Apparatus and method for manufacturing ducts

A method of automated manufacturing an adjustable duct member comprising the steps of:

• a) providing a tube of material having a tapered configuration and predetermined dimensional characteristics for forming the duct member,
• b) positioning of said tube in a work station at a first predetermined position relative to a cutting and forming assembly of said work station,
• c) clamping said tube in said first predetermined position to prevent movement during subsequent operations,
• d) cutting said tube at a first predetermined position to form first and second members,
• e) positioning said first and second members in overlapping relationship to one another,
• f) forming a bead in said first and second members at a position to cooperate with one another to allow relative rotation of said first and second members and interlock said first and second members,
• g) repositioning of said tube in a work station at a second predetermined position relative to a cutting and forming assembly of said work station,
• h) clamping said tube in said second predetermined position to prevent movement during subsequent operations,
• i) cutting said tube at a second predetermined position to form first and second members,
• j) positioning said first and second members in overlapping relationship to one another, and
• k) forming a bead in said first and second members at a predetermined position to cooperate with one another to allow relative rotation of said first and second members and interlock said first and second members.

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

• a housing including at least two work stations formed therein, each workstation adapted to accommodate a tapered work piece,
• a first die associated with said first work station which is selectively positioned at a predetermined location relative to said tapered work piece positioned in said first work station,
• a second die associated with said second work station which is selectively positioned at a predetermined location relative to said tapered work piece positioned in said second work station,
• wherein said first and second dies are different sizes adapted to accommodate different sized sections of said tapered work piece,
• a first cutting and forming assembly associated with said first work station which cooperates with said first die to selectively cut said tapered work piece to form first and second tapered members and to form a coupling bead in said first and second tapered members which cooperate to reconnect said first and second tapered members together at a predetermined angle,
• a second cutting and forming assembly associated with said second work station which cooperates with said second die to selectively cut said tapered work piece to form first and second tapered members and to form a coupling bead in said first and second tapered members which cooperate to reconnect said first and second tapered members together at a predetermined angle,
• wherein each work station includes an insertion channel having predetermined dimensions to provide sufficient clearance to accommodate the tapering diameter of said tapered work piece, and
• wherein a clamping assembly is associated with each insertion channel to securely hold said tapered work piece.