Apparatus and method for production of duct members

An apparatus for forming a sealed duct member for use in an air handling system comprising,

• a work station including a turning head and die assembly, the turning head including at least one forming wheel and at least one cutting wheel, that mate with at least one forming plate and at least one cutting plate of the die assembly, and form a channel for receipt of a work piece therebetween,
• a work piece moving and rotating assembly to move the work piece relative to the turning head and die assembly, wherein the moving assembly allows for moving the work piece to a predetermined position relative to the turning head and die assembly to cut the work piece into first and second sections and reconnect the sections by a connecting bead formed by the turning head and die assembly in the first and second section, and the rotating assembly allows for rotation of the work piece and at least one of the first and second sections after being formed, and
• a sealing assembly which cooperates with the at least one forming plate to seal the connecting bead in the first and second sections after the connecting bead is formed, and
• a control system for controlling operation of the turning head, die assembly, work piece moving and rotating assemblies and sealing assembly.

A method of manufacturing a duct member comprising the steps of:

• a) providing a blank work piece having a cylindrical configuration and positioning the work piece in a work station at a starting position,
• b) using a first clamp to secure the work piece in a first predetermined initial position, and moving the work piece to a first position where a first cut is to be made,
• c) using a second clamp to secure the work piece above the first position,
• d) performing a cutting operation to cut the work piece at the first position to form first and second sections,
• e) moving the first section toward the second section a predetermined amount and engaging a turning head to the interior of the second section,
• f) rotating the second section 180 degrees clockwise and disengaging the turning head,
• g) forming connecting beads in each of the first and second sections to reconnect the sections,
• h) crimping the formed connecting beads together and releasing the second clamp,
• i) moving the work piece to a position where a second cut is to be made and rotating the work piece 180 degrees counter clockwise,
• j) using the second clamp to secure the work piece in a predetermined position,
• k) performing a cutting operation to cut the work piece at the predetermined position to form first and second sections,
• l) moving the first section toward the second section a predetermined amount and engaging a turning head to the interior of the second section,
• m) rotating the second section 180 degrees clockwise and disengaging the turning head,
• n) forming connecting beads in each of the first and second sections to reconnect the sections,
• o) crimping the formed connecting beads together and releasing the second clamp, and
• p) rotating the work piece 180 degrees clockwise and repeating steps c) through h).