Flange Turning Process Machine

A spiral pipe has an integrated radial flange. A machine for forming such a flange comprises a rotor which rotates and a flange roller mechanism connected to the rotor via slides. As the rotor rotates, the flange roller mechanism moves radially via the slides to form an integrated flange on an end portion of the spiral pipe.

A flange turning machine for creating a flange on a spiral pipe, the machine comprising: a mandrel; jaws configured to hold the spiral pipe against the mandrel; arotor configured to rotate; a slide configured to move radially from a start position on the rotor to an end position on the rotor; a central shaft slide configured to move from a rearward position to a forward position; a slide moving arm configuredto move the slide from the start position to the end position as the central shaft slide moves from the rearward position to the forward position; and a flange turning roller mounted on the slide, and configured to create the flange by deforming an endportion of the spiral pipe against the jaws as the rotor rotates and the slide moves from the start position to the end position.

Spiral pipe is used in a variety of duct work applications. Spiral pipe is typically manufactured from galvanized steel, and is available in a wide variety of diameters, ranging from 3-inches to 80-inches. Similarly, spiral pipe is available ina wide wall thickness, ranging from 26-gauge up through 16-gauge. Lastly, spiral pipe may come in a variety of lengths, ranging from 1-foot to 20-feet, with 10-feet lengths being standard.

Spiral pipe is made by forming a coil of metal into a rigid steal tube with a four-ply spiral lock seam. Though it is common in the art to refer to this type of pipe as "spiral pipe" pipe, the seam of the pipe extends helically along the lengthof the pipe. Forming the spiral pipe in this way results in the pipe having a resistance to crushing approximately 21/2times that of a longitudinally box seamed or longitudinally welded pipe. In addition, the spiral pipe has a smooth interior for lowfriction loss because the grooved seam is entirely on the outside. This low friction loss inside the spiral pipe allows the air to flow smoothly or "tumble" down the tube, increasing the efficiency of air flow through the spiral pipe.

Pipe-to-pipe connections are typically made using a fitting size coupling that slips inside the mating pipe sections. A stop bead runs around the middle of the coupling to center the coupling between the two pipe sections. The coupling is thensecured by installing sheet metal screws through the outer shell of the duct a half inch from the stop bead. This method is time-consuming, increases the labor lost, and requires the tools and space necessary to allow the coupling to be attached to thespiral pipes. Further, the resulting connection created at the coupling may reduce the efficiency of the air flow through the spiral pipes. Specifically, the air does not flow efficiently through the pipes due to the coupling, the screws attaching thecoupling to the spiral pipes, and any imperfections in the fit between the coupling and the two lengths of spiral pipe.

As an alternative to a coupling inserted between two pipes, it is possible to fit two lengths of pipe together using a flange integrally formed on the end of each pipe. However, it has proven especially difficult to manufacture spiral pipehaving an integrated flange at the end of the spiral pipe. A major challenge in forming a flange at the end of a spiral pipe is the four-ply seam which extends helically along the length of the pipe. It is difficult to bend the four-ply seam area ofthe spiral pipe to form the flange without damaging the spiral pipe. Often, the spiral pipe will break or crimp when attempting to form a flange at the location of the four-ply spiral seam.

Thus, there is a need in the art for a spiral pipe having an integrated flange located at the end of the length of pipe. Similarly, there is a need in the art for a method of manufacturing a spiral pipe having an integrated flange.

The present invention is a spiral pipe formed with an integrated flange, as well as a machine for forming an integrated flange on the spiral pipe. The machine comprises a mandrel and four jaws for holding the spiral pipe against the mandrel. The machine further comprises a rotor plate which is configured to be rotated. Mounted on the rotor plate are three flange turning rollers. The flange turning rollers are connected to the rotor plate via slides. The slides are configured to allow theflange turning rollers to move from a first position to a second position as the rotor plate is rotating.

The flange turning rollers are positioned so that when the spiral pipe is placed on the mandrel, the flange turning rollers are located on the inner diameter of the spiral pipe. As the machine operates, and the flange turning rollers are movedvia the slides from their first position to their second position, the flange turning rollers move radially from the inner diameter of the spiral pipe to an outer diameter. As the flange turning rollers move from the inner diameter of the spiral pipe toan outer diameter, the spiral pipe is deformed against the jaws by the flange turning rollers. In this way, an integrated flange is formed on the spiral pipe.