Cut and Seal Welding Device with Sensor Feedback Control
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Solution Overview
Problem
Existing cut-off welding devices for film webs face challenges in monitoring and controlling the separating and joining processes, leading to limitations in cycle times, material requirements, and heat input, which affect the quality and efficiency of the welding process.
Innovation Solution
A control device utilizes sensor signals from force and movement sensors to adjust the working gap and heat input, allowing for precise control of the separating and joining processes through a drive device and elastic coupling of the stamps, enabling improved monitoring and regulation of the welding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional cut and seal welding devices are used without sensor monitoring, then the device complexity is low, but the manufacturing precision and reliability of the welding process deteriorate
Solution Approach 1:
The patent implements feedback control by equipping cutting and joining dies with force sensors and motion sensors that continuously monitor the welding process. The control device receives sensor signals and automatically adjusts process parameters such as working gap, approach speed, and heat input to maintain optimal welding conditions, thereby improving manufacturing precision through real-time process monitoring and adjustment.
Solution Approach 2:
The patent replaces manual or simple mechanical control systems with an automated control system that uses sensor feedback to dynamically adjust welding parameters. The control device processes sensor data and automatically modifies the working gap, heating elements positioning, and die approach speed, substituting complex manual operations with intelligent automated control to achieve higher precision.
2Productivity
If the working gap is not dynamically adjusted based on process monitoring, then the device complexity is low, but the productivity and process window are limited
Solution Approach 1:
The patent applies dynamics by making the working gap between dies and the working surface variably adjustable during the welding process. The control device modifies the working gap in real-time based on sensor feedback, allowing the system to adapt to different welding conditions and materials. This dynamic adjustment optimizes the process window and enables faster cycle times while maintaining welding quality.
Solution Approach 2:
The patent implements parameter changes by dynamically modifying multiple process parameters including working gap, approach speed of dies, and heat input based on real-time sensor monitoring. The control device adjusts these parameters during the welding process to optimize productivity and expand the process window, allowing for faster cycle times and better adaptation to different film web materials and thicknesses.
3Manufacturing precision
If uniform heat input is applied to all areas, then the heating system is simple, but the manufacturing precision of separation and joining deteriorates
Solution Approach 1:
The patent applies local quality by enabling independent control of heating elements in different areas of the working surface. The control device can apply different heat input levels to specific zones based on sensor feedback, allowing for optimized heating of separation and joining areas according to their specific requirements. This localized heat control improves the quality of separation and joining by matching thermal input to the actual process needs of each area.
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 solution enhances the process window for cycle times, material usage, and heat input, resulting in a more reliable and visually appealing separation and joining of film webs with improved efficiency and quality.
Implementation Method 1
a temperature-controlled working surface (4) designed for supporting film webs (2, 3) to be joined and separated, and comprising an electric heating device (11, 12, 13)
Implementation Method 2
the desired welding process is carried out through a combination of pressure forces exerted by the joining dies and in interaction with the work surface and heating of the film webs of the film tubes
Implementation Method 3
each cutting die and/or joining die is equipped with a force sensor and/or each with a motion sensor
Implementation Method 4
each cutting die and/or joining die is equipped with a force sensor and/or each with a motion sensor, in particular a displacement sensor
Data Source
Figure 1~2
AI summary
The invention relates to a cutting and welding device for selectively joining and separating weldable film webs (2, 3) with a temperature-controlled working surface (4) for supporting film webs (2, 3) to be joined and separated, which includes an electric heating device (11, 12, 13), and with a counterholder (15) for selectively introducing compressive forces onto the film webs (2, 3), which, together with the working surface (4), defines a variably adjustable working gap (32, 33, 34) and which comprises two joining punches (29, 30) arranged apart from each other and a cutting punch (31) arranged between the joining punches (29, 30), wherein the cutting punch (31) and/or at least one joining punch (29, 30) are movably mounted on the counterholder (15).According to the invention, a force sensor (45) and/or a motion sensor (44), in particular a displacement sensor, are each assigned to the separating punch (31) and/or the joining punch (29, 30) for determining a separation process determined by the separating punch (31) and/or a joining process determined by the joining punch (29, 30).