Duct Blank Male-Female Seam with In-Line Clench 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 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 clench tool, enabling efficient and smooth seam formation without manual handling.
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 the metal is deformed and noise is generated
Solution Approach 1:
The patent replaces the manual hammering mechanical system with a controlled mechanical closure system using a clamping device and backstop. The clamping device applies distributed pressure to close the seam, while the backstop provides support from the inner surface, eliminating the need for repeated hammer impacts that cause deformation and noise.
2Ease of manufacture
If the duct blank is removed to another work station for seam closure, then the seam can be properly closed with support, but production efficiency is reduced due to extra handling steps
Solution Approach 1:
The patent combines the seam closure function with the existing bending apparatus by integrating a clamping device and backstop into the bending apparatus. This allows the duct blank to remain on the same work station throughout the forming process, eliminating the need for removal and repositioning to another work station, thereby maintaining production efficiency while achieving proper seam closure with support.
Solution Approach 2:
The bending apparatus is designed to perform multiple functions: it not only bends the duct blank but also provides clamping and backsupport for seam closure. The clamping device and backstop are integrated into the apparatus, allowing it to serve as both a forming device and a seam-closing device, eliminating the need for separate equipment.
3Productivity
If in-line automated closure is implemented, then production efficiency is improved, but the complexity of the apparatus increases
Solution Approach 1:
The backstop is positioned in advance on the bending apparatus to provide predetermined support during the seam closure operation. The clamping device is pre-configured to apply pressure at the correct location and angle. These preliminary arrangements enable automated in-line closure without requiring complex real-time adjustments or multiple operational steps.
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.