Coil Splicing Welding for Continuous Stamping Material Change
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Solution Overview
Problem
Current automated stamping production lines require manual material changes and shutdowns, disrupting continuous production and limiting efficiency.
Innovation Solution
An automatic material changing and welding system that uses a double-head uncoiling machine, pneumatic cylinders, a welding transfer sliding table, and a control unit to sense material levels and perform welding connections via a welding connection plate, enabling seamless switching between old and new coiled materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual material changing is performed in automated stamping production lines, then material replacement can be completed, but production shutdown and downtime occur disrupting continuous production
Solution Approach 1:
The welding system enables continuous production by automatically welding new and old coiled materials together, eliminating the shutdown period required for manual material replacement. The welding process allows the stamping line to operate continuously without interruption, as the material transition occurs during normal operation rather than requiring production stoppage.
Solution Approach 2:
The system performs automatic material changing through self-service mechanisms including automatic sensing of material levels, automated welding operations, and self-positioning of materials. The control unit coordinates these automatic functions without requiring manual intervention, enabling the production line to change materials autonomously while maintaining continuous operation.
2Extent of automation
If automated welding system is implemented, then material changing automation is achieved, but device complexity increases
Solution Approach 1:
The welding system is designed with multi-functionality to handle various aspects of material changing automation including sensing, positioning, clamping, welding, and control within a single integrated system. This universal approach consolidates multiple functions into one cohesive device rather than requiring separate systems for each function, thereby managing complexity while achieving comprehensive automation.
Solution Approach 2:
The system introduces intermediary components such as the welding connection plate and control unit that mediate between different subsystems. These intermediaries coordinate the interactions between the sensing system, welding mechanism, and material handling system, simplifying the overall system architecture by providing centralized control and coordination points.
3Productivity
If welding connection plate is used to connect materials, then continuous production is enabled, but manufacturing precision requirements increase
Solution Approach 1:
The system replaces manual mechanical positioning and alignment with automated sensing and control mechanisms. The proximity switch and control unit precisely detect material positions and automatically adjust positioning, replacing manual mechanical operations with automated electro-mechanical systems that achieve higher precision consistently.
Solution Approach 2:
The system employs precise control of welding parameters including temperature, pressure, and timing to achieve accurate welding connections. By carefully controlling these parameters, the system ensures high manufacturing precision in the welding process and positioning, enabling continuous production without compromising quality.
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
Enables continuous production by automatically changing and welding materials, reducing downtime and material unevenness, thus enhancing the efficiency of automated stamping production lines.
Implementation Method 1
a proximity switch arranged at the welding feed end and used for sensing the stamping material and generating a material changing signal
Implementation Method 2
two material clamping pneumatic cylinders arranged at the welding discharge end, wherein when the proximity switch does not sense the stamping material, the two material clamping pneumatic cylinders clamp the stamping material
Implementation Method 3
an electric welding machine used for executing a welding procedure
Data Source
AI summary
An automatic material changing and welding system for stamping materials includes a welding transfer sliding table and a welding platform. The automatic material changing device further includes a feeding system. The feeding system includes a double-head uncoiling machine, an automatic feeding machine and a flattening machine. The automatic material changing device is used for automatic feeding for a stamping machine. The system triggers a material changing signal through a sensor to control and integrate the welding transfer sliding table and the welding platform to act to execute a welding procedure, so that the stamping materials are in welding connection with new and old coiled materials through a welding connection plate to realize continuous production operation of an automated stamping production line.