Lock Seam Duct Blank Closure for In-Line Forming
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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 potential metal deformation due to hammering, and existing solutions like Welty's apparatus are not adaptable for in-line use with other 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 a uniform surface, enabling efficient production without manual handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a seam is pre-formed by bending and aligning free edges of the partially formed duct, then the duct blank can be closed by clamping and backsupporting, but the duct blank must be removed from the bending apparatus to another work station for final closure, requiring extra handling steps and reducing production efficiency
Solution Approach 1:
The invention combines the seam closure operation with the existing bending apparatus by integrating a clamping mechanism that can be applied to the duct blank while it remains in the bending apparatus. The clamping mechanism includes a clamp that engages the outer surface of the duct blank and a backsupport that engages the inner surface, allowing the seam to be closed at the same work station where bending occurs, thereby eliminating the need for removal and repositioning to another work station.
2Ease of manufacture
If the duct blank is removed to another work station for seam closure, then the seam can be closed by repeatedly banging a hammer against the free edge, but this creates noise and tends to deform the metal along the seam
Solution Approach 1:
The invention replaces the manual hammering process with a controlled clamping mechanism that applies gradual, distributed force to close the seam. The clamp and backsupport system provides a mechanical advantage that allows the seam to be closed through controlled deformation rather than repeated impacts, eliminating the noise and metal deformation associated with hammering while maintaining the effectiveness of the closure process.
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 position the duct blank relative to the clamps and rollers, and the apparatus is not adapted for in-line use with other machinery
Solution Approach 1:
The invention makes the bending apparatus multi-functional by integrating the seam closure capability into the existing bending mechanism. The clamping mechanism is designed to work with the bending apparatus's existing structure and motion, allowing the same apparatus to perform both bending and seam closure operations. This eliminates the need for separate Welty-type apparatus and manual positioning, as the clamping mechanism moves with the bending apparatus and automatically positions itself relative to the duct blank during the bending process.
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 solution enables in-line closure and finishing of duct blanks, improving manufacturing efficiency by automating the seam closure process, reducing noise and metal deformation, and providing a smoother, more uniform duct surface.
Implementation Method 1
the flanges being notched to permit bending the duct blank so as to form the seam
Implementation Method 2
in-line finishing by clenching together male and female portions of a duct blank seam
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.