A continuously adjustable tensioning system for molds

Abstract

This invention discloses a continuously adjustable tensioning system for molds, comprising multiple rubbing plates. These rubbing plates are distributed at preset positions around the forming surfaces of the upper and lower molds. The lower ends of the rubbing plates are serrated, pressing against the edges of the fabric to be tensioned. Each rubbing plate is connected to a manual or automatic continuously adjustable tensioning mechanism. This mechanism drives the rubbing plate downwards, achieving tensioning of the fabric. The tensioning system of this invention is continuously adjustable, ensuring a perfect balance between stretching and wrinkling. It has a wide range of applications, providing customers with a better product appearance experience. Furthermore, it reduces process edges, lowers material utilization, and enhances product competitiveness.

Description

Technical Field

[0001] This invention relates to the field of fabric tensioning technology, and more specifically to a steplessly adjustable tensioning system for molds. Background Technology

[0002] The automotive market is currently experiencing a surge in demand for personalization, customization, and high-end products, leading to the increasing use of soft materials and processes involving coating and thermoforming. However, during manufacturing, excessive stretching can result in wrinkles and other appearance issues, while excessive stretching can lead to cracking and thinning. Effectively addressing both stretching and appearance problems is a real challenge for manufacturers.

[0003] Existing technologies often use rivets and frame pressing to solve this problem, but they cannot achieve stepless adjustable tension. At the same time, in order to solve the wrinkle problem, there will inevitably be overstretching, which will affect the appearance of the product and reduce the customer's experience. Summary of the Invention

[0004] In view of the shortcomings of the existing technology, the present invention provides a steplessly adjustable tensioning system for molds.

[0005] This invention discloses a steplessly adjustable tensioning system for molds, comprising multiple wiping plates;

[0006] Multiple wiping plates are distributed around the forming surfaces of the upper and lower molds at preset positions. The lower end of each wiping plate is a serrated end, which is used to press the edge of the fabric to be stretched.

[0007] Each of the wiping plates is connected to a manually adjustable tensioning mechanism or an automatically adjustable tensioning mechanism. The manually adjustable tensioning mechanism or the automatically adjustable tensioning mechanism drives the wiping plate to move downward, thereby tightening the fabric to be tightened.

[0008] As a further improvement of the present invention, the manually steplessly adjustable tensioning mechanism includes a screw and a washer;

[0009] The upper or lower mold has multiple screw holes installed at a preset position, and the wiping plate has vertical waist holes; the screw passes through the waist holes and is fixed to the corresponding screw holes, and a gasket is provided between the wiping plate and the mold;

[0010] Loosen the screw, and the wiping plate moves downward under the guidance of the screw to tighten the fabric to be tightened; after tightening, tighten the screw to fix the wiping plate on the mold.

[0011] As a further improvement of the present invention, the automatic steplessly adjustable tensioning mechanism includes: a cylinder;

[0012] The output end of the cylinder is connected to the wiping plate, and the cylinder drives the wiping plate to move downward, thereby tightening the fabric to be tightened.

[0013] As a further improvement of the present invention, the automatic stepless adjustable tensioning mechanism further includes: a linear module;

[0014] The top of the upper mold is equipped with a matrix of linear modules, and one or more cylinders on different sides of the mold are installed on the corresponding linear modules.

[0015] The linear module moves multiple cylinders with wiping plates to a preset position, and then the cylinders drive the wiping plates to move downwards, thereby tightening the fabric to be tightened.

[0016] As a further improvement of the present invention, the automatic stepless adjustable tensioning mechanism further includes: a pressure sensor and a controller;

[0017] The pressure sensor is provided at the connection between the extended end of each cylinder and the wiping plate. The pressure sensor is used to detect the tension force of the fabric to be tightened.

[0018] The pressure sensor is connected to the input terminal of the controller, and the output terminal of the controller is connected to the intake solenoid valve of the cylinder.

[0019] The controller has a preset tension force stored in it. The actual tension force detected by each pressure sensor is compared with the preset tension force stored in the controller. When the actual tension force is less than the preset tension force, the air intake solenoid valve of the cylinder corresponding to the pressure sensor is controlled to increase the downward pressure of the cylinder on the wiping plate. When the actual tension force is greater than the preset tension force, the air intake solenoid valve of the cylinder corresponding to the pressure sensor is controlled to decrease the downward pressure of the cylinder on the wiping plate. This is to ensure that the actual tension of the fabric to be tightened on all wiping plates reaches the preset tension force.

[0020] As a further improvement of the present invention, the wiping plates at different positions are provided with the same or different preset tension forces.

[0021] As a further improvement of the present invention, the automatic stepless adjustable tensioning mechanism further includes: a processor and an input device;

[0022] The input device is connected to the processor, and the processor is connected to the controller;

[0023] The input device is used to input the fabric parameters of the fabric to be tightened, including but not limited to material and thickness;

[0024] The processor matches the preset tension force at each position of the fabric to be tightened based on the fabric parameters input by the input device, and sends the preset tension force to the controller.

[0025] As a further improvement of the present invention, the processor has a known lookup table of fabric parameters and preset tension forces pre-stored in it, and the preset tension forces corresponding to each position of the fabric to be tightened are obtained from the known lookup table based on the fabric parameters input by the input device.

[0026] As a further improvement of the present invention, the wiping plate and the mold are designed to conform to each other.

[0027] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0028] The tensioning system of this invention is infinitely adjustable, ensuring a perfect balance between stretching and wrinkling. It has a wide range of applications and can bring customers a better product appearance experience. It can also reduce process edges, reduce material utilization, and improve product competitiveness.

[0029] The tensioning system of the present invention constitutes a control system through cylinders, linear modules, pressure sensors, controllers, etc. It can apply different tensioning forces according to the characteristics and requirements of different fabrics, and the position and pressure are adjustable to achieve intelligent tensioning. It is also applicable to various covering and thermoforming molds. Attached Figure Description

[0030] Figure 1 This is a front view of a continuously adjustable tensioning system for molds disclosed in one embodiment of the present invention;

[0031] Figure 2 This is a side view of a continuously adjustable tensioning system for molds disclosed in one embodiment of the present invention;

[0032] Figure 3 This is a top view of a continuously adjustable tensioning system for molds disclosed in one embodiment of the present invention;

[0033] Figure 4 This is a front view of a continuously adjustable tensioning system for molds disclosed in another embodiment of the present invention;

[0034] Figure 5 This is a side view of a continuously adjustable tensioning system for molds disclosed in another embodiment of the present invention;

[0035] Figure 6 This is a top view of a continuously adjustable tensioning system for molds disclosed in another embodiment of the present invention;

[0036] Figure 7 This is a control principle diagram of a continuously adjustable tensioning system for molds disclosed in another embodiment of the present invention.

[0037] In the picture:

[0038] 1. Upper mold; 2. Lower mold; 3. Wiping plate; 3-1. Waist hole; 3-2. Serrated end; 4. Cylinder; 5. Linear module; 6. Pressure sensor; 7. Controller; 8. Processor; 9. Input device; 10. Intake solenoid valve. Detailed Implementation

[0039] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0040] The present invention will now be described in further detail with reference to the accompanying drawings:

[0041] like Figures 1-6 As shown, the present invention provides a steplessly adjustable tensioning system for molds, including multiple wiping plates 3, such as... Figure 1-6 The diagram shows six wiping plates 3 arranged along the long side and three wiping plates 3 arranged along the wide side. These wiping plates 3 are distributed at preset positions around the forming surfaces of the upper mold 1 and lower mold 2, and their height can be adjusted as needed. The length of the wiping plate extending beyond the mold determines the degree of fabric stretching; a longer extension results in greater fabric stretching, and a shorter extension results in less fabric stretching, thus achieving different adjustments for different parts of the fabric to be tightened. The lower end of the wiping plate 3 is a serrated end 3-2, which presses against the edge of the fabric to be tightened. The greater the tooth height of the serrated end 3-2, the greater the tightening force; the greater the tooth width, the fewer the force points, and the smaller the force. Each wiping plate 3 is connected to a manually adjustable stepless tightening mechanism or an automatically adjustable stepless tightening mechanism. These mechanisms drive the wiping plate 3 downwards, tightening the fabric to be tightened. Furthermore, the wiping plates 3 are designed to conform to the shape of the mold.

[0042] Specifically:

[0043] like Figures 1-3 As shown, the manual stepless adjustable tensioning mechanism of the present invention includes a screw and a washer. Multiple screw holes are installed at preset positions of the upper or lower mold, and the wiping plate 3 is provided with a vertical waist hole 3-1. The screw passes through the waist hole 3-1 and is fixed on the corresponding screw hole, and a washer is provided between the wiping plate 3 and the mold. In use, the screw is loosened, and the wiping plate 3 moves downward under the guidance of the screw to achieve tensioning of the fabric to be tensioned. After tensioning to the correct position, the screw is tightened to complete the fixation of the wiping plate 3 on the mold.

[0044] like Figure 4-7As shown, the automatic stepless adjustable tensioning mechanism of the present invention includes: a cylinder 4, a linear module 5, a pressure sensor 6, a controller 7, a processor 8, an input device 9, and an air intake solenoid valve 10; wherein, the output end of the cylinder 4 is connected to the wiping plate 3, and the cylinder 4 drives the wiping plate 3 to move downward to achieve tensioning of the fabric to be tensioned.

[0045] Furthermore, in order to make the position of the wiping plate 3 adjustable, the present invention has a matrix of linear modules 5 installed on the top of the upper mold 1, and one or more cylinders 4 on different sides of the mold are installed on the corresponding linear modules 5; the linear modules 5 move multiple cylinders 4 with wiping plates 3 to a preset position, and then the cylinders 4 drive the wiping plates 3 to move downward, so as to tighten the fabric to be tightened.

[0046] Furthermore, in order to achieve intelligent adjustment and display of tension force, the present invention provides a pressure sensor 6 at the connection between the extended end of the cylinder 4 and the wiping plate 3. The pressure sensor 6 is used to detect the tension force of the fabric to be tensioned. The pressure sensor 6 is connected to the input end of the controller 7, and the output end of the controller 7 is connected to the air intake solenoid valve 10 of the cylinder 4. In use, the controller 7 has a preset tension force stored in it. The actual tension force detected by each pressure sensor 6 is compared with the preset tension force stored in the controller 7. When the actual tension force is less than the preset tension force, the air intake solenoid valve 10 of the cylinder 4 corresponding to the pressure sensor 6 is controlled to increase the downward pressure of the cylinder 4 on the wiping plate 3. Alternatively, when the actual tension force is greater than the preset tension force (the clamping force of wiping plate A reaches the preset tension force, but when adjusting the clamping force of wiping plate B, the clamping force of wiping plate A exceeds the preset tension force), the air intake solenoid valve 10 of the cylinder 4 corresponding to the pressure sensor 6 is controlled to decrease the downward pressure of the cylinder 4 on the wiping plate 3. This ensures that the actual tension force of all wiping plates 3 on the fabric to be tightened reaches the preset tension force. Furthermore, the controller 7 is also equipped with a display screen to display the actual tension force detected by all pressure sensors 6. Furthermore, the same or different preset tension forces can be set for wiping plates 3 at different positions.

[0047] Furthermore, to achieve tensioning that can meet the needs of different fabrics, the input device (touchscreen, button, or other input device) 9 of this invention is connected to the processor 8, and the processor 8 is connected to the controller 7. The input device 9 is used to input the fabric parameters of the fabric to be tensioned, including but not limited to material and thickness. Based on the fabric parameters input by the input device, the processor 8 matches the preset tension force at each position corresponding to the fabric to be tensioned, and sends the preset tension force to the controller 7. The method for matching the preset tension force is as follows: the processor 8 has a known lookup table of fabric parameters and preset tension forces pre-stored, and obtains the preset tension force at each position corresponding to the fabric to be tensioned from the known lookup table based on the fabric parameters input by the input device 9.

[0048] The operation process of this invention includes:

[0049] Step 1: The operator selects the fabric parameters to be tightened on the touch screen. The processor 8 matches the preset tension force at each position based on the fabric parameters and sends the preset tension force to the controller 7.

[0050] Step 2: Place the fabric between the upper mold 1 and the lower mold 2, and initially tighten it;

[0051] Step 3: The linear module 5 drives the cylinder 4 to move to the preset position, so that each wiping plate 3 reaches its corresponding position and the serrated end 3-2 of the wiping plate 3 presses against the edge of the fabric.

[0052] Step 4: Start cylinder 4. Cylinder 4 drives the corresponding wiping plate 3 to further tighten the fabric at different positions. During the tightening process, pressure sensor 6 detects the actual tension force. When the actual tension force is less than the preset tension force, controller 7 controls the air intake solenoid valve 10 of cylinder 4 corresponding to pressure sensor 6 to increase the downward pressure of cylinder 4 on wiping plate 3 until the preset tension force of cylinder 4 at that position is reached. After adjustment, the actual tension force of all wiping plates 3 on the fabric reaches the preset tension force.

[0053] Step 5: Cover the fabric and heat-press it into shape. Then, the cylinder is lifted to release the tension, and the upper and lower molds open.

[0054] The advantages of this invention are:

[0055] The tensioning system of this invention is infinitely adjustable, ensuring a perfect balance between stretching and wrinkling. It has a wide range of applications and can bring customers a better product appearance experience. It can also reduce process edges, reduce material utilization, and improve product competitiveness.

[0056] The tensioning system of the present invention constitutes a control system through cylinders, linear modules, pressure sensors, controllers, etc. It can apply different tensioning forces according to the characteristics and requirements of different fabrics, and the position and pressure are adjustable to achieve intelligent tensioning. It is also applicable to various covering and thermoforming molds.

[0057] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A stepless adjustable tensioning system for a mold, characterized by, Includes multiple wipers; Multiple wiping plates are distributed around the forming surfaces of the upper and lower molds at preset positions. The lower end of each wiping plate is a serrated end, which is used to press the edge of the fabric to be stretched. Each of the wiping plates is connected to an automatic stepless adjustable tensioning mechanism, which drives the wiping plate to move downward to tighten the fabric to be tightened. The automatic stepless adjustable tensioning mechanism includes a cylinder and a linear module. The output end of the cylinder is connected to the wiping plate. The cylinder drives the wiping plate to move downward, thereby tightening the fabric to be tightened. A matrix of linear modules is installed on the top of the upper mold. One or more cylinders on different sides of the mold are installed on the corresponding linear modules. The linear modules move multiple cylinders with wiping plates to a preset position, and then the cylinders drive the wiping plates to move downward, thereby tightening the fabric to be tightened.

2. The infinitely adjustable tension system for molds as claimed in claim 1, wherein The automatic stepless adjustable tensioning mechanism also includes: a pressure sensor and a controller; The pressure sensor is provided at the connection between the extended end of each cylinder and the wiping plate. The pressure sensor is used to detect the tension force of the fabric to be tightened. The pressure sensor is connected to the input terminal of the controller, and the output terminal of the controller is connected to the intake solenoid valve of the cylinder. The controller has a preset tension force stored in it. The actual tension force detected by each pressure sensor is compared with the preset tension force stored in the controller. When the actual tension force is less than the preset tension force, the air intake solenoid valve of the cylinder corresponding to the pressure sensor is controlled to increase the downward pressure of the cylinder on the wiping plate. When the actual tension force is greater than the preset tension force, the air intake solenoid valve of the cylinder corresponding to the pressure sensor is controlled to decrease the downward pressure of the cylinder on the wiping plate. This is to ensure that the actual tension of the fabric to be tightened on all wiping plates reaches the preset tension force.

3. The infinitely adjustable tensioning system for molds as claimed in claim 2, characterized in that, The same or different preset tension is set for the wiping plates at different positions.

4. The infinitely adjustable tensioning system for molds as claimed in claim 2, characterized in that, The automatic steplessly adjustable tensioning mechanism also includes: a processor and an input device; The input device is connected to the processor, and the processor is connected to the controller; The input device is used to input the fabric parameters of the fabric to be tightened, including the material and thickness; The processor matches the preset tension force at each position of the fabric to be tightened based on the fabric parameters input by the input device, and sends the preset tension force to the controller.

5. The continuously adjustable tensioning system for molds as described in claim 4, characterized in that, The processor has a pre-stored lookup table of fabric parameters and preset tension forces. Based on the fabric parameters input by the input device, the preset tension forces corresponding to each position of the fabric to be tightened are obtained from the lookup table.

6. The continuously adjustable tensioning system for molds as described in any one of claims 1 to 5, characterized in that, The wiping plate is designed to conform to the shape of the mold.

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