Duct Lock Seam Pre-Forming 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 seam during the manufacturing process, leading to separation issues during duct blank removal 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, 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 a seam is pre-formed by aligning and bending free edges of the partially formed duct, then the duct blank can be closed to form the duct, but the free edges separate during removal from the apparatus requiring manual realignment and reformation
Solution Approach 1:
The apparatus pre-forms the seam by aligning and bending free edges before duct blank removal, creating a preliminary seam structure that maintains edge alignment during handling and removal from the apparatus
Solution Approach 2:
The apparatus introduces an intermediary seam-forming mechanism between the bending process and final closure, using aligned free edges as an intermediate structure that prevents separation during removal while enabling automated final closure
2Ease of operation
If the duct blank is removed from the apparatus along the line of the seam, then the duct can be handled and finalized offline, but manual alignment and reformation of the seam is required
Solution Approach 1:
The apparatus performs preliminary seam alignment and bending before duct blank removal, so that when the duct is removed along the seam line, the edges remain aligned and ready for final closure without requiring manual realignment
Solution Approach 2:
The apparatus enables the duct blank to essentially self-maintain its seam alignment during removal through the pre-formed edge configuration, eliminating the need for manual intervention to realign edges that would otherwise separate
3Adaptability or versatility
If hand tools or separate machinery are used for final closure offline, then varying duct sizes can be accommodated, but the process is inefficient and requires manual intervention
Solution Approach 1:
The apparatus creates a universal pre-formed seam structure that can accommodate varying duct sizes while enabling automated final closure, making the same apparatus suitable for different duct configurations without requiring size-specific manual tools or separate machinery
Solution Approach 2:
The apparatus replaces manual hand tools and separate offline machinery with an integrated automated seam-forming and closure system that uses controlled bending and alignment mechanisms to achieve final closure efficiently for various duct sizes
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 secure lock seam, enhancing the ease of manufacture and ensuring reliable duct closure without manual intervention.
Implementation Method 1
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.