Container Weld Seam Tightness Testing via Partial Clamping
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Solution Overview
Problem
Current methods for checking the tightness of containers, such as tubes, are inefficient and costly, often requiring separate test stands, expensive sensors, and potentially damaging test gases, while also not accurately simulating real-world usage conditions.
Innovation Solution
A method where the weld seam is clamped partially and subjected to increased internal pressure, allowing for detection of deformation using sensors, ensuring no product escapes even if the seam is faulty, with optional additional checks for tube shape and weight to confirm integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If compressed air is used to pressurize the tube for tightness testing, then the tightness can be checked, but the tube closure must be opened beforehand which means the tube cannot be sold and must be disposed of
Solution Approach 1:
The weld seam is clamped by clamping elements before the internal pressure is increased, preventing product escape in advance. This preliminary clamping action allows the tube to remain sealed and intact throughout the testing process, enabling soldable tubes to be identified rather than requiring disposal of all tested tubes
Solution Approach 2:
Clamping elements are introduced as an intermediary mechanism between the test tube and the testing environment. These elements temporarily secure the weld seam during pressurization, allowing non-destructive testing while preventing product leakage, thus eliminating the need to open the tube closure beforehand
2Reliability
If pressure force is exerted on the tube wall from outside to check for leaks, then leak detection is possible, but the product escapes and the test stand must be cleaned which is time-consuming and costly
Solution Approach 1:
The clamping elements apply a counteracting force to the expected product escape by securing the weld seam before pressure testing. This preliminary protective action prevents product from escaping into the test stand environment, eliminating the need for subsequent cleaning operations and reducing both time and cost losses
3Reliability
If test gas is introduced into the tube together with the product to detect leaks, then tightness can be checked, but expensive sensors and large amounts of test gas are required and the performance of the filling machine is reduced
Solution Approach 1:
The tightness testing function is extracted from the filling machine process by using externally applied pressure through the tube wall rather than introducing test gas through the filling machine. This separation allows the filling machine to operate at full speed without interruption while the extracted testing mechanism provides reliable leak detection independently
Solution Approach 2:
Instead of using test gas introduced through the product flow, the invention uses external pneumatic pressure applied to the tube wall. This alternative pneumatic approach achieves the same tightness verification without requiring expensive gas sensors or reducing filling machine productivity
4Reliability
If the weld seam is clamped over its entire surface, then complete sealing is achieved, but deformation detection becomes difficult as the weld cannot open freely
Solution Approach 1:
The clamping is applied locally to specific portions of the weld seam rather than uniformly across the entire surface. This localized clamping provides sufficient sealing to prevent product escape while leaving other areas of the weld free to deform and open, allowing sensors to detect deformation patterns that indicate weld integrity issues
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 method reliably detects faulty welds without product loss, reduces costs, and simulates real-world usage conditions, ensuring only non-defective tubes proceed to packaging.
Implementation Method 1
the weld seam is clamped tightly and sealingly between clamping elements, for example clamping jaws
Implementation Method 2
the internal pressure in an interior of a container being increased by external influences
Implementation Method 3
a pressure force is exerted on the tube wall from the outside and then it is detected whether the weld seam opens
Implementation Method 4
the resulting deformation of the weld seam is recorded
Data Source
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Figure 5~6
AI summary
A container has a tube-like or tubular shell, which is sealed against the surrounding atmosphere and has a weld seam at at least one end. For checking the tightness of the container the internal pressure in an interior space of the container is increased by means of external action and the thereby ensuing deformation of the weld seam is detected. Provisions are made in this connection for the weld seam to be clamped between clamping elements before increasing the internal pressure only in a partial area of its surface, which has a distance from the end of the weld seam facing the interior space.