Adjustable Waveguide Segment for Plastic Welding Tolerance Compensation
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Solution Overview
Problem
Existing waveguides for plastic welding often result in energy losses and uneven welding due to dimensional deviations between manufacturing processes, leading to inconsistent welding seams.
Innovation Solution
A waveguide segment comprising adjustable first and second sub-segments with inclined entry and exit sides, allowing for adjustable width and length to match the welding seam line, minimizing energy losses and accommodating tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fixed waveguide is used, then the structure is simple, but dimensional deviations cause uneven welding and energy losses
Solution Approach 1:
The waveguide is designed with adjustable sub-segments that can be moved relative to each other along the width direction, transforming a fixed structure into a dynamic one. This allows the waveguide to adapt to dimensional deviations and ensure uniform welding by adjusting the exit width to match the actual welding seam line.
Solution Approach 2:
The waveguide is divided into multiple adjustable sub-segments instead of being a single fixed structure. Each sub-segment can be independently positioned, allowing precise adjustment of the overall waveguide width to compensate for manufacturing tolerances and achieve uniform energy distribution across the welding seam.
2Reliability
If the waveguide width is increased to accommodate tolerances, then welding uniformity improves, but energy losses increase
Solution Approach 1:
The adjustable width mechanism allows the waveguide to be dynamically configured to match the actual welding seam dimensions. Instead of using a fixed oversized waveguide that causes energy losses, the system can be adjusted to the precise required width, minimizing energy losses while maintaining welding uniformity.
3Adaptability or versatility
If the waveguide is made adjustable, then adaptability to tolerances improves, but device complexity increases
Solution Approach 1:
The waveguide is segmented into multiple adjustable sub-segments that can be independently positioned. This segmentation enables tolerance compensation through simple relative movements of the sub-segments, achieving adaptability without requiring complex mechanical systems.
Solution Approach 2:
The adjustable sub-segment design serves multiple functions: it compensates for manufacturing tolerances, adapts to different welding seam dimensions, and maintains uniform energy distribution. This multi-functionality achieves high adaptability without proportionally increasing device complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The adjustable waveguide segment ensures uniform energy distribution and reduced energy losses, enabling precise alignment and stronger welding seams by compensating for manufacturing tolerances.
Implementation Method 1
a first wall (10) having a first inner face (12) by means of which laser light can be reflected
Data Source
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AI summary
The invention provides a waveguide segment 5 consisting of two mating waveguide sub-segments 1, 3. A first waveguide sub-segment 1 comprises a first wall 10 and a second wall 20, each having an inner face 12, 22 by means of which laser light can be reflected. The inner faces 12, 22 are arranged opposite to each other and a depth D1 of the waveguide sub-segment 1 is defined by a distance between the first 12 and the second inner face 22. Further, each wall 10, 20 comprise an exit side 14, 24, which faces the components T, A to be welded in operation, and an opposite entry side 16, 26. The height Hi, H2of each wall 10, 20 is defined by the distance between the exit 14, 24 and the entry side 16, 26 and the width W1, W2 of each wall 10, 20 is defined by the extension perpendicular to the respective height H1, H2 as well as to the depth D1, D2 of the waveguide sub-segment 1. The entry side 16, 26 of each wall 10, 20 of the first sub-segment 1 extends at least in a portion 18, 28 in an angle α1, α2 with respect to the height, for which applies: 0° < α < 90°. The second sub-segment 3 is preferably formed complementary so that the second sub-segment 3 comprises a respective portion 38, 48 at the exit side 34, 44 of each wall 30, 40. Thus, and during usage, laser light passing through the second waveguide sub-segment 3 enters at least partially the first waveguide sub-segment 1 between the first 18 and the second portion 28.