Compact Welding Machine With Drum Drive Motor for Edge Access
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Solution Overview
Problem
Existing automatic welding machines for material webs are bulky, making it difficult to work close to edges or surfaces, and the welding area is not easily visible due to the complex power transmission system and motor placement.
Innovation Solution
A compact automatic welding machine design with a drum drive motor integrated into the pressure roller, featuring a brushless DC motor and epicyclic gear, allowing the pressure roller to be modular and adjustable, and the chassis to be L-shaped or T-shaped for better edge access and visibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate electric motor and reduction gear are used to drive the pressure roller, then the drive function is reliable, but the device occupies a lot of space and becomes bulky
Solution Approach 1:
The patent combines the electric motor and reduction gear into a single integrated drum drive motor unit. The motor shaft directly drives the pressure roller through an integrated gear mechanism, eliminating the need for separate motor and gear components. This merging reduces the overall device volume while maintaining reliable drive function.
Solution Approach 2:
The reduction gear is nested within the motor housing, with the gear mechanism positioned inside the motor casing. The motor shaft extends through the gear mechanism to directly drive the pressure roller. This nesting arrangement compactly houses both the motor and gear reduction components in a single space, significantly reducing the device footprint.
2Reliability
If a complex power transmission device connects the drive roller to the reduction gear, then the drive mechanism is functional, but the design becomes voluminous and hinders work close to edges
Solution Approach 1:
The power transmission device is merged with the pressure roller itself. The motor shaft is directly coupled to the pressure roller through the integrated gear mechanism, eliminating intermediate power transmission components. This direct coupling reduces the device width, enabling operation in confined spaces close to edges while maintaining reliable power transmission.
Solution Approach 2:
The chassis is designed with a laterally displaceable transverse leg that can adjust its position relative to the longitudinal leg. This dynamic configuration allows the device to adapt its width according to working conditions, enabling edge work when space is limited while maintaining full functionality on larger surfaces.
3Ease of manufacture
If the electric motor and reduction gear are positioned separately from the pressure roller, then the components are easily accessible, but the welding area visibility is obstructed
Solution Approach 1:
The motor and reduction gear are merged into a compact unit positioned at the rear end of the pressure roller. This integration minimizes the protrusion of drive components, improving the operator's view of the welding area. The compact design maintains component accessibility while reducing visual obstruction during welding operations.
4Ease of manufacture
If the pressure roller width is fixed, then the manufacturing is simpler, but the device cannot adapt to different welding widths and surfaces
Solution Approach 1:
The pressure roller is segmented into a modular design with exchangeable roller bodies of different widths. The basic roller structure remains standardized for easy manufacturing, while interchangeable modules allow adaptation to different welding widths and surface requirements. This segmentation maintains manufacturing simplicity while providing versatility.
Solution Approach 2:
The pressure roller width can be dynamically adjusted by selecting different roller body modules based on the specific welding task. This dynamic adaptability allows the device to handle various welding widths and surface types while the standardized interface maintains manufacturing simplicity.
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 efficient welding close to edges and surfaces with improved visibility of the welding area, as the compact design and modular pressure roller allow for adjustable width and shape, facilitating welding on various surfaces without obstructing the view.
Implementation Method 1
brushless DC motor
Implementation Method 2
epicyclic gear
Implementation Method 3
heating device with a laterally projecting contact heating element
Implementation Method 4
electric or gas heating element
Implementation Method 5
pressure roller that can be placed on the edge areas of the material webs
Data Source
Figure 1~2a
Figure 2b~3a
Figure 3b~3d
AI summary
Welding machine (1) for the edge-side connection of material webs overlapping at the edge, which can be bonded to one another under the action of heat and subsequent application of pressure, having a chassis (2) on which at least running rollers (5), a heating device (6) and at least one pressure roller ( 8) is arranged. The heating device (6) has a laterally projecting contact heating element (7) which can be inserted between the edges of the material webs, the chassis (2) being driven by an electric motor which is arranged on a longitudinal leg of the chassis (2). According to the invention, the electric motor is designed as a brushless DC motor and the reduction gear is designed as an epicyclic gear, which are combined to form a drum drive motor (9). In this case, the DC motor is preferably a pancake motor. The chassis (2) has a transverse leg (4) which can be adjusted perpendicularly to the direction of travel relative to the longitudinal leg (3). (Figure 1)