Automated method and system for producing an inflatable product
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Solution Overview
Problem
Current inflatable product manufacturing is manual, time-consuming, expensive, and prone to human error due to the need for individual welding of tensioning structures onto mattress sheets.
Innovation Solution
An automated system and method that includes an upstream tensioning structure production subsystem and a downstream preassembly production subsystem to simultaneously produce and couple tensioning structures between sheets, using welders and molds to efficiently weld and cut the structures, enabling the production of inflatable products in an automated, efficient, and repeatable manner.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual welding of tensioning structures is used, then flexibility and adaptability are maintained, but production time increases and productivity decreases
Solution Approach 1:
The patent replaces manual mechanical welding operations with an automated welding system that uses a programmable controller to coordinate multiple welders. The system automatically positions and operates welders based on pre-programmed sequences, eliminating manual labor while maintaining precise control over the welding process, thereby increasing productivity without sacrificing quality
Solution Approach 2:
The patent implements preliminary alignment of tensioning structures with the sheets before welding begins. The system pre-positions the tensioning structures using alignment mechanisms and pre-programs the welding sequence, so that when production starts, the automated welders can immediately begin operation without manual intervention, significantly reducing production time
2Ease of manufacture
If manual production processes are used, then operational flexibility is maintained, but production costs increase
Solution Approach 1:
The patent replaces manual production processes with an automated system that uses a programmable controller to coordinate multiple welders and handling mechanisms. This automation reduces labor costs and operational expenses while increasing manufacturing efficiency, as the system can operate continuously without breaks and maintains consistent quality across all products
Solution Approach 2:
The patent designs the automated system with multi-functional components that can handle different tensioning structure configurations and sheet types. The programmable controller can be reconfigured for different production requirements, making the system universally applicable to various product types while maintaining cost-effectiveness and high productivity
3Reliability
If individual welding of tensioning structures is performed manually, then precision control is possible, but human error increases
Solution Approach 1:
The patent replaces manual welding operations with an automated welding system controlled by a programmable controller. This eliminates human error in welding operations while maintaining precise control over weld parameters through digital programming. The system consistently reproduces the same high-quality welds without variation, significantly improving reliability without reducing productivity
Solution Approach 2:
The patent implements feedback mechanisms in the automated welding system that monitor weld quality and process parameters in real-time. The programmable controller receives feedback from sensors and automatically adjusts welding parameters to maintain optimal conditions, ensuring consistent quality and eliminating the variability associated with manual operations
4Productivity
If simultaneous welding at multiple points is implemented, then production time decreases, but system complexity increases
Solution Approach 1:
The patent divides the welding process into multiple independent welding stations, each with its own welder and control circuitry. The programmable controller coordinates these segmented welding operations to occur simultaneously at different points along the assembly. This segmentation allows the system to achieve high productivity through parallel processing while managing complexity by modularizing the system architecture
Solution Approach 2:
The patent employs a universal programmable controller that can manage multiple welders and coordinate their simultaneous operation. This single control system performs multiple functions including positioning, timing coordination, parameter control, and quality monitoring for all welders, thereby managing system complexity through centralized intelligent control rather than requiring separate complex systems for each welder
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 automated system significantly reduces production time and costs while minimizing human error, enabling the efficient and consistent manufacturing of inflatable products like mattresses.
Implementation Method 1
simultaneously welding the leading end of the first tensioning structure to the first sheet and the trailing end of the first tensioning structure to the second sheet by simultaneously operating the first and second welders
Data Source
AI summary
An automated system and method are disclosed for producing an inflatable product having a first sheet, a second sheet, and a plurality of tensioning structures between the first and second sheets. The system includes an upstream tensioning structure production subsystem that produces the tensioning structures and a downstream preassembly production subsystem that couples the tensioning structures to the first and second sheets. The subsystems may operate simultaneously to produce the inflatable product in an automated, efficient, and repeatable manner.