APPARATUS AND METHOD FOR CLOSING DUCT SEAMS AND FOR INSERTING ANGLE PLATES AND CLOSING DUCT SEAMS

Abstract

Apparatus and methods are described for automatically closing the seam of duct work and for automatically inserting angle plates into duct work and then closing the seam of the duct work. The seam closing apparatus includes a first seam closing members for closing the top and bottom portions of the seam and a second seam closing member for closing the remainder of the seam of the duct work.

Claims

1. An apparatus for automatically inserting angle plates into a duct flange and for automatically closing a seam of a duct comprising (a) a dual head assembly having a lower head and an upper head wherein each head includes a platen for receiving a duct and an assembly for automatically inserting an angle plate into the duct flange; and (b) a seam closing assembly for automatically closing a seam of the duct comprising (1) a first bender at the lower head and a second bender at the upper head, the first and second benders adapted to first close the top and bottom portions of the seam; and (2) a carriage assembly comprising a pair of vertical support members constructed and arranged outside of the work area of the assembly for automatically inserting an angle plate, a seam closing carriage connected to the vertical support members and having a seam forming member, means for moving the seam closing carriage up and down the vertical support members, the seaming assembly adapted to close the remaining portion of the seam; wherein when a duct is positioned in the apparatus, the assembly for automatically inserting an angle plate will automatically insert an angle plate in the duct flange and the seam closing assembly will automatically close the duct seam.

2. The apparatus of claim 1 wherein the assembly for automatically inserting an angle plate into the duct flange comprises at least one clamping member for clamping the duct into position on the platen, a feed member for feeding an angle plate into place in the duct flange, at least one press member for pressing an angle plate into the duct flange, a supply hopper having a plurality of angle plates for supplying angle plates to the feed member, and at least one crimper member for crimping the flange of the duct over the angle plate after the angle plate has been inserted into the duct flange.

3. The apparatus of claim 1 wherein the benders comprise a rocker for bending and closing the seam; a saddle for holding the rocker; a piston; an hydraulic cylinder; and guide rods, wherein the hydraulic cylinder moves the piston and guide rods back and forth to move the rocker into position to close the seam of the duct.

4. The apparatus of claim 1 wherein the apparatus is adapted to first insert angle plates in the duct flange and then close an open seam of the duct.

5. The apparatus of claim 1 wherein at least the lower head or the upper head includes a pair of light bars adapted to sense the presence of an unseamed duct corner.

6. The apparatus of claim 4 wherein the lower head and the upper head each include a pair of light bars and a first of said light bars includes a light source and a second of said light bars includes a means for detecting the light source.

7. The apparatus of claim 1 wherein said seam closing carriage comprises a horizontal bar having means for riding on said vertical support members.

8. The apparatus of claim 1 wherein said seam closing carriage comprises a horizontal bar having at least one air cylinder adapted to move the horizontal bar and the seam closing carriage away from the unseamed duct.

9. The apparatus of claim 8 wherein the horizontal bar further includes means for attaching an endless chain drive at each end of the horizontal bar.

10. The apparatus of claim 1 wherein the seam forming members are selected from the group consisting of a plurality of roll forming members and cam followers.

11. The apparatus of claim 10 wherein the plurality of roll forming members comprises three roll forming members in vertical relation, the upper-most roll forming member having a flat area, the center roll forming member having a V-shape member; and the lower-most roll forming member having a V-shape, wherein the plurality of roll forming members are adapted to close the duct seam no matter the orientation of the duct.

12. The apparatus of claim 1 wherein the platen includes guide posts and guide bars for positioning the duct.

13. The apparatus of claim 12 wherein the guide bars include proximity sensors adapted to sense the position of the duct and to begin the sequence of the angle plate insertion.

14. The apparatus of claim 1 wherein the at least one clamping member comprises a pair of clamping members adapted to clamp the duct flange and to lock the flange in place.

15. The apparatus of claim 1 wherein the at least one clamping member comprises a clamp which pivots from the underside of the platen to engage the inside of the duct to hold the duct in place.

16. The apparatus of claim 1 wherein the upper head is adjustable and the apparatus is adapted to receive different lengths of duct.

17. The apparatus of claim 1 wherein the seam closing carriage is adapted to close the duct seam by moving vertically upward on the vertical support members, wherein the seam forming member closes the duct seam.

18. The apparatus of claim 17 wherein the seam closing carriage is further adapted to move vertically downward to further finish the seam closing and return the seam closing carriage to its starting position.

19. An apparatus for automatically closing a seam of a duct comprising (1) a frame having a first end and a second end; (2) a means to hold the duct in the frame; (3) a first bender at the first end of the frame and a second bender at the second end of the frame, wherein the first and second benders are adapted to close first and second end portions of the seam of the duct; and (4) a seam closing carriage for closing the remainder of the seam and having a means for moving the seam closing carriage from one end of the frame to the other end of the frame and having a seam forming member for closing the remaining portion of the seam.

20. The apparatus of claim 19 wherein the benders comprise a rocker for bending and closing the seam; a saddle for holding the rocker; a piston; an hydraulic cylinder; and guide rods, wherein the hydraulic cylinder moves the piston and guide rods back and forth to move the rocker into position to close the seam of the duct.

21. A method for automatically inserting angle plates into a duct flange and for automatically closing a seam of a duct comprising (a) inserting a duct having transverse flanges into an apparatus adapted to automatically insert angle plates into the duct flanges and to automatically close a seam of the duct; (b) the apparatus including a dual head assembly having a lower head and an upper head wherein each head includes a platen for receiving a duct and an assembly for automatically inserting an angle plate into a duct flange, the assembly for automatically inserting an angle plate into a duct flange including at least one clamping member for clamping the duct into position on the platen, a feed member for feeding an angle plate into place in the duct flange, at least one press member for pressing an angle plate into the duct flange, a supply hopper having a plurality of angle plates for supplying angle plates to the feed member, and at least one crimper member for crimping the flange of the duct over the angle plate after the angle plate has been inserted into the duct flange; (c) the apparatus further including a seam closing assembly for automatically closing a seam of a duct comprising (1) a first bender at the lower head and a second bender at the upper head, the first and second benders adapted to close the top and bottom portions of the seam; and (2) a carriage assembly comprising a pair of vertical support members constructed and arranged outside of the work area of the assembly for automatically inserting an angle plate, a seam closing carriage connected to the vertical support members and having a horizontal member with a seam forming member, and means for moving the seam closing carriage up and down the vertical support members for closing the remaining portion of the seam; (d) clamping the duct into the apparatus; (e) inserting angle plates into the duct flanges; and (f) closing the seam of the duct, wherein the first and second benders first close top and bottom portions of the seam and then the seam closing carriage moves vertically on the vertical support members and wherein the seam forming member closes the remainder of the seam of the duct.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The following detailed description of the specific non-limiting embodiments of the present invention can be best understood when read in conjunction with the following drawings, where like structures are indicated by like reference numbers.

[0018] Referring to the drawings:

[0019] FIG. 1 is a front and side perspective view of the apparatus of the invention.

[0020] FIG. 2 is another front and side perspective view of FIG. 1.

[0021] FIG. 3 is a partial enlarged view of the top and bottom heads of FIG. 1.

[0022] FIG. 4 is a back view of FIG. 1.

[0023] FIG. 5 is an enlarged view of the bender in relation to the duct in the apparatus.

[0024] FIG. 6 is a view of the bender closing the lower seam of the duct.

[0025] FIG. 7 is a perspective view of the bender.

[0026] FIG. 8 is an enlarged view of the carriage with the rollers in relation to a duct for closing the seam of the duct.

[0027] FIG. 9 is a perspective view of the carriage.

[0028] FIG. 10 is a perspective view of the carriage in relation to a duct for closing the seam of the duct.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0029] Referring to the Figures, the present invention is directed to new apparatus and methods for (1) automatically closing the seam of a duct, and (2) automatically inserting angle plates into duct flanges and automatically closing the seam of a duct. The apparatus and method for automatically closing the seam of a duct will be described first (not shown). It will be described with respect to closing a Pittsburgh seam. The apparatus and method can be similar to the CORNERMATIC Combo Machine without the corner insertion components but will further comprise a bender at the top and bottom of the apparatus for first closing the top and bottom four to five inches of the seam and thereafter closing the remainder of the seam. The bender 400 is shown, for example, in FIG. 7. The bender 400 comprises a rocker 402 for bending and closing the seam; saddle 404 for holding the rocker; piston 406; an hydraulic cylinder 408; and guide rods 410. Hydraulic cylinder 408 moves the piston 406 and guide rods 410 back and forth to move the rocker into position to close the seam of a duct. A bender useful for the invention is sold by Ready Technologies under the trademark Ready Bender. Thereafter, the remainder of the seam is closed as discussed hereafter.

[0030] The second apparatus and method of the invention is a combination corner inserter and seam closer. The apparatus is similar to the CORNERMATIC Combo machine and includes a bender at the top and bottom of the machine for first closing the top and bottom four to five inches of the Pittsburgh seam that the CORNERMATIC Combo machine cannot close. The bender is the same as disclosed above for the seam closing apparatus and discussed below.

[0031] The apparatus 10 is a dual head apparatus, the lower and upper heads being substantially similar. For ease of reference, the lower head assembly will be described with the understanding that the upper head is substantially similar, except when otherwise indicated. The apparatus includes a platen 20 for receiving a duct D. The duct D shown, for example, in FIGS. 1 and 5 has a duct flange and may be a TDC or TDF duct flange or similar duct flange. Other ducts without flanges may be seamed such as a slip on connector; and slip and drive duct work. The apparatus includes guide posts 22 and guide bars 24 for positioning the duct in position. It is understood that a work table will be placed adjacent to the machine for working with the duct and the angle plate insertion and duct seaming, or the machine may be built into the ground of a fabricator's workshop. The apparatus further includes clamping members 30 and 32 for clamping the duct into position; a feed member 60 for feeding an angle plate into place in the duct flange; press members 70 for pressing an angle plate into the duct flange; and an angle plate support hopper 90 for receiving a plurality of angle plates, e.g. in a STRAP-PAK package, or other angle plate supply assemblies for supplying angle plates to the feed member; and crimper members (not shown) for crimping the duct flange after the angle plate has been inserted into the duct. These foregoing members are used for automatically inserting angle plates into the duct work and for also holding the duct work in position for automatically seaming the duct. As previously stated, in a preferred apparatus and method, the duct work first has angle plates inserted into a duct flange at each of the top and bottom corners of the duct, i.e. a dual head angle plate inserter apparatus (angle plates are also known as corners in the industry). Thereafter, the apparatus and method will close the seam of the duct, e.g. a Pittsburgh seam, although other types of seams may be closed using the apparatus and method of the invention.

[0032] The angle plate insertion mechanisms of the apparatus may be generally as disclosed in the commercial CORNERMATIC Combo machine; Systemation's U.S. Pat. Nos. 9,027,376 and 5,283,944; the CORNERMATIC PLUS machine; Systemation's U.S. Pat. Nos. 8,875,388; 9,151,513; and 9,937,592 or combinations of these disclosures, which disclosures have been incorporated in their entirety herein by reference and may not be repeated in detail herein.

[0033] The primary components of the apparatus are discussed in greater detail hereafter with reference to the lower head of the apparatus, the upper head being substantially the same, and include a platen 20, clamping members 30 and 32 for clamping the duct in position; a feed member 60 for feeding an angle plate into place in the duct flange; press members 70 for pressing an angle plate into the flange; an angle plate supply hopper 90 for receiving a plurality of angle plates for supplying angle plates to the feed member from, for example, an angle plate package inserted into the supply hopper; and crimper members (not shown) for crimping the duct flange after the angle plate has been inserted into the duct flange. These components of the invention will be discussed in greater detail below.

[0034] The platen 20 includes guide posts 22 and guide bars 24 for positioning the duct in place in the machine. Guide posts 22 are fastened adjacent to the platen 20. As stated above, the apparatus may seam both duct work having duct flanges (which require angle plate insertion) such as TDC and TDF duct work or duct work not having duct flanges (which do not require angle plate insertion) such as a slip on connector or slip and drive duct work. With duct work having flanges, the flanges contact the guide posts 22. For duct work with and without flanges, the duct sides contact the guide bars 24. The guide bars 24 may include proximity sensors which indicate that a duct is in position and starts the angle plate insertion process as discussed below. Additionally, the apparatus may include light beam bars which include a light beam source and a light beam receiving member for generating a light beam to sense when a duct is in place and not seamed as the open ended female edge portion breaks the light beam, e.g. a fiber optic light beam. The machine, therefore, knows that the seam needs to be closed after the angle plate insertion operation. It is understood that other means for detecting the open-ended female edge portion may be used or a manual means for engaging the seam closing assembly may be used.

[0035] With respect to the clamp members 30, the clamp member 30 includes a clamp arm for clamping the duct work in place. There are two clamp members 30 which function the same and clamp adjacent flanges of a duct. The clamp arm includes a clamp head and clamp finger which engages the duct flange. The clamp arm is connected to a clamp block by a pin upon which the clamp arm pivots. The clamp 30 is attached to an air cylinder 40. A piston moves the clamp arm from an unclamped to a clamped position. The clamp members 30 are triggered to clamp the duct work in place by proximity sensors. When the duct sides engage proximity sensors, the proximity sensors signal the start of the angle plate insertion process causing air cylinder 40 and piston to move the clamp arms downward and clamp the duct flange into position. During the clamping process, the clamp members 30 pull the flange of the duct outward and will also straighten out any duct flange which has been deformed. This provides for easier receipt of an angle plate into the duct flange. More specifically, the clamp members 30 pull the duct into place and then clamps the duct into position for receiving the angle plate. In doing so, it flattens out the flanges so that there is no interference between the duct flange and the feeding of the angle plate to the duct flange. The clamp members 30 also open up the area of the channel which allows for easier placement of an angle plate into the flange.

[0036] Referring to FIGS. 2 and 3, there is shown a second clamping member 32. This clamping member 32 clamps the duct work into place on the inside of the duct. Clamping member 32, in conjunction with clamping members 30, secures the duct in place. Clamping member 32 is shaped in a cylindrical configuration to avoid tearing insulation or other materials adhered to the inside of the duct. Similarly, other radius configurations may be used.

[0037] The feed member 60 feeds the angle plate into the duct flange. The feed member 60 slides forward and has a V-shaped member which engages an angle plate and moves the angle plate into engagement with the duct flange. The feed member 60 is operated by an air cylinder having piston rods connected to feed plate 60. The operating stroke of the piston rods and feed plate 60 push an angle plate from the bottom of the stack of angle plates to engage an adjacent corner of a duct and overlying the two adjacent duct channel flanges.

[0038] The angle plate useful in the invention and in the packaging discussed hereafter is as disclosed in, for example, U.S. Pat. No. 5,342,100, and sold commercially by Ductmate Industries, Inc. under the trademark CORNERMATIC. A presently preferred package of angle plates is disclosed in Systemation's U.S. Pat. Nos. 9,545,695 and 9,377,213 and sold by Ductmate under the trademark STRAP-PAK.

[0039] Referring to FIGS. 2 and 3, the apparatus includes press members 70 adjacent to each side of the duct work. The pressers 70 will press the angle plate down into position in the duct flange. Preferably, the pressers 70 will press the angle plate axially. Referring, for example to FIG. 3, there is shown an air cylinder 74 of the press member 70. The air cylinder 74 has a piston rod for moving the press head of the pressers 70 for pressing an angle plate. The press head includes a press wedge for contacting the angle plate and pressing the angle plate into the flange.

[0040] The apparatus includes crimper members (not shown) for crimping the duct flange to hold the angle plate in the flange. The crimper mechanism is generally as disclosed in U.S. Pat. No. 5,283,944. The crimper members extend upwardly through an opening in the platen 20. Each crimping member is carried by an angle lever which is pivotally mounted on a pivot pin. The angle lever is connected to an air cylinder 124 having a piston rod for movement of the angle lever. The crimper member includes a crimper arm for engaging and crimping the duct flange.

[0041] As previously stated, the above description has generally referenced the angle plate inserter components in relation to the lower head assembly. The components are substantially similar for the upper head and will not be repeated in detail herein. The upper head is shown in FIGS. 1-4.

[0042] Referring to FIGS. 1 and 2, there is generally shown a pneumatic control panel 130. This panel includes air regulators and a pneumatic manifold with control valves for operating the air cylinders for the upper and lower heads of the apparatus. Each valve has a manual override which can be used for setup and maintenance. The control panel includes incoming air supply regulators; incoming air supply regulator gauges; valves for the benders; valves for the clamping members 30; valves for clamping members 32; valves for the feed members 60; valves for the presser members 70; and valves for the crimping members. Each valve has a manual override valve. It is understood that the apparatus may also be operated by electrical controls or other means known to those skilled in the art.

[0043] FIG. 4 also shows upper platen 20 which is adjustable to accommodate different size duct. Platen 20 adjusts by an air piston and piston rods and includes a support member 284 at the rear of the machine through which rod 286 moves up and down.

[0044] The operating sequence of the machine, as discussed hereafter, is controlled by a programmable logic control (PLC) which may be located in an electrical enclosure 140 on the machine. The machine may operate with a standard 220 VAC outlet circuit. When the machine is plugged into a power source, power may be applied to the system and the PLC by pressing on a power on push-button switch. Power may be removed by pressing a power off push-button switch. The machine operation may be controlled by a series of inputs within the PLC. As discussed below, the sequence is activated by the proximity sensors that connect to inputs of the PLC. Once these inputs are activated, the sequence of the corner insertion begins and steps through to completion as discussed hereafter. When duct work without flanges are to be seamed, the control panel includes a separate control for operation of the seam closing assembly.

[0045] In the angle plate insertion operation, the duct fitting will be placed on the platen 20 of the apparatus and pushed against guide posts 22 and guide bars 24 where it will engage proximity sensors. This causes the clamp members 30 and 32 to clamp the duct work into place. During the clamping stage, the clamps 30 will pull the flange of the duct outward and straighten out the flange for easier receipt of the angle plate. The clamp will also pull the duct in place and then flatten the flanges so that there is no interference of the duct during the angle plate feed cycle. This also widens out the flange and allows for easier integration of the angle plate into the flange. Clamp 32 pivots upward and further positions the duct. Once the duct fitting is clamped in place, feed members 60 moves an angle plate into place in the duct flange. Once the angle plate is in place, press members 70 will axially press the angle plate down into position in the duct flange. Once the angle plate is pressed into place, the crimpers will cause the crimping arms to crimp the flange over the angle plate to hold the angle plate in the flange. An angle plate is inserted in the lower and upper ends of the duct. The duct may require anywhere from one to four seams. The assembly for seaming will engage when a light beam senses that there is a non-seamed corner of the duct in position for seaming.

[0046] The apparatus 10 further includes a seam closing assembly comprising (1) first and second benders 400 for first closing the top and bottom four to five inches of the seam, and (2) a carriage assembly 200. The benders 400 are as discussed above and shown in FIG. 7. Referring to FIGS. 5-7, the operation of bender 400 for the lower head of the apparatus will be described, the upper head functioning in substantially the same way. Referring to FIG. 5, duct D is held in place on platen 20 by clamping members 30 and 32. Bender 400 is bolted to the platen 20. Rocker 402 of bender 400 is shown prior to seaming the lower four to five inches of the Pittsburgh seam S. Referring to FIG. 6, the bender 400 is actuated and hydraulic cylinder 408 moves piston 406 on guide rods 410 and rocker 402 engages seam S and closes the seam at the lower four to five inches of the seam. Thereafter, the remainder of the seam is closed by seaming assembly 200.

[0047] The carriage assembly 200 includes support members 210 which provide support for a seam closing carriage 220 for closing the remainder of the seam. The seam closing support members 210 may be linear rails. The support members are attached to the frame of the apparatus by suitable fasteners such as bolts (not shown). The seam closing carriage 220 includes a horizontal bar 222. Bar 222 includes guide members 224 which ride on support members 210 and chain members 226 for connecting chain drives at the ends of the bar 222. Bar 222 includes a seam closing carrier including a housing 228 having a seam forming member. Bar 222 further includes air cylinders 227 that move bar 222 and the seam closing carriage 220 back to clear the female duct flange of the Pittsburgh seam when the duct D is loaded into the machine. In the prior art CORNERMATIC Combo Machine, the flange is bent over by a worker with a hammer. The seam closing carriage 220 moves vertically on linear rails 210. The seam closing carriage moves by endless chain drives 250. Referring, for example, to FIG. 3, the chain drives 250 are moved by an electric motor 260 having a drive shaft 262 and drive sprockets 264 engaging each chain drive 250.

[0048] As seen in FIG. 4 and discussed above, the apparatus 10 includes an adjustable upper head which will move up and down by the piston member and include supports 284 at each side of the rear of the machine for vertical movement of rods 286. For example, a slip on connector or slip and drive duct work is generally longer than flanged ducts and the upper head must be raised to accommodate this type of duct work.

[0049] The assembly further includes at the lower and upper heads bolts 290 to mechanically stop the carriage and electrical switch 292 which the carriage will contact to electrically stop the carriage. Bolts 290 are attached to the platens 20.

[0050] A housing 228 is connected to the horizontal bar 222 as shown, for example, in FIGS. 9 and 10.

[0051] Referring to FIG. 9, the rollers are attached to the housing 228 by pins and will rotate. The housing 228 includes seam forming members which include a first roller 272 having a straight surface; a second roller 274 having about a 120 to 145 degree V-shape, 135 degrees is shown and preferred; and a third roller 276 having about an 85 to 90 degree V-shape, 88 degrees is shown and preferred. These seam forming members will form or close the seam of the duct as discussed below. The duct may be placed in the apparatus in any orientation and the seaming assembly will close the duct seam. In the alternative to roller members, the carriage may use cam followers for closing the seam.

[0052] In operation, after the corners are inserted into the flanges of the duct (assuming a duct having flanges), the clamping members will hold the duct into position. When an unseamed duct corner is sensed by a light beam, the seaming operation takes place. First, the top and bottom benders 400 are actuated to close the top and bottom four to five inches of the seam as described above. Next, the carriage assembly 200 will start the seaming operation from the bottom of the machine and move up along linear rails 210 by chain drive members 250. The seam forming members 272, 274 and 276, will close the Pittsburgh seam as shown in FIG. 10. Roller 272 will first engage the edge of the female seam member and bend the seam approximately forty-five degrees. Thereafter, the second roller 274 will further bend the edge of the female seam member. Thereafter, roller 276 will further bend the edge of the female seam member ninety degrees to complete the closing of the seam. The carriage will then move back down to provide a smooth and clean finish to the duct seam.

[0053] Alternative seam forming members are shown in U.S. Pat. No. 9,027,376 which has been incorporated herein by reference. It is understood that other seam forming members may be used without departing from the scope of the invention, e.g. cam followers.

[0054] The exemplary embodiments herein disclosed are not intended to be exhaustive or to unnecessarily limit the scope of the invention. The exemplary embodiments were chosen and described in order to explain the principles of the present invention so that others skilled in the art may practice the invention. As will be apparent to one skilled in the art, various modifications can be made within the scope of the aforesaid description. Such modifications being within the ability of one skilled in the art form a part of the present invention and are embraced by the appended claims.