TECHNICAL FIELD

[0001] The invention relates generally to an apparatus and method for production of sealed or adjustable duct members.

BACKGROUND

[0002] In general, duct work is commonly used in forced air heating and air-conditioning systems for buildings and the like, with the duct work providing a distribution system to various areas of the building from a furnace and/or air-conditioning system. The duct work is generally formed from cylindrical tubing which extends to various portions of the building or the like. Duct members include specialized sections such as elbows, which may be fixed in position or allow the orientation and position of duct to be adjusted, to make turns in runs of ductwork. Known machines for producing elbows or the like typically require a skilled operator that must handle a blank used for production of the elbow. The operator cuts and forms sections or gores for an elbow from the blank and assembles them together. The sections of the elbow are generally coupled to an adjacent section by means of a bead coupling which locks the pieces together. Known machines for producing elbows require the stages of production of the sections to be performed manually. A skilled operator is therefore necessary to properly form each section and couple the sections together. The difficulty of properly forming each section and connecting the sections together result in a high percentage of scrap.

[0003] Other problems associated with these machines include the loss of air through the connections or beads between the gores of the duct system. As air circulates through the duct system, air dissipates through the connecting beads or seams that are between the gores, which in turn, causes a loss of energy and thus creates a less efficient system. Sealing of the duct increases the efficiency of the HVAC system, and conserves energy, which is highly desirable. The sealing of such duct members has generally been performed after installation using tape or mastic for example, which though helping to prevent the egress of air, is not particularly efficient and increases the cost of installation. There have been attempts to produce sealed duct members, which are then installed, but the machines used to form such duct members require significant operator handling and pose safety hazards to the operators. The production process also takes significant time, thereby increasing the cost. There is thus a need to have an apparatus and method for automated manufacture of elbow ducts that may be sealed to be highly efficient with respect to the preventing leakage therefrom.

SUMMARY

[0004] The invention is therefore directed in one respect to an apparatus for forming a sealed duct member for use in an air handling system. The apparatus comprises at least one work station adapted to accommodate a work piece. A cutting assembly is configured to cut the work piece in a predetermined manner to form first and second sections. A forming assembly including a forming member and at least one die member to form a connecting bead in the first and second sections which cooperate to reconnect the first and second sections together at a predetermined position. A work piece moving and rotating assembly moves the work piece relative to the cutting assembly and forming assembly, wherein the rotating assembly allows for rotation of the work piece and at least one of the first and second sections after being formed. A sealing assembly is further provided which cooperates with the at least one die member to seal the connecting bead in the first and second members after the connecting bead is formed. The sealing assembly comprises at least one crimping plate that forces the at least one die member against the formed connecting bead to crimp the connecting bead together. A control system is provided for controlling operation of the cutting, forming, work piece moving and rotating assembly and sealing assemblies.

[0005] The invention also relates to a method of automated manufacturing of a duct member. The method includes providing a work piece having a cylindrical configuration and positioning the work piece in a work station at a first predetermined position. A clamping system includes a first clamp to secure the work piece in a first predetermined position, and the work piece is moved to the position where a first cut is to be made and may be rotated 180 degrees clockwise. A second clamp is activated to secure the work piece in a second predetermined position, and a cutting operation is performed to cut the work piece at a first predetermined position to form first and second sections. The first section is moved toward the second section a predetermined amount and a turning head is engaged to the interior of the second section. The second section is then rotated 180 degrees clockwise and the turning head is disengaged. A forming operation is initiated to form connecting beads in each of the first and second sections to reconnect the sections, and a crimping system seals the formed connecting beads together. The second clamp is then opened to release the work piece. The work piece is then moved to the position where a second cut is to be made and rotated 180 degrees counter clockwise. A second clamp is activated to secure the work piece in a predetermined position, and a cutting operation is performed to cut the work piece at a first predetermined position to form first and second sections. The first section is moved toward the second section a predetermined amount and a turning head is engaged to the interior of the second section. The second section is then rotated 180 degrees clockwise and the turning head is disengaged. A forming operation is initiated to form connecting beads in each of the first and second sections to reconnect the sections, and a crimping system seals the formed connecting beads together. The second clamp is then opened to release the work piece. The work piece is then moved to the position where at least a third cut is to be made and rotated 180 degrees clockwise. A second clamp is activated to secure the work piece in a predetermined position, and a cutting operation is performed to cut the work piece at a first predetermined position to form first and second sections. The first section is moved toward the second section a predetermined amount and a turning head is engaged to the interior of the second section. The second section is then rotated 180 degrees clockwise and the turning head is disengaged. A forming operation is initiated to form connecting beads in each of the first and second sections to reconnect the sections, and a crimping system seals the formed connecting beads together. The second clamp is then opened to release the work piece.

[0006] These and other features of the claimed invention, as well as details of illustrated examples thereof, will be more fully understood from the following description and drawings.

BRIEF DESCRIPTION OF DRAWINGS

[0007] FIG. 1 is a plan view of a duct member as formed according to an example of the invention;

[0008] FIG. 2 is a plan view of the tube or work piece used as a blank to form the cut member of FIG. 1; [0009] FIG. 3 is a side view of an example of the apparatus for automated cutting and forming of an elbow or like duct member;

[0010] FIG. 4 is a side view of the apparatus as shown in FIG. 3; [0011] FIG. 5 is a top view of the apparatus as shown in FIG. 3;

[0012] FIG. 6 is a perspective view of die members and a cutting and forming assembly in the apparatus of FIG. 3;

[0013] FIGS, and 7 and 8 show sectional view along the line A - A of FIG. 6, showing different operational states;

[0014] FIG. 9 is a perspective view of a portion of the die assembly according to an example;

[0015] FIG. 10 is a side view with partial sections of the die assembly as shown in FIG. 9;

[0016] FIG. 11 is a block diagram showing operation of the apparatus according to an example;

[0017] FIG. 12 shows an example operator interface to the control system for operation of the apparatus;

[0018] FIG. 13 is a partial view of a turning head used in the apparatus according to an example; and

[0019] FIG. 14 is a partial view of an alternative turning head used in the apparatus according to an example.

DESCRIPTION OF EXAMPLES OF THE INVENTION

[0020] Turning now to FIGS., an example of the invention is directed at producing an elbow duct member 10 such as shown in FIG. 1, wherein the duct member 10 is formed from a cylindrical tube 12 as shown in FIG. 2. To form the duct 10, the tube 12 is cut into gores or sections 14-18 that are then re-attached to form the elbow configuration. In this example, the duct 10 is shown as a 90 degree elbow, which may be formed by cutting of the tube 12 with four cuts at increments of 22.5 degrees apart as shown at x, to form the 90 degree elbow configuration, but other configurations may be formed, such as from three sections cut in 30 degree increments for example. In this example, the sections or gores 14 - 18 are re-attached by a connecting bead, with a portion of one section positioned in overlapping relationship, and connected together at that location via the connecting bead. The duct member 10 further includes a first opening 20 and a second opening 22, being adapted to be coupled between other duct members in a duct system. Though not shown, to facilitate connection of the duct member 10, an opening may be crimped for engagement with an inner wall of anther duct member. The tube 12 may be produced from a flat blank of material which is rolled with opposed seams of the blank coupled to one another to form the tubular configuration. As an example, the tubular configuration of the formed blank of material may provide a starting work piece 12 as shown in FIG. 2, which may then be operated on by the apparatus and methods of the invention. The work piece 12 as shown in FIG. 2 is designed to have a predetermined diameter for use in the apparatus and methods of the invention, but any suitable particular dimensional characteristics of the work piece can be accommodated.

[0021] The apparatus and methods of the invention may be operated to take the work piece 12 as shown in FIG. 2 and produce the duct member 10 of FIG. 1 automatically into the final preferred form, which may be without operator intervention.

[0022] Turning now to FIGS. 3 - 5, an example of the apparatus for forming the elbow duct is shown in more detail. The apparatus generally designated 50 includes a housing or frame construction 52 which supports various components of the apparatus. Housing or frame 52 includes an upper surface 54. The upper surface 54 is angled at a predetermined angle relative to horizontal or ultimately to the plane of the outlet opening on the tube 12 described previously. The top includes a nest 56 for receipt of the work piece 12 to perform the operations for cutting and forming the elbow duct member 10. The nest 56 includes a die and crimping assembly 58 supported adjacent the nest 56, which in this example comprises first and second semicircular die members 60 and 62 which are positioned on opposed sides of the nest 56. The die members 60 and 62 may be stationary, or may be made moveable toward and away from the nest 56 if desired. The die members are positioned beneath a crimping plate 59, that is moveable toward the die members 60 and 62. Within the nest 56, a cutting and forming system 70 is provided. The cutting and forming system 70 may include a turning head with levers in association with a forming head with a plurality of cassettes that carry cutting and forming wheels that are movable into engagement with the work piece, such as by cam biasing. Between the die members 60 and 62 and the cutting and forming system 70, a channel is formed to accept the work piece 12 as shown in FIG. 2, with the work piece 12 extending into the channel to a predetermined depth. A moveable support surface or tub 68 is provided at the bottom of channel, on which the work piece is supported within the nest 56 and moved to predetermined positions relative to the die members 60 and 62 and cutting and forming system 70. A moving assembly 55 (FIG. 3) is provided to move the tube 12 to desired positions relative to the forming head and die members. The moving assembly 55 may move the work piece 12 by any suitable mechanism. The cutting an forming assembly 70 extends through the moveable support surface or tub 68, and is connected to a drive system 73 and drive motor 75. Also associated with the channel is a clamping and rotating system to clamp the work piece 12 into a desired position and rotate the work piece or sections or gores thereof, to form the desired duct member. The clamping system includes an upper clamping system 63 and a lower clamping system 61 to clamp and rotate the work piece 12 and/or upper and lower sections or gores of the work piece 12 after being cut, to then be reconnected. Any suitable clamping and rotating system may be provided, such as including a clamp assembly comprising one or more clamp members which are hydraulically or electrically actuated to grip a surface of the work piece 12 above and below a cut, and then to rotate and/or position each section of work piece 12 at a desired position. The work piece 12 and sections are securely held in place as cutting and forming operations are performed thereon.

[0023] The cutting and forming system 70 is designed to cut, pre-form and finish form the connecting beads between sections or gores of the duct 10, and can also be utilized to seal the connections after being made. As shown in FIGS. 6 - 8, the cutting and forming assembly 70, in association with the dies 60 and 62 operate to cut and reconnect the sections of the work piece 12. The dies 60 and 62 in this example are formed from a cutting plate 65 and a forming plate 67. The cutting and forming assembly includes at least one cutting roller 72 and forming roller 74, that are moveable toward and away from the cutting plate 65 and forming plate 67 to perform the cutting and pre-forming, forming and crimping operations on the work piece 12 positioned in the channel. In FIG. 7, the cutting roller 72 is shown in the advanced position to engage the work piece 12 and cut the work piece 12 in association with the cutting plate 65. In FIG. 8, the forming roller 74 is shown in the advanced position to engage the work piece 12 and reconnect the cut pieces of the work piece 12 in association with the forming plate 67.

[0024] In this example, the die assembly 58 supported adjacent the nest 56 is formed by the first and second semicircular die members 60 and 62 which are positioned on opposed sides of the nest 56. One of these is shown in FIGS. 9 - 10 in more detail. The die member 60 includes a cutting plate 65 along with a forming plate 67, mounted in association with a base plate 69. A pair of thin semicircular plates or spacer rings 71 are mounted in association with the cutting plates 65 to facilitate forming the desired connecting beads in association with the cutting and forming assembly 70. After formation of the connecting beads, the beads may be crimped and sealed to substantially prevent the egress of air therethrough. A crimping assembly 59 or plate is moved against the formed connecting beads in each section, to apply force to the formed connecting beads to seal the connecting beads. In this example, the crimping plate 59 is moved by four hydraulic cylinders, but any suitable system can be used.

[0025] A block diagram of an exemplary, non-limiting embodiment to describe operation of the system is shown in FIG. 11. Operation of the apparatus and components may be controlled by a control system, including a computing device that may comprise one or more processor(s) configured to execute computer-executable instructions, such as instructions composing operation of one or more components of the machine 50. Such computer-executable instructions can be stored on one or more computer-readable media including a non-transitory, computer- readable storage medium such as memory associated with the computing device.

[0026] In general, once the work piece 12 is positioned in nest 56, the operation is started at 100. The bottom clamp 61 is closed at 102 to secure the work piece 12 into positon. The work piece is moved to the position of a first cut at 104 by the moving system 55 and may be rotated 180 degrees clockwise at 106 by the clamping and rotating assembly. The top clamp assembly 63 is closed at 108 and a first cutting operation performed at 110 by operation of the cutting and forming system 70, which will initially cut the work piece along a predetermined angular position defined by the angle of the die members 60 and 62 and cutting and forming assembly 70 relative to the work piece 12 positioned within the channel. The cutting operation is performed by engaging the cutting wheel 72 with the work piece in association with the cutting plate 65. Once the work piece is cut by the cutting and forming system 70, the support surface or tub 68 is moved up a predetermined amount, such as between 0.03 to 0.10 inches, or in this example, 0.060 inches, at 112, to position a portion of the cut section relative to the cutting and forming system 70. The cutting and forming assembly 70 is then operated to pre-form a portion of the work piece by engaging the turning head of system 70 to engage the forming wheel 74 with the work piece. The top piece of the cut work piece is then rotated 180 degrees clockwise at 116, and the turning head is disengaged at 118. At this point, the machine operation performs a breed lift operation at 120. After being cut and pre-formed, the breed lift causes the bottom section of tube to be inserted into an overlapping position with the top section. A pre-crimping operation is performed at 122, to form a portion of the work piece for subsequent sealing. The semi-circular rings associated with the cutting and forming assembly 70 facilitate controlling the flow or forming of material of the work piece during the breeding and pre-crimping processes. Thereafter, a forming operation is performed at 124, wherein the forming wheel in association with the forming plate produce a connecting bead in the work piece sections to reconnect the sections. A step of lifting or moving of the crimping plate 59 is performed at 126 to provide a crimping operation at 128. The pressure applied by the crimping plate 59 may be controllable and adjustable if desired. At this point, the first connecting bead is formed between gores or sections in the work piece 12, which may be tightly sealed.

[0027] As noted from the first operation, after cutting and preforming the connecting bead , the machine will automatically turn the first section 180 degrees, and then machine will complete the forming operation of the connecting bead. After the connecting bead is complete, the crimping plate will apply pressure and make a tight non-adjustable seal. The machine can produce an adjustable duct member by not using full pressure on the crimping process if desired.

[0028] The tub 68 is then moved to the position to form the second connecting bead at 132, and is rotated 180 degrees counter clockwise at 134. The top clamp 63 is closed at 136 and a second cutting operation performed at 138. As in the first connecting bead forming operation, the tub is moved up an amount, such as 0.060 inches at 140 and the turning head is engaged at 142. The top cut section is then rotated 180 degrees clockwise at 144, and the turning head disengaged at 146. The breed lift is performed at 148 and pre-crimping at 150. A second forming operation is then performed at 152, to form the second connecting bead. The crimping plate is lifted at 154 to crimp the formed connecting bead at 156. The top clamp 63 is then opened at 158, and the sealed second connecting bead is formed between gores or sections.

[0029] The tub 68 is then moved to the position to form the third connecting bead at 160, and is rotated 180 degrees clockwise at 162. The top clamp 63 is closed at 164 and a second cutting operation performed at 166. As in the first and second connecting bead forming operations, the tub is moved up an amount, such as 0.060 inches at 168 and the turning head is engaged at 170. The top cut section is then rotated 180 degrees clockwise at 172, and the turning head disengaged at 174. The breed lift is performed at 176 and pre-crimping at 178. A third forming operation is then performed at 180, to form the third connecting bead. The crimping plate is lifted at 182 to crimp the formed connecting bead at 184. The top clamp 63 is then opened at 186, and the sealed third connecting bead is formed between gores or sections.

[0030] The tub 68 is then moved to the position to form the fourth connecting bead at 188, and is rotated 180 degrees counter clockwise at 190. The top clamp 63 is closed at 192 and a fourth cutting operation performed at 194. As in the prior connecting bead forming operations, the tub is moved up an amount, such as 0.060 inches at 196 and the turning head is engaged at 198. The top cut section is then rotated 180 degrees clockwise at 200, and the turning head disengaged at 202. The breed lift is performed at 204 and pre-crimping at 206. A fourth forming operation is then performed at 208, to form the fourth connecting bead between gores. The crimping plate is lifted at 210 to crimp the formed connecting bead at 212. The top clamp 63 is then opened at 214, and the sealed fourth connecting bead is formed, and the part is now formed into a sealed 90 degree elbow in final form, without operator intervention except to position work piece 12 and remove the final form duct member.

[0031] In the above operations, each step may be performed automatically. As seen in FIG. 12, a control system 250 for the machine 50 may be provided by suitable systems, such as computer, including processor(s), PLC controllers or any other suitable system. A computer typically includes a variety of computer readable media and can be any available media that can be accessed by computer. The system memory may include computer storage media in the form of volatile and/or nonvolatile memory such as read only memory (ROM) and/or random access memory (RAM). By way of example, and not limitation, there may be provided an operating system, application programs, other program modules, and program data. A user or operator is enabled to enter commands and information into the computer. In this example, the control system 250 includes a touch screen to allow setting and selection of operation of machine 50, which may be by an unskilled operator. The machine 50 may be started at 251 and set up in automatic mode at 252. Recipes or predetermined operational steps such as outlined in the above example, may be set in relation to the production of desired duct members, and such recipes may be called up and implemented automatically at button 254. In this way, an unskilled operator can simply recall a particular recipe for the type of duct member to be produced, alleviating the necessity for a skilled operator and simplifying the manufacturing process. A manual mode may be provided at 256. A machine drive reset button 258 may be provided to reset the starting position of the machine if needed. A parts counter 260 may be provided, with a reset button at 262. Indicators may be provided to indicate operation of systems as noted , and an emergency stop button 264 may be provided for emergencies. But, as noted above, the formation of the duct member is automatically performed on a work piece 10 inserted into the channel, and there are no further actions by an operator required.

[0032] The control system 250 also provides access to control all machine functions, such as the top clamp 63 at 266, bottom clamp 61 at 268, and the crimping system at 270, including a low pressure crimp option at 271. The cutting and forming head may be controlled at 272, while tub movement is controllable at 274. Rotational movement of the tub or top clamp is controllable at 276. Other functionality may be provided, such as setting the desired positions of connecting beads to form the gores of the duct member at 278 for example, or any other requirements as may be desired.

[0033] In examples as shown in FIGS. 13 and 14, the cutting and forming assembly 70 may include a rotating head 300 driven by a central gear 302. The head 300 includes three cassettes 304 which are movable on a support 306. Associated cams 308 cause movement of the cassettes to move outwardly and engage the work piece as described in association with the cutting and forming wheels in each cassette 304. Alternatively, the cutting and forming assembly 70 may include a rotating head 310 driven by an eccentric drive 312, to cause engagement of the cutting and forming wheels with the work piece. Other suitable configurations may be used. [0034] In the operation of the cutting and forming assembly 70, a pre-forming operation may be performed as described, to simultaneously pre-form the bottom edge of the top cut section and the top edge of the bottom section with a slight inward taper to assist in moving the cut sections into overlapping relationship. In general, the material from which the work piece 10 is formed is of significant structural integrity whereby the connecting beads formed are deep and consistently formed to facilitate maintaining the connection between the gores and providing the desired seal.

[0035] While the above description has been presented with specific relation to particular examples of the systems and methods, it is to be understood that the claimed invention is not to be limited thereby. Illustrative embodiments have been described, hereinabove. It will be apparent to those skilled in the art that the above devices and methods may incorporate changes and modifications without departing from the general scope of the claimed subject matter. It is intended to include all such modifications and alterations within the scope of the claimed subject matter. Furthermore, to the extent that the term "includes" is used in either the detailed description or the claims, such term is intended to be inclusive in a manner similar to the term "comprising" as "comprising" is interpreted when employed as a transitional word in a claim.