Automated Balloon Gore Sealing Assembly
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Solution Overview
Problem
Current balloon assembly processes for high-altitude applications are extremely labor-intensive and prone to human error, limiting mass production due to the difficulty in controlling dimensions and achieving consistency in assembling flexible balloon gores.
Innovation Solution
An automated balloon gore sealing assembly that includes a table component with movable platforms and a sealing component, allowing for the automatic assembly of balloon gores by controlling film roll-out, handling, folding, tendon application, and sealing without human intervention, enhancing repeatability and dimensional accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual assembly techniques are used for balloon envelope components, then flexibility in assembly process is maintained, but the process becomes extremely time-consuming and lacks consistency
Solution Approach 1:
The assembly system is divided into multiple specialized platforms (first platform for receiving and positioning, second platform for sealing, third platform for collection) that work in sequence. Each platform performs a specific function in the assembly process, allowing complex balloon envelope assembly to be broken down into manageable, automated steps that improve productivity without requiring a single overly complex device.
Solution Approach 2:
The patent replaces manual mechanical assembly operations with an automated system that uses controlled platform movement, automated sealing mechanisms, and programmed coordination between components. This substitution of manual mechanical systems with automated control systems enables high-speed assembly while maintaining precision and consistency.
2Manufacturing precision
If manual assembly is used, then device complexity remains low, but manufacturing precision and consistency deteriorate
Solution Approach 1:
Manual positioning and sealing operations are replaced with automated platform movement and controlled sealing mechanisms. The first platform automatically positions sheet portions with precise dimensional control, and the sealing component applies consistent heat seals, ensuring manufacturing precision while accepting the complexity of automated control systems.
Solution Approach 2:
The system uses movable platforms that can dynamically adjust positions and configurations during the assembly process. The first platform moves to position materials, the second platform moves for sealing operations, and platforms can be reconfigured for different assembly stages, enabling precise control throughout the manufacturing process.
3Productivity
If automated assembly is implemented, then productivity increases, but the extent of automation and system complexity worsens
Solution Approach 1:
The automated assembly system is segmented into distinct functional platforms (first platform for material handling, second platform for sealing, third platform for collection) that operate in sequence. This segmentation allows complex automated assembly to be achieved through coordinated simple operations on each platform, improving productivity while managing automation complexity through modular design.
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 assembly significantly reduces labor and human error, improving the efficiency and consistency of balloon production while maintaining dimensional accuracy, enabling mass production of high-quality balloon envelopes.
Implementation Method 1
The sealing component may be configured to move along the second platform and to apply a heat seal to bond the first sheet portion to the second sheet portion in order to join the first and the second gores of the balloon envelope.
Data Source
AI summary
An assembly for manufacturing a balloon envelope includes a table component and a sealing component. The table component may include a first platform, a second platform, a third platform, and a lateral opening between the first and second platforms. The first and second platforms can receive a first sheet of material that forms a first gore of the balloon envelope and a second sheet of material that forms a second gore of the balloon envelope. At least a portion of the first platform may move relative to the third platform so as to allow for the tendon and the portion of the second sheet attached to the tendon to move toward the third platform. The sealing component may be configured to bond the first sheet to the second sheet in order to join the first and the second gores of the balloon envelope.