is pre-formed with locking features (interlocking tabs and slots) that secure the free edges together before the duct blank leaves the apparatus. This preliminary formation of the seam with built-in locking mechanisms prevents separation during handling and removal, eliminating the need for manual realignment and reformation.
2Productivity
If manual alignment and bending of free edges is performed, then the seam can be formed, but the process becomes inefficient requiring removal from the manufacture line
Solution Approach 1:
The lock seam structure is designed to be self-forming through the bending process, with the interlocking features automatically engaging to secure the seam. The apparatus performs the alignment and locking actions automatically during the forming process, eliminating the need for manual intervention and allowing continuous inline manufacturing without removal from the production line.
3Adaptability or versatility
If the duct blank is removed from the apparatus for final closure, then varying duct sizes can be accommodated, but the seam must be reformed offline
Solution Approach 1:
The lock seam is completely formed with interlocking features during the inline manufacturing process, creating a preliminary sealed structure that remains secure during removal. This allows the duct blank to be taken offline for final closure or assembly without requiring time-consuming reformation of the seam, as the locking features maintain seam integrity throughout handling and storage.
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 enables efficient inline manufacturing by preventing seam separation during handling and allowing for automatic formation of a durable lock seam, enhancing the ease of manufacture and ensuring reliable final closure without manual intervention.
Implementation Method 1
a wiper, and a controller directing the motions of the apparatus. The controller directs the motions of the apparatus so as to bend a metal web into the form of a duct blank comprising a lock seam
Data Source
AI summary
A ductmaking apparatus bends a metal web to form a duct blank having a lock seam with male and female portions. Prior to shearing off the duct blank, the apparatus bends the web to form a lock tab that secures the lock seam during subsequent handling of the duct blank.