U.S. patent application number 09/730512 was filed with the patent office on 2001-10-18 for angled ductwork fittings, flexible fitting machine and methods of manufacture.
Invention is credited to Froning, Mark A., Moyers, Gregory C., Price, Miller S..
Application Number | 20010029764 09/730512 |
Document ID | / |
Family ID | 26864735 |
Filed Date | 2001-10-18 |
United States Patent
Application |
20010029764 |
Kind Code |
A1 |
Price, Miller S. ; et
al. |
October 18, 2001 |
Angled ductwork fittings, flexible fitting machine and methods of
manufacture
Abstract
Machines and methods for making an angled ductwork fitting from
a length of flexible spiral pipe, which may be flat oval, having
two ends. A pair of end securing devices are attachable to
respective ends of the length of flexible spiral metal pipe. A
mechanism moves the end securing devices relative to each other
through a range of movement to an end position which effects
bending of the length of spiral metal pipe to a desired angled
configuration. Another disclosed method employs a preformed
inflatable bladder which, when inflated, assumes the shape of an
elbow. The preformed inflatable bladder is inserted in collapsed
form into a length of flexible spiral metal pipe, and thereafter
inflated.
Inventors: |
Price, Miller S.;
(Morristown, TN) ; Froning, Mark A.; (Arden,
NC) ; Moyers, Gregory C.; (Arden, NC) |
Correspondence
Address: |
Steven C. Schnedler
Carter & Schnedler, P.A.
56 Central Avenue, Suite 101
P.O. Box 2985
Asheville
NC
28802
US
|
Family ID: |
26864735 |
Appl. No.: |
09/730512 |
Filed: |
December 5, 2000 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60169076 |
Dec 6, 1999 |
|
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|
Current U.S.
Class: |
72/295 |
Current CPC
Class: |
B21D 7/00 20130101; B21D
9/01 20130101 |
Class at
Publication: |
72/295 |
International
Class: |
B21D 011/02 |
Claims
What is claimed is:
1. A machine for making an angled ductwork fitting from a length of
flexible spiral metal pipe having two ends, said machine
comprising: a pair of end securing devices attachable to respective
ends of the length of flexible spiral metal pipe; and a mechanism
for moving said end securing devices relative to each other, while
attached to the respective ends, through a range of movement to an
end position which effects bending of the length of spiral metal
pipe to a desired angled configuration.
2. The machine of claim 1, which further comprises an inner radius
die positioned so as to contact a portion of the length of spiral
metal pipe intermediate the two ends.
3. The machine of claim 1, which further comprises: an intermediate
securing device attachable to a portion of the length of spiral
metal pipe intermediate the two ends; and wherein said mechanism
for moving the end securing devices relative to each other in
addition moves the intermediate securing device relative to at
least one of the end securing devices.
4. The machine of claim 1, wherein one of said end securing devices
is attached to a fixed table, and the other of said end securing
devices is attached to an articulating arm.
5. The machine of claim 4, which further comprises an inner radius
die positioned so as to contact a portion of the length of spiral
metal pipe intermediate the two ends.
6. The machine of claim 1, wherein said mechanism for moving said
end securing devices relative to each other comprises: a table to
which one of said end securing devices is attached; a movable
element to which the other of said end securing devices is
attached; an arm attached to said movable element and extending
past a pivot point; and an actuator attached to said arm.
7. The machine of claim 6, wherein the position of said pivot point
is adjustable.
8. The machine of claim 1, wherein said mechanism for moving said
end securing devices relative to each other comprises an X and Y
axes drive mechanism attached to one of said end securing
devices.
9. The machine of claim 8, which further comprises: an intermediate
securing device attachable to a portion of the length of spiral
metal pipe intermediate the two ends; and another X and Y axes
drive mechanism attached to said intermediate securing device.
10. A method for making an angled ductwork fitting, said method
comprising: providing a length of flexible spiral metal pipe having
two ends; employing a machine having a pair of end securing devices
attachable to respective ends of the length of flexible spiral
metal pipe, and a mechanism for moving the end securing devices
relative to each other, to manipulate the length of flexible spiral
metal pipe to a desired configuration.
11. The method of claim 10, wherein said step of providing a length
of flexible spiral metal pipe having two ends comprises providing a
length of flat oval flexible spiral metal pipe.
12. A method for making an angled ductwork fitting, said method
comprising: providing a length of flexible spiral metal pipe having
two ends; providing a preformed inflatable bladder which, when
inflated, assumes the shape of an elbow; inserting the preformed
inflatable bladder in a collapsed form into the length of flexible
spiral metal pipe; and inflating the bladder.
13. The method of claim 12, wherein said step of providing a length
of flexible spiral metal pipe having two ends comprises providing a
length of flat oval flexible spiral metal pipe.
Description
CROSS-REFERENCE TO PROVISIONAL PATENT APPLICATION
[0001] The benefit of U.S. provisional patent application Ser. No.
60/169,076, filed Dec. 6, 1999, is claimed.
BACKGROUND OF THE INVENTION
[0002] The invention relates to angled ductwork fittings, such as
elbows and offsets, used for joining sections of round spiral and
flat oval ductwork, such as is employed in heating, ventilation and
air conditioning (HVAC) system applications.
[0003] Conventional practice is to employ die-formed elbows and
gored elbows. Both die-formed elbows and gored elbows are available
from E. H. Gustafson & Co., 5115 Suffield Terrace, Skokie, Ill.
60077. Die-formed and gored elbows are conventionally available in
increments of 30.degree., 45.degree., 60.degree. and
90.degree..
[0004] With reference to FIGS. 1 and 2, a prior art gored elbow 10
joins two flat oval ductwork sections 12 and 14. The ductwork
sections 12 and 14 however are representative of a variety of
elements which it may be desired to join at right angles, such as
transition fittings or air distribution louvers.
[0005] Gored elbows are hand-manufactured by cutting triangular
sections out of round pipe, bending and welding. The particular
gored elbow 10 of FIGS. 1 and 2 is a 90.degree. elbow, and
comprises a set of five sections 16, 18, 20, 22 and 24, called
gores, that are individually cut out, rolled, fastened and fitted
together. A substantial amount of time is required to produce a
gored elbow, and they are relatively costly.
[0006] Thus, conventional fittings are manufactured either in
several pieces as gores that are welded or mechanically joined, or
by stamping the fitting from a solid piece of metal. The stamped
fittings are limited in size to approximately fourteen inches in
diameter.
SUMMARY OF THE INVENTION
[0007] The invention is embodied in a machine for making an angled
ductwork fitting from a length of flexible spiral metal pipe having
two ends. The length of flexible spiral metal pipe may be flat
oval. The machine includes a pair of end securing devices
attachable to respective ends of the length of flexible spiral
metal pipe, as well as a mechanism for moving the end securing
devices relative to each other, while attached to the respective
ends, through a range of movement to an end position which effects
bending of the length of the spiral metal pipe to a desired angled
configuration.
[0008] A method embodying the invention includes the steps of
providing a length of flexible spiral metal pipe having two ends,
and employing the machine to manipulate the length of flexible
spiral metal pipe to a desired configuration.
[0009] Another method embodying the invention includes the steps of
providing a length of flexible spiral metal pipe having two ends,
and providing a preformed inflatable bladder which, when inflated,
assumes the shape of an elbow. The preformed inflatable bladder is
inserted in a collapsed form into the length of flexible spiral
metal pipe, and thereafter inflated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1, referred to hereinabove, depicts a prior art gored
elbow;
[0011] FIG. 2, also referred to hereinabove, is a cross-section
taken on line 2-2 of the prior art gored elbow;
[0012] FIG. 3 is a three-dimensional representation of a first
machine embodying the invention;
[0013] FIG. 4 is a three-dimensional representation similar to FIG.
3, depicting additional elements of the first machine embodying the
invention;
[0014] FIG. 5 is a side elevational view of a second representative
machine embodying the invention;
[0015] FIG. 6 is a plan view depicting a third representative
machine embodying the invention, prior to movement to effect
bending of a length of spiral metal pipe;
[0016] FIG. 7 is a plan view of the machine of FIG. 6, subsequent
to movement to an end position which effects bending of the length
of spiral metal pipe to a desired angled configuration;
[0017] FIG. 8 depicts a method embodying the invention wherein a
preformed inflatable bladder in collapsed form is inserted into a
length of flexible spiral metal pipe; and
[0018] FIG. 9 depicts a condition subsequent to that of FIG. 8,
where the preformed bladder has been inflated.
DETAILED DESCRIPTION
[0019] The subject invention provides a lower-cost alternative to
die-formed elbows and gored elbows.
[0020] As an initial step, a round section or length of spiral
metal ductwork or pipe is manufactured employing a Drossbach
"Spiroflex Tubeformer" Model SPF300 or similar machine. Suitable
"Spiroflex Tubeformer" machines are manufactured by Drossbach GmbH
& Co. KG, Max-Drossbach-Stra.beta.e 7, D-86639 Rain/Lech,
Germany, and are available in the United States through Ovalformer
LLC, 45 Loop Road, P.O. Box 793, Arden, N. C.28704. Flexible metal
ductwork was previously known. However, previous flexible metal
ductwork has been relatively light gauge (30 to 40 gauge), and
cannot hold the pressures that are required in most commercial and
industrial type HVAC systems. Machines such as the Drossbach SPF300
can produce flexible ductwork up to 22 gauge in thickness.
[0021] Next, the length or section of round ductwork is deformed to
a flat-oval cross-section, employing an ovalizer such as is
disclosed in Price et al U.S. Pat. No. 6,000,260. A suitable
machine embodying the invention of Pat. No. 6,000,260 is an
Ovalformer Model OF1018, manufactured by Ovalformer LLC, 45 Loop
Road, P.O. Box 793, Arden, N.C. 28704.
[0022] Next, a flexible fitting machine is employed to manipulate
the ovalized flexible spiral metal pipe into any one of a variety
of elbows, offsets and fittings. In overview, the flexible fitting
machine deforms the pipe employing a series of hydraulic actuators,
and shoe and anvil sets that are custom fit to a variety of
different sizes. The fitting machine can be portable to allow
on-site fabrication of such fittings.
[0023] After the ductwork is deformed by the fitting machine to the
required shape, flanges are mounted to its end to help the fitting
maintain its shape. For example, the flanges disclosed in U.S.
provisional patent application Ser. No. 60/168,498, filed Dec. 2,
1999 by Miller S. Price, Mark A. Froning and Gregory C. Moyers,
titled "HVAC Flange and Flange Machine," and in a subsequent
nonprovisional application Ser. No. filed Dec. 1, 2000, the entire
disclosures of which are hereby expressly incorporated by
reference, may be employed to make the flanges.
[0024] FIGS. 3 and 4 illustrate elements of a fitting machine 28
embodying the invention during use.
[0025] In an exemplary embodiment, the fitting machine 28 includes
a fixed table represented at 30 oriented in a X-Z plane. One end 32
of a length 34 of flexible spiral metal pipe 34, which may also be
termed flexible ductwork 34, is secured to the table 30 by an end
securing device represented at 33, which may take the exemplary
form of an internal sleeve and an external clamp. The ductwork 34
has a free end 36 which initially extends straight up in the
orientation of FIGS. 3 and 4.
[0026] A movable driven assembly, generally designated 40, includes
a mounting plate 42 supporting another end of securing devices
generally designated 43, which takes the form of a set of external
jaws 44, as well as an internal sleeve 46, which engage the free
end 36 of the ductwork 34.
[0027] A mechanism, generally designated 47, moves the end securing
devices 33 and 43 relative to each other, while attached to the
respective ends 32 and 36, to the end position depicted in FIGS. 3
and 4, thereby effecting bending of the length 34 of spiral metal
pipe to a desired angled configuration. In FIGS. 3 and 4, a right
angle bend is depicted, but any desired angle, such as 450 for
example, may be made.
[0028] More particularly, driving the movable driven assembly 40 is
an articulating arm mechanism 48 connected to the mounting plate
42. The arm mechanism 48 includes suitable actuators (not shown)
under the control of a PLC controller, as well as feedback sensors
(not shown). Preferably the articulating arm mechanism 48 has three
degrees of motion.
[0029] Prior to a bending operation, at least one inner radius die
50 is rigidly mounted, and positioned at a location consistent with
the inner radius of the final product. The radius die 50 is
selected and positioned depending on the necessary final fitting
size.
[0030] With the ductwork 34 initially in a straight up position
(not illustrated) in the orientation of FIGS. 3 and 4, the arm
mechanism 48 and movable driven assembly 40 are adjusted so as to
position the mounting plate 42 on the free end 36 of the ductwork
34.
[0031] Under direction of the PLC controller, the arm mechanism 48
then pulls the end 36 of the ductwork 34 around the inner radius
die 50.
[0032] After complete forming of the fitting, the internal and
external jaws release, and the arm mechanism 48 moves back to its
home position.
[0033] The fitting is then unclamped from the X-Z table 30, and the
machine is ready to form the next fitting.
[0034] By omitting the step of deforming to flat-oval, a round
fitting could also be made.
[0035] FIG. 5 is a side elevational view of another fitting machine
60 embodying the invention. The fitting machine 60 includes a
horizontal table 62 supported on legs 64 and 66. For securing the
lower end of the flexible ductwork to the table 62 there is an end
securing device in the form of a set of four clamping shoes 68. The
shoes 68 have threaded apertures which engage rotatable drive
screws 70, so that the clamping shoes 68 selectively move towards
or away from the center of the table 62 as drive motors 72 rotate
the drive screws 70.
[0036] The FIG. 5 fitting machine 60 includes a movable plate 74.
For securing the upper end of the ductwork to the movable plate 74
there is another end securing device in the form of a set of four
clamping shoes 76 like the clamping shoes 68 on the table 62.
Similarly, threaded apertures in the clamping shoes 76 engage
rotatable drive screws 78 driven by drive motors 80. A fixed radius
die (not shown) may be employed if required.
[0037] At the beginning of operation, the ends of a section of
flexible ductwork (not shown in FIG. 5) are clamped to the table 62
and movable plate 74, with the ductwork section extending between
the table 62 and movable plate 74.
[0038] The movable plate 74 has an attached arm 82 fixed to the
main portion of the plate 74 and extending past a pivot point 84.
The pivot point 84 is defined by a pair of pivot blocks 86 (only
one of which is visible in the side elevation of FIG. 5) which move
up and down within a vertical guide 88 fixed to the table 62. The
pivot blocks 86 have a pair of parallel vertically-extending
threaded apertures which engage a pair of rotatable drive screws 90
(only one of which is visible in the side elevation of FIG. 5) so
that the pivot blocks 86 move up and down within the vertical guide
88 as drive motors 92 rotate the drive screws 90.
[0039] Pivotally attached and extending between the distal end 92
of the arm 82 and a pivot point 94 fixed with reference to the
table 62 is an actuator in the form of an hydraulic cylinder
96.
[0040] The table 62, arm 82, pivot point 84 and actuator 96
accordingly comprise a mechanism, generally designated 98, for
moving the end securing devices 68 and 76 relative to each
other.
[0041] As the hydraulic cylinder 96 retracts and extends and as the
pivot blocks 86 are driven up and down, the plate 74 with the upper
end of the ductwork secured thereto, is driven through a range of
motion to form the ductwork to an elbow, and then returned to a
starting position after a formed elbow is unclamped and a new
section of flexible ductwork is placed in position.
[0042] FIGS. 6 and 7 are plan views showing another fitting machine
100 embodying the invention. In FIG. 6, a section of flexible
ductwork 102 is laid flat on a table 104 and secured by an end
securing device in the form of a fixed collar 106 at one end 108.
Movable collars 110 and 112 are attached to the middle 114 and
opposite end 116. The movable collar 112 thus comprises another end
securing device, and the movable collar 110 comprises an
intermediate securing device. Two drive mechanisms 118 and 120,
each movable in both the X and Y axes, are attached to the
respective collars 110 and 112 (which are able to pivot). The X and
Y axes drive mechanisms 118 and 120 move the collars 110 and 112 in
an appropriate manner to effect bending, as shown in FIG. 7.
[0043] FIGS. 8 and 9 depict another method embodying the invention,
which uses a preformed inflatable bladder 130. When fully inflated,
the bladder 130 assumes the shape of an elbow. For use, the bladder
130 in collapsed form is placed inside a straight section of
flexible duct 132 to be bent (FIG. 8). As the bladder 130 is
inflated it assumes its final shape (FIG. 9), bending the ductwork
section 132 in the process.
[0044] Accordingly, embodiments of the invention replace die-formed
elbows and gored elbows with simple elbows made out of ribbed
flexible duct, which simple elbows may be ovalized. The invention
is embodied in methods and machines for doing the bending.
[0045] The fittings of the subject invention can be manufactured at
significantly less cost compared to die-formed elbows and gored
elbows, and can be custom shaped to virtually any
configuration.
[0046] While specific embodiments of the invention have been
illustrated and described herein, it is realized that numerous
modifications and changes will occur to those skilled in the art.
It is therefore to be understood that the appended claims are
intended to cover all such modifications and changes as fall within
the true spirit and scope of the invention.
* * * * *