Flexible duct connector processing system
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Solution Overview
Problem
The manual process of measuring, notching, and cutting flexible duct connector stock for forming duct connector frames is prone to inaccuracies due to fabric bunching, leading to variations in metal strip width and vibration absorption issues in air conditioning and heating systems.
Innovation Solution
A flexible duct connector processing system comprising a decoiler machine and a processing machine that uses expanding rollers to keep the fabric taut, a control system for programmed cutting and notching, and a conveyor system for batch collection, enabling accurate and automated production of duct connector frames.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual measuring and notching is used, then operation simplicity is maintained, but manufacturing precision deteriorates due to fabric bunching causing width variations
Solution Approach 1:
The patent replaces manual mechanical measuring and notching operations with an automated processing machine that uses sensors, controllers, and mechanical actuators to perform measurements and create notches automatically, eliminating the precision problems caused by manual fabric bunching
Solution Approach 2:
The patent applies preliminary action by using expanding rollers to stretch and tension the fabric before the notching operation occurs, preventing fabric bunching from happening during the measuring and notching process, thereby ensuring consistent metal strip width and accurate notching positions
2Manufacturing precision
If automated processing with expanding rollers is used, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent applies universality by designing a multi-functional processing machine that combines several operations (fabric tensioning with expanding rollers, measuring, notching, and cutting) into a single integrated device, reducing the need for multiple separate machines and operators while maintaining high precision
Solution Approach 2:
The patent implements self-service through a control system that automatically coordinates the expanding rollers, measuring devices, notching mechanism, and cutting blade, allowing the machine to regulate its own operations based on sensor feedback without requiring complex manual intervention
3Device complexity
If manual pulling and measuring is used, then equipment cost is reduced, but productivity deteriorates due to time-consuming manual operations
Solution Approach 1:
The patent applies continuity of useful action by designing the processing machine to operate continuously through coordinated expanding rollers that maintain fabric tension, automated measuring systems that continuously track dimensions, and sequential notching and cutting operations that proceed without manual intervention between steps, significantly increasing production rate
Data Source
AI summary
The flexible duct connector processing system of the present invention comprises a decoiler machine and a processing machine. The decoiler machine stores one or more rolls of flexible duct connector stock which are fed to the processing machine. The processing machine beads, notches, and cuts the flexible duct connector stock according to programmed instructions received from a control system. A conveyor system disposed after the processing machine optionally collects the cut flexible duct connector stock and conveys it in batches.