Flanged Duct Lock Seam for In-Line Automated Closure
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Solution Overview
Problem
Existing methods for manufacturing ventilation ducts require manual handling and additional steps for seam closure, leading to inefficiencies and deformation of metal due to repeated hammer impacts, and existing solutions like Welty's apparatus are not adaptable for in-line use with machinery.
Innovation Solution
A lock seam structure is introduced, featuring a duct blank with notched male and female portions and flanges that can be bent in-line to form a seamless connection, allowing for automated closure and finishing using a forming apparatus with a clench tool and shear blades, enabling efficient and smooth seam formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual hammering is used to close the seam, then the seam can be closed, but noise is generated and metal deformation occurs
Solution Approach 1:
The patent replaces the manual hammering mechanical system with a controlled mechanical closure system using a clamping device and forming apparatus. The clamping device applies controlled force to hold the edges together, while the forming apparatus shapes the metal without repeated impacts, thereby eliminating noise and deformation associated with hammering.
Solution Approach 2:
The patent introduces a clamping device as an intermediary between the manual operation and the seam closure. This clamping device provides stable support from the inner surface of the duct blank, enabling proper force application for closure without direct hammer impacts on the metal edges.
2Ease of manufacture
If the duct blank is removed to another work station for seam closure, then the seam can be closed with support, but production efficiency decreases due to extra handling steps
Solution Approach 1:
The patent merges the bending apparatus and seam closure apparatus into a single integrated system. The bending apparatus forms the duct blank with notched flanges, and the same apparatus subsequently performs the seam closure operation in-line, eliminating the need to transfer the duct blank to a separate work station and thereby maintaining production efficiency.
Solution Approach 2:
The forming apparatus is designed with multi-functionality, serving both as a bending apparatus for creating the duct blank and as a closure apparatus for sealing the seam. This universal apparatus performs multiple operations in sequence without requiring equipment changes or work piece removal.
3Productivity
If in-line forming and finishing is implemented, then manufacturing efficiency improves, but the seam structure must be specifically designed with notched flanges
Solution Approach 1:
The patent applies preliminary action by forming notched flanges on the duct blank during the initial bending process. These notches are created in advance to facilitate the subsequent seam closure operation, allowing the edges to be properly aligned and held together during the closure process without requiring complex additional structuring.
Data Source
AI summary
A flanged duct blank has a male part defined by lead notches formed at each side of a leading end and has a female part defined by trail notches formed at each side of a trailing end. The male part includes a lock tab. The female part includes a leg part and a Z-bend. The Z-bend includes a leg part and a gap. The duct blank is repeatedly clamped and bent by a pivoting wiper to form a duct portion. The pivoting wiper includes a clench tool that has a retractable rib and a retractable roller. With the lock tab inserted into the Z-bend and the retractable rib engaged with the Z-bend, the retractable roller clenches the leg part over the lock tab to lock the male and female parts together in a duct seam.