Calibration Roller Force Sensing for Stable Roll Seam Welding
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Solution Overview
Problem
Existing methods for roll seam welding of container shells face challenges in maintaining precise overlapping of metal sheet edges due to lateral deviation under welding pressure, leading to inconsistent seam quality and increased wear on equipment, especially when metal sheet quality or cutting errors occur.
Innovation Solution
A method and device that utilize force measurement on calibration rollers to evaluate the overlapping width of container shells, allowing for precise calibration force adjustment to prevent excessive wear and ensure consistent welding, by using a yoke-connected force measurement system to detect deviations from predefined thresholds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the overlapping of metal sheet edges is minimized to yield a compact seam, then the seam compactness is improved, but the metal sheet edges deviate laterally and glide away from one another due to welding pressure
Solution Approach 1:
The calibration wreath applies preliminary counteracting force to the metal sheet edges before welding occurs. This pre-positioning action prevents the edges from deviating laterally when welding pressure is applied, thereby maintaining both seam compactness and edge position precision during the welding process
Solution Approach 2:
The calibration wreath acts as an intermediary device between the metal sheet edges and the welding rollers. It mediates the interaction by providing stabilizing contact and preventing lateral deviation, allowing the welding process to proceed with minimal overlapping while maintaining edge alignment
2Manufacturing precision
If a calibration tool is introduced to prevent lateral deviation of metal sheet edges, then the edge position precision is improved, but the device complexity increases
Solution Approach 1:
The calibration wreath is designed to perform multiple functions: it calibrates the edge position, prevents lateral deviation, and provides stable positioning during welding. This multi-functionality reduces the need for separate devices, thereby limiting the increase in device complexity while achieving improved edge position precision
Solution Approach 2:
The calibration wreath employs a curved, wreath-shaped design that conforms to the cylindrical geometry of the container shell. This curved structure allows seamless contact around the circumference, providing effective calibration and positioning without requiring complex mechanical components
3Manufacturing precision
If the calibration force is increased to stabilize the overlapping metal sheet edges, then the edge position precision is improved, but the wear of the device increases and production stability decreases
Solution Approach 1:
The calibration wreath is designed with adjustable parameters that allow dynamic optimization of the calibration force. By adjusting the wreath geometry and position, the system adapts to different metal sheet qualities and cutting conditions, maintaining edge position precision while avoiding excessive calibration force that would cause increased wear and production instability
4Measurement precision
If force measurement is implemented on calibration rollers to evaluate overlapping width, then the measurement precision is improved, but the device complexity increases
Solution Approach 1:
The force measurement system replaces complex mechanical measurement mechanisms with force sensors that directly measure the calibration force. This substitution provides precise overlapping width measurement through electrical signals rather than mechanical linkages, thereby improving measurement precision while limiting the increase in 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
This approach simplifies the setting of production devices, reduces unnecessary wear, and enables early detection of poorly welded shells by ensuring the overlapping width is within optimal limits, thereby maintaining stable production and improving seam quality.
Implementation Method 1
a force measurement installation (17) is provided, which measures the force exerted by the respective container shell on at least one calibration roller
Implementation Method 2
particularly in such a way that the calibration tool consists of two parts (18, 18'), each of which carries calibration rollers, and wherein the force exerted by the respective container shell on the two parts is measured
Data Source
AI summary
A welding installation with a calibration tool is provided in a device for producing container shells. The force exerted by the container shells on the calibration tool is measured and evaluated as information for the overlapping width of the respective container shell. This allows adjusting the calibration tool during configuration of the device and allows the removal of container shells welded with too large or too small overlapping during production of container shells.