Automated Material Sheet Splicing With Rod-and-Gate Actuation
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Solution Overview
Problem
Manual splicing of material sheets in manufacturing processes, such as rubber sheeting, is cumbersome and inefficient, leading to potential material waste and downstream processing issues.
Innovation Solution
A material-joining device with a moveable gate and actuators that automate the splicing process by aligning and joining trailing and leading ends of material sheets using rods and chambers, facilitated by sensors and compressed air for precise control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual splicing process is used, then operator can join material sheets, but operator presence is required for extended period and process is cumbersome
Solution Approach 1:
The splicing device performs the joining operation autonomously without requiring operator presence during the actual splicing process. The device includes automated components such as a splicing mechanism with jaws that clamp and join material sheets automatically, eliminating the need for continuous operator intervention and reducing downtime.
Solution Approach 2:
The device prepares and positions material sheets in advance before the splicing operation. A feeding mechanism automatically feeds material sheets into the splicing device, and the device pre-positions the sheets in the correct alignment before activation, enabling rapid automated splicing without operator involvement during the critical joining phase.
2Productivity
If manual splicing process is used, then material can be joined, but large amount of material accumulates in one section causing downstream processing issues
Solution Approach 1:
The device performs splicing operations in advance before material sheets are needed downstream. By pre-positioning and joining sheets in the splicing device, the system ensures continuous material supply to downstream machinery without accumulation, maintaining precise feed control and preventing processing issues.
Solution Approach 2:
The splicing device enables continuous material handling by automatically joining sheets as they are fed through the device. This continuous operation prevents material accumulation sections and ensures steady, controlled material flow to downstream machinery, improving both productivity and manufacturing precision.
3Ease of manufacture
If manual splicing process is used, then material sheets can be joined, but sharp knives and heating elements are involved creating safety and quality issues
Solution Approach 1:
The device replaces manual mechanical splicing with an automated mechanical system that uses controlled jaws and clamping mechanisms instead of sharp knives. The automated mechanism gradually closes jaws to join material sheets, eliminating the need for dangerous blade elements and reducing safety hazards while maintaining joining effectiveness.
Data Source
AI summary
A material-joining device is provided for joining a trailing end of a first material sheet to a leading end of a new supply of material sheeting. The joining device comprises a main body and a gate coupled to the main body. A plurality of rods are moveably held within the main body along with at least one actuator coupled to the plurality of rods. The actuators can move the rods from a retracted position to an extended position. The gate includes a plurality of chambers aligned with the rods. The chambers accommodate a portion of the rods when in the extended position. Using the material-joining device, at least portions of the first material and the new supply of material fit within the space between the main body and the gate. When the at least one actuator moves the rods to the extended position, the separate material sheets are joined together.