Inline Seam Rollformer Lateral Head for Lock Seams
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Solution Overview
Problem
Existing sheet metal duct forming systems are time-consuming and costly, especially for smaller manufacturers, due to the need for extensive floor space and labor-intensive processes, particularly when forming male and female lock seams in square or rectangular ductwork, which often require a 90-degree transfer of the sheet material for seam formation.
Innovation Solution
An inline pass through seam rollformer that travels laterally across the sheet material, using a laterally moving rollforming head assembly with outboard tooling or rollers mounted on opposed spindles to form male and female lock seams simultaneously in a single pass, minimizing floor space and eliminating the need for 90-degree transfers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional duct forming systems are used to form male and female lock seams, then the seams can be formed, but the process requires 90-degree transfer of sheet material and extensive floor space
Solution Approach 1:
Instead of moving the sheet material through the rollformer in a traditional linear path requiring 90-degree transfers, the patent inverts the approach by having the rollforming head assembly move laterally across the stationary sheet material. This eliminates the need for complex material handling and 90-degree transfers, directly resolving the technical contradiction between ease of operation and floor space requirements
2Ease of operation
If traditional duct forming systems are used to form lock seams, then the seams can be formed, but the process is time-consuming and labor-intensive
Solution Approach 1:
The patent combines multiple seam formation operations into a single lateral pass of the rollforming head assembly. The head assembly forms both male and female lock seams simultaneously as it moves across the sheet material in one continuous motion, eliminating the need for separate operations and 90-degree transfers, thereby reducing production time and labor requirements
3Productivity
If fully automated duct forming systems are used, then production efficiency is improved, but the equipment cost and floor space requirements increase significantly
Solution Approach 1:
The patent segments the duct forming process by using a modular rollforming head assembly that can be independently positioned and operated. This segmented approach allows the system to achieve automated seam formation without requiring a fully integrated complex automated line, thereby improving productivity while reducing equipment complexity and floor space requirements
Solution Approach 2:
The patent introduces dynamic positioning capability to the rollforming head assembly, allowing it to move laterally across the sheet material as needed. This dynamic approach replaces the need for fixed, complex automated positioning systems, achieving high productivity with simpler, more flexible equipment that requires less floor space
Data Source
AI summary
A pass through inline seam rollformer having a head assembly and a cradle moveably mounted with a frame. The head assembly laterally moves upon the cradle whereby a seam may be formed upon a sheet material via tooling mounted upon the head assembly. The cradle moves relative to said frame whereby the head assembly may be retracted from a pass line of the sheet material and the sheet material may move through the apparatus without interference from the head assembly. For the preferred embodiment, the tooling utilizes one or more rollers having circumferential grooves or profiles which allow a male or a female lock seam to be formed as the head assembly moves over a leading or trailing edge of the sheet material without the need to transfer the sheet material 90 degrees or remove the sheet material from a production line.