System and method for forming a full engagement male lock in a ductline
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Solution Overview
Problem
Existing metal duct forming processes require significant manual labor to seal air leaks in Pittsburgh male lock seams due to incomplete engagement and material removal for corner notches, leading to inefficiencies and increased costs.
Innovation Solution
A metal forming apparatus that alters the corner cutting assembly to form a full engagement Pittsburgh male lock by delaying the formation of the male lock seam until after the connecting flange has been rolled, eliminating the need for initial notching and ensuring a complete, seamless duct through precise location and bending of the male lock seam.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If corner notches are removed from the male lock seam to allow connecting flange rolling, then the flange can be formed properly, but air leaks occur at the seam and require manual labor to seal
Solution Approach 1:
The male lock seam is formed in advance before the connecting flange rolling operation, so that the seam is already in place and can be properly engaged. This preliminary formation of the male lock seam allows the subsequent flange rolling to proceed without creating gaps or air leaks, eliminating the need for manual sealing while maintaining both manufacturability and reliability
2Reliability
If the male lock seam is formed before connecting flange rolling, then the seam can be properly engaged end-to-end, but the process complexity increases
Solution Approach 1:
The forming process is divided into distinct sequential stages: first forming the male lock seam, then rolling the connecting flange. This segmentation allows each operation to be optimized independently while ensuring proper engagement. The male lock seam forming is completed as a separate preliminary step, creating a ready-to-engage structure that simplifies the overall process control and reduces complexity
3Ease of manufacture
If traditional corner cutting is used to allow flange rolling, then the flange can be formed, but material is removed that prevents full engagement of the male lock seam
Solution Approach 1:
The male lock seam is formed completely before the flange rolling operation begins. This preliminary action ensures that the full-length male lock seam is in place with proper engagement capability. The flange rolling then proceeds without removing any material from the seam area, preserving the complete engagement surface and achieving full precision end-to-end sealing
Data Source
AI summary
The present invention provides a method for producing a full engagement Pittsburgh male lock using specific cutting assemblies and protocols that reduce the amount of metal that is removed from the male portion of the corner notches in the duct. Forming of the male portion of the lock is done after the connecting flange forming has been completed as opposed to before the connecting flange forming has been completed.