Patent Publication Number: US-10758962-B2

Title: Apparatus and method for production of duct members

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application is a continuation of co-pending U.S. application Ser. No. 13/835,681 filed Mar. 15, 2013, which is hereby incorporated herein by reference. 
    
    
     TECHNICAL FIELD 
     The invention relates generally to an apparatus and method for production of adjustable duct members, and more particularly to forming adjustable duct members and sealing the beads in order to increase the efficiency of the duct members. 
     BACKGROUND 
     In general, duct work is commonly used in forced air heating and air-conditioning systems for buildings and the like, with the duct work providing a distribution system to various areas of the building from a furnace and/or air-conditioning system. Coupling a round duct to the furnace or main trunk line is commonly provided via a top take off duct member which is positioned in association with the air handling equipment. The top take off provides the outlet for forced air to exit the trunk line or extended plenum for distribution to the registers. Typically, such a top take off comprises a cylindrical fitting associated with a length of cylindrical tubing which is coupled to an outlet opening in a high pressure plenum of the air handling system. The fitting is installed into and fixed in position with respect to the outlet opening in the wall of a trunk line or plenum. This take off duct can then be coupled into cylindrical duct work which extends to various portions of the building or the like. Depending on the particulars of an installation of an air handling system, it is many times problematic to efficiently couple into the top take off, as the position of the duct work may not correspond to the location of the top take off. Various fittings and interconnections are then necessary to couple the duct work to the air handling system, being a labor intensive and time-consuming process. Attempts to simplify connection of round duct work to a trunk line or plenum have included forming the top take off as an adjustable elbow which allows the orientation and position of the take off to be readily adjusted to simplify positioning and interconnection to the duct system. Such adjustable elbows typically will include three sections, each section being rotatable relative to the others. Each section in the take off is formed so as to be connected at an angular orientation relative to an adjacent section, whereupon relative rotation will vary the orientation of the outlet portion of the take off to simplify coupling into further duct work. Known adjustable take offs may be produced in different ways, but typically utilize a machine which a skilled operator uses for cutting and forming of each of the sections in the take off. Each of the sections may be adjustably coupled to an adjacent section by means of a bead coupling wherein a portion of each section is flared outwardly to engage a similar bead in an adjacent section, thereby locking the pieces together but allowing relative rotation therebetween. Known machines for producing and locking these sections together to form an adjustable take off are problematic, in that many of the stages of production of the sections in the take off are performed manually with a machine for cutting and beading of the take off sections. A skilled operator is therefore necessary to properly form each section and couple the sections together in a manner that they can be adjusted to one another. The difficulty of properly forming each section and connecting the sections together result in a high percentage of scrap as well as take offs which do not function well. More recently, automated take off machines have been produced which are designed to form straight take offs, wherein a cylindrical tube is cut into multiple pieces with the pieces being reassembled and locked together in an adjustable coupling. Although such apparatus is capable of forming a more uniform adjustable coupling between sections of the take off in a repeatable fashion, only straight take offs are able to be manufactured, with each section of the take off having a common diameter. 
     Other problems associated with these machines include the loss of air through the beads between the gores of the duct system. As air circulates through the duct system, air dissipates through the beads or seams that are between the gores, which in turn, causes a loss of energy and thus creates a less efficient system. Presently, no apparatus or methods exist for automated manufacture of adjustable ducts that are highly efficient with respect to the leakage that occurs at the beads or seams of the duct system. 
     SUMMARY 
     The invention is therefore directed to an apparatus for forming and sealing an adjustable duct member for use in an air handling system that includes at least one work station adapted to accommodate a tapered work piece, a repositionable die associated with the work station which is selectively positioned at a predetermined location relative to the work piece positioned in the work station, a cutting and forming assembly associated with the work station which cooperates with the repositionable die to selectively cut the work piece to form first and second members and to form a coupling bead in the first and second members which cooperate to reconnect the first and second members together at a predetermined position, a sealing assembly associated with the first work station which cooperates with the first repositioning die to selectively seal the coupling bead in the first and second members which cooperate to crimp the coupling bead together at the predetermined angle, wherein the work station includes an insertion channel having predetermined dimensions to accommodate at least a portion of the work piece, wherein a clamping assembly is associated with the insertion channel to securely hold the tapered work piece at the predetermined position during the cutting and forming and sealing operations, the clamping system comprising at least two movable clamping members positioned in an opposing manner about the insertion channel, and a control system for at least selective control of at least the clamping, the cutting and forming, and the sealing assemblies. 
     Another embodiment of the present invention includes a method of automated manufacturing an adjustable duct member includes 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 the tube in a work station at a first predetermined position relative to a cutting and forming assembly of the work station, c) clamping the tube in the first predetermined position to prevent movement during subsequent operations, d) cutting the tube at a first predetermined position to form first and second members, e) positioning the first and second members in overlapping relationship to one another, f) forming a bead in the first and second members at a position to cooperate with one another to allow relative rotation of the first and second members and interlock the first and second members, g) sealing the bead in the first and second members at the position to decrease an amount of air dissipated between the first and second members, h) repositioning of the tube in a work station at a second predetermined position relative to a cutting and forming assembly of the work station, i) clamping the tube in the second predetermined position to prevent movement during subsequent operations, j) cutting the tube at a second predetermined position to form first and second members, k) positioning the first and second members in overlapping relationship to one another, l) forming a bead in the first and second members at a predetermined position to cooperate with one another to allow relative rotation of the first and second members and interlock the first and second members, and m) sealing the bead in the first and second members at the predetermined position to decrease an amount of air dissipated between the first and second members. 
     Yet another embodiment of the present invention includes a forming and sealing air duct system kit that includes a pair of slidable plates with repositionable die members, wherein said repositionable die members are operatively attached and repositionable to said slidable plates, wherein said repositionable die members include at least one mounted cam, a pair of crimping plates, and a pair of at least one secondary hydraulic rams. 
     These and other features of the claimed invention, as well as details of illustrated embodiments thereof, will be more fully understood from the following description and drawings 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         FIG. 1  is a plan view of a tube which is manufactured into an adjustable duct according to the invention; 
         FIG. 2  is a plan view of the tube as shown in  FIG. 1 , with a first adjustable bead formed therein between two gores of the tube; 
         FIG. 3  shows an enlarged partial cutaway view of the tube as shown in  FIG. 2 , showing a die and associated cutting and forming system for producing the two gores in the tube and forming the adjustable bead therebetween; 
         FIG. 4  is a plan view of the tube as shown in  FIG. 2 , and further showing a second adjustable bead formed between gores of the tube; 
         FIG. 5  is a plan view of the duct member, showing adjustability of each gore of the duct member relative to one another; 
         FIG. 6  shows a plan view of an apparatus for forming an adjustable duct member according to the invention; 
         FIG. 7  is a side view of the apparatus as shown in  FIG. 6 ; 
         FIG. 8  is a top view of the apparatus as shown in  FIG. 6 ; 
         FIG. 9  is a schematic diagram of the control system associated with each nest in the apparatus of the invention; 
         FIG. 10  shows an enlarged partial sectional view of the upper plate and die assembly; 
         FIG. 11  shows a partial sectional view of the cutting and forming assembly; 
         FIG. 11A  shows a partial top plan view of the cutting and forming assembly shown in  FIG. 11 ; 
         FIG. 12  shows a partial sectional view of the roller assembly associated with the assembly shown in  FIG. 11 ; 
         FIG. 13  shows a partial cross-sectional perspective view of the clamping assembly ring in accordance with the present invention; 
         FIG. 14  shows a partial cross-sectional view of the clamping assembly ring of  FIG. 13 ; 
         FIG. 15  shows top plan view of an alternate embodiment of the clamping assembly of the present invention; 
         FIG. 16  shows a cross-sectional view of an individual clamp assembly of the type shown in  FIG. 15 ; 
         FIG. 17  shows a top plan view of an individual clamp assembly of the type shown in  FIG. 15 ; 
         FIG. 18  shows a perspective view of a prior art drive shaft and eccentric shaft; 
         FIG. 19  shows a perspective view of the shaft shown in  FIG. 18  incorporating and embodiment of the present invention comprising a protective shield cover; 
         FIG. 20  shows a top view of another embodiment of the present invention; 
         FIG. 21  shows an enlarged partial sectional view of the sealing system and the die assembly of another embodiment of the present invention; 
         FIG. 22  shows a partial sectional view of the die assembly of another embodiment of the present invention; 
         FIG. 23  shows a partial cross-sectional view of the sealing system and the die assembly of another embodiment of the present invention; and 
         FIGS. 24, 25 and 26  each show a partial perspective view of the cutting and forming assembly and of the sealing assembly of an embodiment of the present invention. 
     
    
    
     DESCRIPTION OF EXAMPLES OF THE INVENTION 
     Turning now to  FIGS. 1-5 , the invention is directed at producing an adjustable duct member such as shown in  FIGS. 4 and 5 , wherein the duct member  10  may include three sections or gores  12 ,  14 , and  16 . The duct member  10  further includes an inlet opening  18  and an outlet opening  20 , being adapted to be coupled between other members in a duct system, or preferably as a top takeoff connected into a plenum associated with the air handling system. To facilitate connection of the duct member  10  in association with a plenum, inlet opening  18  may be provided with a plurality of tabs  22  which may be selectively bent into engagement with an inner wall of the plenum through an opening formed therein. The duct member  10  may include a taper from the inlet opening  18  to the outlet opening  20 , such that each of the gores  12 ,  14  and  16  become progressively smaller. The tapering of the gores  12 ,  14  and  16  provide a significant increase in velocity of air passing through duct  10  from the plenum of the air handling system. Although the invention is described with reference to a tapered duct, wherein first and second work stations are preferably utilized, it should be recognized that the invention applies to non-tapered duct members also. The duct member  10  may be produced from a flat blank of material which is rolled such that opposed seams of the blank slightly overlap and are coupled to one another to form the tubular configuration. Coupling at the overlapping seams may be provided in any suitable manner, such as by riveting or the like. As an example, the tubular configuration of the formed blank of material may provide a starting work piece as shown in  FIG. 1 , which may then be operated on by the apparatus and methods of the invention. The work piece as shown in  FIG. 1  is designed to have a predetermined configuration and dimensional characteristics for use in the apparatus and methods of the invention, but any suitable particular dimensional characteristics of the work piece can be accommodated. As an example, the tapered tube as shown in  FIG. 1  may have an inlet opening  18  having a diameter of seven inches, while the outlet opening  20  has a diameter of 5.7 inches. 
     The apparatus and methods of the invention will take the work piece as shown in  FIG. 1  and produce adjustable seams or beads  24  and  26  in the work piece to form the duct member  10  in the final preferred form as shown in  FIGS. 4 and 5 . To produce this configuration, a first adjustable seam  24  is produced at a predetermined position and orientation relative to the inlet and outlet openings  18  and  20 . It is noted that in the desired configuration of the work piece as shown in  FIG. 1 , the inlet opening  18  is angled relative to the outlet opening  20 , such that when the duct member  10  is installed in association with a plenum, the first gore  12  will be angled at 30° relative to the wall of the plenum. The first adjustable seam  24  produced in duct member  10  is thereafter preferably oriented at an angle of 15° relative to the plane of the outlet opening  20 , and oriented in opposing relationship to the orientation of outlet opening  18 . The second adjustable coupling bead  26  is thereafter preferably formed again at an angle of 15° relative to the plane of outlet opening  20  and in opposing relationship to adjustable coupling bead  24  as shown in  FIG. 4 . With this preferred configuration, the duct member  10  may be configured such that inlet and outlet openings  18  and  20  are coaxial as shown in  FIG. 4 , or by adjustment of gores  12 ,  14  and  16  relative to one another, at 90° to one another. The adjustment of gores  12 ,  14  and  16  relative to one another is shown in  FIG. 5 . 
     The coupling beads  24  and  26  formed in the duct member  10  are preferably formed by means of a cutting and forming system in conjunction with a die positioned about the member  10 . As shown in  FIG. 3 , the apparatus of the invention includes a die, generally shown at  28  having a shaping section  30  formed on a portion of the die  28  adjacent the exterior surface of member  10 . On the interior of the tube  10 , a cutting and forming system generally designated  32  is provided to selectively cut and shape portions of the tube in cooperation with die  28  to form the coupling beads  24  and  26 . The operation of the apparatus will be discussed in more detail as the description proceeds. 
     Turning now to  FIGS. 6-8 , a preferred embodiment of the apparatus according to the invention is shown in more detail. The apparatus generally designated  50  includes a housing or frame construction  52  which supports various components of the apparatus. Housing or frame  52  includes an upper surface  54  which is preferably defined by a floating support plate  56  which is adjustably mounted to the frame  52 . The upper support plate  56  is angled at a predetermined angle relative to horizontal or ultimately to the plane of the outlet opening  18  associated with the work piece (described previously in  FIGS. 1-5 ), which is supported on a base plate provided as a part of an operating nest arrangement to be more fully described hereafter. Providing plate  56  with some adjustability allows an operator to adjust this predetermined angle to produce a predetermined component as desired. The plate  56  may be held in position by a plurality of support fasteners  58  or other suitable devices. The upper surface  54  of the apparatus  50  may include two work stations or nests generally designated  60  and  62 , each of which is formed as a recess adapted to accept the work piece discussed in previous figures to perform the operations for cutting and forming the coupling beads between gores of the work piece as described. Alternatively, the apparatus of the invention could utilize only one work station in which multiple cutting and coupling bead forming steps could be performed to fabricate the desired adjustable duct member. The work station would provide the cutting and coupling bead forming steps in at least two predetermined locations, and with the tapered tube, would accommodate different diameters of the tube to perform these steps. 
     In the particular embodiment shown, each of the nests and associated components to perform those operations are substantially identical in many respects, except that the work piece is positioned differently in each nest  60  or  62  to form one or the other of the cutting and forming operations to produce the adjustable duct member of the invention. As shown in the figures, each nest  60  or  62  can include a die supported on the upper surface, which in the preferred embodiment may be comprised of first and second semicircular members  64  and  66  which are positioned on opposed sides of the nests  60  or  62 . The die members  64  and  66  are positioned immediately adjacent the nest  60  or  62  in operation, but preferably may be moved into a nonoperational position away from the nest  60  or  62  when desired in a manufacturing cycle. Therefore, each of the die member  64  and  66  may be supported in association with a slidable plate  68  and  70  which is supported in sliding engagement with support blocks  72  and  74  in a channel or slot  76 . The support block  74  may be adjusted relative to the plates  68  and  70  for smooth slidable operation of the plates within slot  76 . Each of the plates  68  and  70  may be moveable toward and away from the nest  60  or  62  by means of a hydraulic ram  77  or other suitable mechanism. Within the nest  60  or  62 , a cutting and forming system  80  is provided in the recessed portion of the nest  60  or  62 . Between the die members  64  and  66  and the cutting and forming system  80 , a circular channel  82  is formed by the recess of the nest  60  or  62 , the channel  82  being dimensioned to accept the work piece as shown in  FIG. 1 , with the work piece extending into the channel  82  to a predetermined depth. Associated with the nest  60  or  62  is a at the bottom of channel  82  on which the work piece is supported within the nest  60  or  62  at the predetermined position. As will be hereinafter described in more detail, the base plate is formed in association with a moveable platen  84  which is operated on by a pair of hydraulic rams  86  or other suitable mechanism. Providing hydraulic rams  86  or other suitable mechanism on opposed sides of the moveable platen  84  ensures proper operation to selectively move platen  84  upwardly or downwardly with respect to the housing and other components of the apparatus  50 . The moveable platen  84  preferably carries at its upper end the base plate  88 , with a drive plate  90  at the bottom end thereof. The central portion  92  of platen  84  is a cylindrical portion extending between plates  88  and  90 . The plates  88  and  90  each have apertures coinciding with the cylindrical portion  92  to define a hollow interior through which a drive shaft arrangement  94  is positioned. The drive shaft system  94  is coupled to be driven by a hydraulic motor  96  supported in association with housing  52 . The platen assembly  84  is moveable about the drive shaft assembly  94  upwardly and downwardly to selectively position a work piece relative to the die members  64  and  66  and the cutting and forming system  80 . The platen assembly  84  may further include a guide mechanism  98 , which will prevent rotation of the platen assembly  84  by any lateral forces which may be imposed thereon. The guide mechanism  98  may simply comprise a guide pin positioned within a track or channel member  100  supported in association with housing  52 . Other suitable mechanisms may also be utilized, or no guide mechanism may be necessary. 
     Referring now to  FIGS. 13 and 14 , the base plate  88  has a clamp assembly  200  mounted thereto comprising a base ring  202  having an upwardly turned tubular extension  204  along and interior diameter thereof. The interior diameter of extension  204  provides clearance for support block  142  which will be discussed in detail below. The outer diameter of extension  204  is of a predetermined size such that either the inlet end  18  or outlet end  20  of duct member  10  fits over the extension  204  and is positioned a predetermined depth by contact with the top surface  206  of base ring  202 . Clamp assembly  200  also comprises a clamp ring  208  mounted and affixed to the top surface  206  of base ring  202 . Clamp ring  208  has an interior diameter larger than the outer diameter of extension  204  such that a channel  82  is formed allowing clearance for the insertion of one of either the inlet end  18  or outlet end  20  of duct member  10 . The clamp ring  208  comprises one or more clamp members  210  which are hydraulically or electrically actuated by one or more corresponding pistons  212 . The clamp members  210  are generally oriented perpendicular to extension  204  and parallel to the top surface  206  of base ring  202 . The clamp members  210  are generally shown herein as cylindrical members having a gripping irregular surface  211  on one end thereof. As shown in  FIGS. 13 and 14 , the piston  212  is connected to a piston ring  214  which moves upward and downward within clamp ring  208 . The piston ring  214  has an angled surface  216  along and interior diameter surface thereof. The angled surface  216  engages an angled surface  218  on clamp member  210 , on an end opposite the gripping irregular surface  211 , such that upward movement of piston ring  214  forces the clamp member  210  inward against the wall of duct member  10 , and against extension  204 . The duct member  10  is securely held in place by the gripping irregular surface  211  as cutting and forming operations are perform thereon as will be discussed in detail below. The gripping pressure can be increased by adding additional pistons/gripping members. 
     In an alternate embodiment, especially with larger diameter duct members  10  the clamp assembly  200 ′ comprises one or more clamping devices  220 . The clamping devices  220  are mounted on base plate  88  in at least opposing relationship, such as at predetermined angular intervals as is shown in  FIG. 15 . Although the clamping devices  220  may have slightly different configurations for different size of duct members  10 , each device  220  comprises a backing surface member  222 , a body member  224 , and a piston  226  for engaging a clamp member  210 . Referring now to  FIG. 16  and  FIG. 17 , a representative clamping device  220  is shown.  FIG. 17  shows a top plan view of a clamping device  220 . The device  220  is mounted to the base plate by one or more set screws  228  shown through the backing surface member  222 . The backing surface member  222  is fixably attached to the body member  224  as shown in  FIG. 16 , forming a clearance  82 . The wall  230  of the backing surface member  222  forming clearance  82  is curved at a predetermined radius generally corresponding to that of the duct member  10 . The clamping devices  220  each comprise a piston  222  having a piston rod  224  extending therefrom and having an angled surface  226  at an end thereof. The angled surface  226  of piston rod  224  engages a ball  228  and forces of the ball  228  against clamp member  210 . As in the previous embodiment, clamp member  210  is oriented perpendicular to wall  230  and parallel to base plate  88 . The clamp member  210  engages the wall of duct member  10  and clamps the duct member firmly securely against wall  230 , in a manner preventing rotation during the cutting and forming operations. The gripping pressure can be increased by adding additional clamp devices  220 . 
     The clamp devices  220  are quickly and easily removed and replaced on the base plate with clamp devices designed to be used for duct members  10  having a different diameter. It is contemplated that some changeovers can be accomplished by rotating the base plate to use a second set of clamping devices already attached to the base plate at intermediate angles between the first set of clamping devices. 
     Clamp assemblies  200 ,  200 ′ are provided as embodiment of the present invention to effectively clamp the duct member  10 , such as a tapered top take off, and prevent movement or rotation during the cutting and forming operations which will be described in greater detail below. These embodiments are not intended to limit the scope of a particular version of a clamp assembly as it is contemplated that modifications and adaptations of the embodiments shown are included in the scope of the present invention. 
     The cutting and forming system  80  associated with each of the nests  60  or  62  is preferably designed to simultaneously cut, pre-form and finish form the coupling beads which reconnect and lock together cut portions or gores of the work piece as previously described. In general, once the work piece is positioned in nest  60  or  62 , operation of the cutting and forming system  80  will initially cut the work piece along a predetermined angular position defined by the angle of the upper surface  54  relative to the work piece positioned within nest  60  or  62 . In desired operation, the cut performed by the cutting and forming system  80  is oriented at 15° relative to the outlet opening of the work piece as previously described, and at a predetermined position or distance from the outlet opening  20 . Once the work piece is cut by the cutting and forming system  80 , the coupling bead must then be formed in the respective gores of the work piece adjacent the cut line and the gores interconnected via the formed coupling bead. To accomplish this, in the preferred operation and with reference to  FIG. 4  showing the finished duct member  10 , the work piece is positioned in nest  60  in a first stage of operation, to form the cut and coupled bead connection  26  between gores  14  and  16  in duct member  10 . In the preferred operation, the cutting and forming system  80  will simultaneously pre-form the bottom edge of gore  14  and the top edge of gore  16  with a slight inward taper so that gore  16  can be moved into overlapping relationship with gore  14 . The beads formed in the gores  14  and  16  may also be pre-formed for thereafter forming the coupled bead  26  which interconnects these gores so that they cannot be separated, but allows relative rotation therebetween. Once the gores  14  and  16  are overlapped, the beads in each are finally formed in conjunction with one another to form coupled bead  26 , by means of the cutting and forming system  80  so as to cooperate with one another in this fashion. Preferably, the material from which the work piece is formed is of significant structural integrity whereby the beads formed in each of the gores  14  and  16  are relatively deep and consistently formed to facilitate maintaining the connection between these gores while ensuring smooth and easy relative rotation between the gores. 
     Subsequent to formation of the coupling bead  26 , the work piece is then removed from nest  60  and positioned in nest  62  to form the second cut and coupled bead  24  between gores  12  and  14 . The work piece is rotated 180° before being positioned in nest  62  to form the opposing 15° moveable seam  24 . If a single work station is used to perform both operations, a mechanism to rotate the work piece may be provided. In the described embodiment, the work piece is positioned within the recess formed by nest  62  to a deeper extent so as to position the coupled bead  24  at a predetermined position relative to the other gores of duct member  10 . A similar operation is then performed by the cutting and forming assembly  80 , whereby the work piece is cut forming gores  12  and  14 , the edges of the gores  12  and  14  are pre-formed so as to ease positioning in slightly overlapping relationship and the cooperating beads may be pre-formed in each of the gores. Once the gores are repositioned in overlapping relationship, the beads are finally formed in conjunction with one another to reconnect the gores in locked relationship while allowing relative rotation therebetween. As should be recognized, because the work piece from which the duct member is made is preferably formed as a tapered tube, the size of the nest  62 , die member  64  and  66  and cutting and forming assembly  80  are differently sized from those components in nest  60  to accommodate the greater diameter at the location of coupled bead  24 . In this way, the apparatus  50  can be configured to accommodate any size tube, and these components can also be interchangeable for varying the size of duct member produced thereby. Additionally, it may be desirable to have a longer throat portion or gore  12  associated with the duct member  10 , and again the nests  60  and  62  as well as associated die members and cutting and forming systems  80  would all be designed to accommodate such a configuration. 
     Also in the preferred embodiment, as cutting and forming operations are performed by the assembly  80 , there may be a lubricating system generally designated  102  which will selectively apply lubrication to the interior of the work piece at the location of the cutting or forming operations as desired. The typical prior art lubrication systems consist of merely of a copper tube which is pinched with pliers to control the pattern of the lube spray. The lubrication system  102  of the present invention uses a lubrication spray head  102  which is typically removable and replaceable. The lubrication spray head  102  is typically made of brass and has a precise hole for proper delivery of the lubrication spray. Any suitable lubrication system may be used in this regard. In addition, the apparatus  50  preferably includes a control system generally designated  110 , which may be any suitable system such as a microprocessor or PLC based system, to selectively perform the various operations and steps to produce the duct member  10  according to the methods of the invention. Preferably, control system  110  can be designed to automatically perform various operations in a manufacturing sequence to produce a particular type of duct member  10 . Each different type of duct member will effectively have a process sequence recipe that can be simply recalled using the control system  110 , with subsequent automated performance of each step in the manufacture of the duct member  10 . In this way, an unskilled operator can simply recall a particular recipe for the type of duct member to be produced, alleviating the necessity for a skilled operator and simplifying the manufacturing process. The functions controlled by the control system  110  will be described in more detail with reference to a preferred hydraulic circuit which controls various functions in the apparatus  50 . 
     Turning to  FIG. 9 , the various control functions of the preferred embodiment are shown schematically for one of the nests  60  or  62  and the associated functions performed when the work piece is inserted therein. It should be understood that the control functions as described in  FIG. 9  are similar for each of the nests  60  or  62  and the associated components, and therefore only one of the hydraulic control systems is shown for clarity. In  FIG. 9 , a hydraulic control circuit is shown, although other types of controls are contemplated in the invention, and the invention is not limited to the control of various functions by hydraulic mechanisms. Corresponding to the operation of the apparatus  50  as previously described, and in the preferred embodiment, the work piece once positioned in a nest  60  or  62  is preferably clamped in position to ensure proper positioning with respect to the cutting and forming assembly. 
     Within the recess or channel  82  of nest  60  or  62 , a work piece retaining mechanism is provided, the preferred embodiment to be described hereafter. In general, the work piece retaining mechanism may be a tube clamp which is engaged with the bottom of the work piece positioned within recess  82 , but any suitable clamping mechanism may be utilized. Operation of the clamp may be controlled hydraulically by means of a hydraulic circuit including valve  120  operated by the control system  110  previously described. Once the work piece is properly positioned and clamped, the cutting and forming operation may begin, wherein it may be desirable to initially lube the surfaces of the work piece prior to cutting and forming. A lube mechanism controlled by a hydraulic circuit and associated valve  122 . The cutting and forming operation performed by the cutting and forming assembly  80  is then initiated by means of a hydraulic circuit component  124 , and preferably includes a proportional valve used to control the hydraulic motor  126  to extend the life of the hydraulic motor by avoiding excessive wear caused by repeatedly starting and stopping the motor during a manufacturing cycle or in distinct cycles. In association with the cutting and forming operation, the control system  110  further controls a hydraulic circuit and associated valve  128  to operate the hydraulic cylinders engaging the platen assembly on which the work piece is supported. The position of the work piece relative to the cutting and forming assembly is thus varied to form the cooperative bead coupling as previously described by up and down movement of the platen assembly. Other control functions may also be performed by the control system as desired. 
     Turning now to  FIG. 10 , the top plate assembly and associated die members and cutting and forming head are shown in more detail. The die members  64  and  66  as previously described are designed to cooperate with one another to form when positioned adjacent the work piece a stationary form into which material of the work piece is pushed by the cutting and forming system  80 . Preferably the die members  64  and  66  are formed to include a recess, which will cooperate with a portion of the forming system  80  to generate an outwardly directed bead in the work piece of substantial depth. It is pointed out that, die members  64  and  66  also perform a clamping function in addition to the forming function of the die. This enables both sections  12 ,  14 ,  16  to be properly secured during and after the cutting and forming operation. Below the forming section of the die, a separate plate  132  may be provided with an outwardly extending knife edge  134  which is designed in cooperation with the cutting and forming assembly to cut the work piece at the desired position. The cutting plate, or ring  132 , is fixably attached to the die members  64  and  66 . Providing the knife as a separate member  132  facilitates maintenance of the apparatus, as it is possible for the knife or knife edge to become damaged, simplifying replacement of the plate  132  without impact on the forming section of the die formed by die member  64  and  66 . The particular shape of the forming portion or knife portion of the die may be modified to produce a desired coupling bead configuration other than that shown in the preferred embodiment. 
       FIGS. 11 and 12  refer to a preferred embodiment of the cutting and forming assembly  80  of the invention, although other mechanisms to preform the functions of assembly  80  would occur to those skilled in the art. In  FIG. 11 , the cutting and forming assembly may comprise a head portion  140  including a supporting block  142  carrying a rotating working head  144  shown in section. The drive shaft  94  driven by motor  96  is positioned to extend through the support block  142  and is coupled to the working head  144  for selective rotation thereof. The working head  144  includes a moveable slide block  146  mounted within a slot  147 , having a cutting wheel  148  at one end thereof and a beading wheel  149  on the other end. The slide block  146  is moved back and forth to provide cutting and beading steps successively, with each of the wheels  148  and  149  being successively exposed to perform these operations as the head  144  rotates. In the present embodiment, it has been found that enlarging the width of the beading and cutting wheels allows a deeper cut and better bead formation enabling the sections  12 ,  14 ,  16  of the duct member  10  to have a better connection, facilitating proper rotation with respect to one another. The back and forth motion of the slide block  146  within slot  147  is created by an eccentric drive shaft  151  mounted in the center of the working head  144 . The eccentric shaft  151  includes an eccentric drive head  145 . This shaft is driven through an appropriate gear assembly  310  to couple rotation of the drive shaft  94  to the eccentric drive shaft  151  as best shown in  FIG. 18 .  FIG. 18  shows one end of drive shaft  94  drivingly coupled to eccentric drive shaft  151  in a prior art manner wherein the end of drive shaft  94  is unsupported and the gears  312  are unprotected from dirt and other contaminants common to the environment of machine operation. In one embodiment of the present invention, this gear assembly  310  connection is improved by providing a protective cover  300  as best shown in  FIG. 19 . The protective cover  300  prevents dirt and contamination of the gears  312  thereby increasing the life of the gear assembly  310 . The protective cover  300  can also provide a housing for bearings  314  for the drive shaft  94  and the eccentric drive shaft  151  which provides additional support, maintains alignment of the gear assembly, and also increases the life of the gear assembly  310 . Returning to  FIGS. 11 and 12 , an off-center pin  150  associated with the eccentric drive head  145  is engaged in a slot in the bottom of the slide block  146  which moves the slide block  146  within slot  147  so as to selectively expose one of the wheels  148  or  149  as the head  144  rotates. The slide block  144  is initially centered within slot  147 , and the cutting wheel  148  is then moved out into engagement with the interior of the work piece, and cooperates with the knife edge on the stationary die member as previously described to cut the work piece. The slide block  146  then moves to expose the beading wheel  149  after the cut pieces of the tube are positioned in overlapping relationship. In cooperation with the stationary die member, the bead coupling is formed. The operation of the head  144  may be similar to that provided in a machine produced by Iowa Precision Industries referred to as an AEM Gearhead Machine. 
     Referring now to  FIG. 11A , it is also desired in the preferred embodiment that the mounting of the slide block  146  within the working head  144  is adjustable by repositioning the eccentric pin  150  in a different mounting hole  153  within the eccentric drive head  145 . The different mounting holes  153  are located at slightly different distances away from the center of the eccentric shaft drive head  145 . This permits the range of motion, or stroke, of the slide block  146  to be slightly increased or decreased by using a different eccentric pin mounting hole  153  location. Allowing adjustment of the eccentric drive head  145  enables the user to fine tune the coupled bead formation for the particular work pieces being used. The fine-tuning is particularly helpful when using differing material thicknesses, different materials, aluminum coated materials, painted materials, or other variables in the work pieces or operation. The adjustment allows more or less material into the overlap such that the cutting and forming process can be optimized resulting in an increase in the precision of the formation of the coupling beads  24 ,  26 . The increase in precision results in an increase in the speed of the operation such that multiple passes are not required, thus allowing a decrease in production cycle times. 
     Also in the preferred embodiment, the wheels  148  and  149  are mounted in the slide block  144  with bearing assemblies  152  and  154  above and below the wheels and bearings  156  about a center post  158  to ensure proper alignment and operation of the wheels. Using this construction in association with the stationary die member provides very high precision in the cutting and forming of the coupling beads for smooth rotation between the gores of the duct member. 
     Referring to  FIGS. 20 through 26 , a sealing system  400  is shown that may include a repositionable die member  420  and  422 , a slidable plate  430  and  432 , and a crimping plate  410  and  412 . As in the previous embodiments of the present invention and shown in the previous figures, each of nests  60  or  62  can include a die supported on the upper surface, which in another embodiment may be comprised of the first and second semi-circular repositionable member  420  and  422 , which are positioned on opposed sides of the nests  60  or  62 . The repositionable die members  420  and  422  are positioned immediately adjacent the nest  60  or  62  in operation, but may also be moved into a non-operational position away from the nest  60  or  62  when desired in a manufacturing cycle. Therefore, each of the repositionable die member  420  and  422  may be supported in association with the slidable plate  430  and  432  which is supported in sliding engagement with support blocks  72  and  74  in a channel or slot  76 . The support blocks  72  and  74  may be adjusted relative to the slidable plates  430  and  432  for smooth slidable operation of the plates  430  and  432  within the slot  76 . Each of the plates  430  and  432  may be moveable toward and away from the nest  60  or  62  by means of a hydraulic ram  77  or other suitable mechanism. Within the nest  60  or  62 , a cutting and forming system  80  and a sealing system  400  is provided in the recessed portion of the nest  60  or  62 . Between the repositionable die members  420  and  422 , the cutting and forming system  80 , and the sealing system  400 , a circular channel  82  is formed by the recess of the nest  60  or  62 , the channel  82  being dimensioned to accept the work piece as shown in  FIG. 1 , with the work piece extending into the channel  82  to a predetermined depth. Associated with the nest  60  or  62  is a at the bottom of channel  82  on which the work piece is supported within the nest  60  or  62  at the predetermined position. As will be hereinafter described in more detail, the base plate is formed in association with a moveable platen  84  which is operated on by a pair of hydraulic rams  86  or other suitable mechanism. The platen assembly  84  is moveable about a drive shaft assembly  94  upwardly and downwardly to selectively position a work piece relative to the repositionable die members  420  and  422 , the cutting and forming system  80 , and the sealing system  400 . The platen assembly  84  functions as discussed above with respect to the previous embodiments of the present invention. 
     Continuing to refer to  FIGS. 20 through 26 , the repositionable die members  420  and  422  supported in association with the slidable plate  430  and  432  includes support from a positioning cavity  460  that allows the repositionable die member  420  and  422  to transition from one position to another or second position. The positioning cavity  460  may include a positioning device  470 , which may include a spring or any other suitable device that facilitates moving the repositionable die member  420  and  422  from a first position to a second position and vice versa. The repositionable die members  420  and  422  may include a cam  440  and a mounting rod  450  that also facilitates the repositioning of the repositionable die members  420  and  422 . Operation of the cam  440  with respect to the repositionable die members  420  and  422  will be discussed further at a subsequent paragraph. Additionally, the top portion of the cam  440  is slanted at an angle to receive a corresponding angled slant from the crimping plate  410  and  412 . The cam  440  is attached to the repositionable die member  420  and  422  by the mounting rod  450  or by another suitable method or mechanism. Furthermore, with regard to the repositionable die members  420  and  422  and the positioning device  470 , the repositionable die members  420  and  422  may be held at a particular position by one or more of the positioning devices  470 . In  FIG. 20 , three positioning devices are shown for illustrative purposes. 
     Referring to  FIGS. 20, 21, and 23 , each of the crimping plates  410  and  412  may be supported in association with the slidable plate  430  and  432  and the repositionable die members  420  and  422 , which are supported in sliding engagement with the support blocks  72  and  74 . The support blocks  72  and  74  may be adjusted relative to the slidable plates  430  and  432  and the crimping plates  410  and  412  for smooth slidable operation of the plates  430  and  432  within the channel or slot  76 . Each of the crimping plates  410  and  412  may be moveable toward and away from the nest  60  or  62  by means of a secondary hydraulic ram  477  or other suitable mechanism.  FIG. 20  shows two secondary hydraulic rams  477  for illustrative purposes. Additionally, the crimping plates  410  and  412  include a crimping portion that may be a cut-away section that also includes a slanted section with an angle corresponding to the angled slant of the cam  440 . This corresponding angled slant allows the cam  440  to force the repositionable die members  420  and  422  in a downward direction when the crimping plates  410  and  412  move towards the nest  60  or  62 , as shown in  FIG. 21 . 
     Regarding the sealing system  400 , after creation of seams  24  and  26  and before retracting the repositionable die members  420  and  422  by the cutting and forming system  80 , which includes the operation of the repositionable die members  420  and  422  and the slidable plate  430  and  432 , the crimping plates  410  and  412  move towards the nest  60  or  62 , which in turn forces the cam  440  and repositionable die members  420  and  422  in a downward manner. This results in the crimping or sealing of the gores at the seams or beads  24  and  26 . Crimping or sealing of the beads  24  and  26  decreases the loss of air in the air duct system, thereby increasing the air duct system&#39;s efficiency. After sealing the seams  24  and  26  by the downward force of the cam  440  and the repositionable die members  420  and  422 , the secondary hydraulic ram  477  moves the repositionable die member  420  and  422  away from the nest  60  or  62 . 
     The present invention also allows for the replacement or substitution of a die member  64  and  66  and the a slidable plate  68  and  70  with the repositionable die member  420  and  422  and the slidable plate  430  and  432 , respectively. Additionally, the slidable plate  430  and  432  and the crimping plate  410  and  412  are supported in sliding engagement with support blocks  72  and  74 , as shown in  FIG. 23 . The slidable plate  430  and  432  and the crimping plate  410  and  412  are both supported in the channel or slot  76 . The sealing system  400  may also be utilized after the completion of each of the coupled bead connection  24  and  26  between gores  14  and  16  in duct member  10 . The sealing system  400  may be used in conjunction with and subsequently to the cutting and forming system  80  to effectively seal the beads  24  and  26  to create a more air tight environment. 
     Additionally, the repositionable die member  420  and  422 , as previously described, are designed to cooperate with one another to form, when positioned adjacent to the work piece, a stationary form into which material of the work piece is pushed by the cutting and forming system  80 . The repositionable die members  420  and  422  are formed to include a recess, which will cooperate with a portion of the forming system  80  to generate an outwardly directed bead in the work piece of substantial depth. Furthermore, the repositionable die members  420  and  422  perform a clamping function and a sealing function in addition to the forming function of the die. This enables both sections  12 ,  14 , and  16  to be properly secured during and after the cutting and forming operation and this also enables sealing of the coupling beads  24  and  26 . 
     While the above description has been presented with specific relation to a particular embodiment of the invention and methods of producing a tapered and adjustable duct member, it is to be understood that the claimed invention is not to be limited thereby and can just as easily be applied to a non-tapered work pieces. Embodiments of this invention can be directly applied in other forming machines such as those described in U.S. patent application Ser. No. 09/507,952, herein incorporated by reference. In these type of embodiments, the invention will typically be utilized in a single workstation. It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are obtained. Certain changes may be made without departing from the scope of the invention and the above description is intended to be interpreted as illustrative and not limiting.