Lock Seam Duct Blank Structure for In-Line Seam 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 hammer impacts, and previous solutions like Welty's apparatus are not adaptable for in-line use with machinery.
Innovation Solution
A lock seam structure is introduced, featuring male and female portions with notches that allow for in-line forming and finishing, using a clench tool to automate the insertion and closure of the seam, ensuring smooth bending forces and efficient production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a seam is closed by repeatedly banging a hammer against the free edge, then the seam can be closed, but the repeated impacts are noisy and tend to deform the metal along the seam
Solution Approach 1:
The patent replaces the manual hammering process with a mechanical clamping and rolling system. The seam closure apparatus uses a clamping mechanism to hold the free edge against a backstop, then uses rollers to progressively fold and seal the seam, eliminating the need for repeated impact forces that cause noise and deformation.
Solution Approach 2:
The patent introduces intermediate components (clamps, backstops, and rollers) that mediate the seam closure process. These intermediaries distribute the closing forces evenly along the seam length, preventing the concentrated impact forces that cause metal deformation and reducing noise through controlled, progressive folding.
2Manufacturing precision
If the duct blank is removed from the bending apparatus to another work station for final closure of the seam, then the seam can be closed with proper support, but extra steps for handling and aligning the duct blank are required, reducing production efficiency
Solution Approach 1:
The patent combines the bending apparatus and seam closure apparatus into a single integrated system. The bending apparatus positions and holds the duct blank, while the seam closure apparatus (with its clamps, backstops, and rollers) is mounted on or adjacent to the bending apparatus, allowing seamless transition from bending to seam closure without removing the duct blank.
Solution Approach 2:
The bending apparatus is designed with multi-functionality, serving both as a positioning device during bending and as a support structure for the seam closure operation. The apparatus can perform multiple functions (bending, holding, and supporting during seam closure) without requiring the workpiece to be transferred between stations.
3Ease of manufacture
If Welty's apparatus is used for forming and closing seams, then seam closure can be achieved, but manual handling is required to properly position the duct blank, and the apparatus is not adapted for in-line use with other machinery
Solution Approach 1:
The patent employs dynamic positioning mechanisms that can adjust and accommodate duct blanks of varying sizes and positions. The clamping and rolling mechanisms are designed to adapt to different duct configurations, eliminating the need for precise manual positioning while maintaining seam closure quality.
Solution Approach 2:
The seam closure apparatus is divided into modular components (clamps, backstops, rollers) that can be independently adjusted and positioned. This segmentation allows the system to adapt to different duct sizes and configurations while maintaining integration with the bending apparatus, enabling in-line operation without manual handling.
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.