Spiral Air Conduit Perforation for Aligned Variable Hole Arrays
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Solution Overview
Problem
Existing solutions for manufacturing spirally wound air conduits with aligned holes lack flexibility in accommodating varying strip widths and conduit diameters, and fail to optimize hole geometries based on functional parameters, leading to inefficient air distribution and potential damage from plasma cutting.
Innovation Solution
An apparatus comprising a forming device, cutting device, and feeding system that allows for the creation of spirally wound conduits with aligned holes of varying shapes and sizes, using a cutting head movable along multiple axes to adapt to different strip and conduit dimensions, and a control unit to coordinate movements and select appropriate punches or cutting tools for precise hole placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a punching machine is arranged upstream to a forming device for perforating the strip before it is spirally wounded, then holes can be aligned on the conduit after forming, but the apparatus lacks flexibility to adapt to varying strip widths and conduit diameters
Solution Approach 1:
The punching device is made movable along the strip width direction, allowing dynamic adjustment of hole positions. The punching device can be repositioned according to different strip widths and conduit diameters, enabling the same apparatus to handle various specifications while maintaining precise hole alignment on the final conduit.
Solution Approach 2:
The system allows changing geometric parameters such as hole diameter, hole shape, and hole position by adjusting the punching device. The control unit coordinates the punching device movement and selection of different punching tools to adapt to varying strip widths and conduit diameters, maintaining manufacturing precision across different specifications.
2Device complexity
If the punching machine moves only according to a vertical punching direction, then the punching mechanism is simple, but the apparatus cannot accommodate varying strip widths and conduit diameters without reconfiguration
Solution Approach 1:
While maintaining a relatively simple vertical punching mechanism, the system adds dynamic positioning capability along the strip width. The punching device can move horizontally to adjust its position before performing vertical punching, providing adaptability to different strip widths without significantly complicating the core punching mechanism.
Solution Approach 2:
The punching device is designed to perform multiple functions: it can punch holes of different sizes, different shapes, and at different positions along the strip. By combining vertical punching capability with horizontal positioning, a single device can accommodate various strip widths and conduit diameters without requiring separate punching machines for each specification.
3Productivity
If plasma cutting is used to create holes on the conduit, then cutting speed is high, but the conduit surface suffers damage compromising suitability for certain applications
Solution Approach 1:
The harmful thermal effects of plasma cutting are extracted and removed from the process. Instead of using plasma cutting, the patent employs mechanical punching or cold cutting methods that create holes without generating excessive heat, thereby avoiding surface damage while maintaining acceptable productivity through efficient tooling and process design.
Solution Approach 2:
The invention uses consumable punching tools or cutting edges that can be replaced when worn, rather than using expensive plasma equipment that causes irreversible damage to the conduit. The focus shifts to maintaining tool integrity rather than protecting the conduit from thermal damage, achieving both productivity and surface quality.
4Ease of manufacture
If rollers are shaped to create holes on the strip before bending and seaming, then hole creation is integrated into the forming process, but the geometry of perforation is fixed and the machine lacks flexibility for industrial production
Solution Approach 1:
Instead of fixed-shaped rollers, the invention employs movable punching devices that can be repositioned along the strip width and adjusted to create different hole geometries. This dynamic approach allows the same forming process to accommodate varying hole patterns while maintaining integration with the bending and seaming operations.
Solution Approach 2:
The system enables changing hole geometry parameters (diameter, shape, spacing, position) by adjusting the punching device configuration and positioning. The control unit coordinates these parameter changes with the forming process, allowing flexible adaptation to different product specifications while keeping the manufacturing process integrated and efficient.
Data Source
Figure 1~2
Figure 3A~5B
Figure 6~7
AI summary
Apparatus (10) for forming a spirally wound conduit (14) from a flat strip (2) comprising: a forming device (6) comprising a bending section (7) configured to spiralling bend the strip (2) and a joining section (8) configured to join opposite longitudinal sides (2A,2B) of the strip (2) each other; a feeding device (11) of the strip (2) along a feeding direction (F) parallel to the longitudinal edges (9) of the strip (2); a cutting device (1) arranged upstream the forming device (6) comprising a cutting head (3) for cutting the strip (2) and moving means configured to move said cutting head (3) along a plurality of moving axes (Χ,Υ,Ζ) orthogonal to each other; a control unit (18) configured to command said moving means according to diameter (D) of the conduit (14) to be realized and to the width (B) of the strip (2) so that said cutting head (3) realizes on the strip (2) a plurality of arrays (12) of holes (13) each one tilted with respect to one of the longitudinal edges (9) of the strip (2) by an angle (a) function of the width (B) of the strip (2) and of the diameter (D) of the spiral conduit (14) to be realized. The present invention relates also to a air conduit (14), a perforated strip (2') and a coil (19) of a perforated strip (2') comprising a plurality of said arrays (12) of holes (13) wherein said holes (13) comprise at least two different shapes.