Diagonal Plastic Welding Tool for Complex Undercuts
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional plastic welding devices struggle with welding components having complex projections or undercuts due to limited angular positioning and mobility, leading to potential damage or destruction of components and tools during friction welding.
Innovation Solution
A plastic welding device with tools that can move diagonally or obliquely relative to their carriers, allowing for engagement of components with complex geometries without undercuts, using a single drive for diagonal mobility and incorporating a preheating arrangement for efficient heating and welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If tools are moved only along the vertical axis, then the control system is simple, but components with complex projections or undercuts cannot be welded without damage
Solution Approach 1:
The patent introduces diagonal movement capability to the tool, transitioning from purely vertical axis movement to movement in multiple dimensions. This allows the tool to approach components with complex projections or undercuts from optimized angles, enabling welding of geometries that would be inaccessible with vertical-only movement while avoiding damage to components and tools
2Productivity
If multiple tools are moved simultaneously in the same direction, then the lifting table control is simplified, but mirror-symmetric components cannot be welded simultaneously
Solution Approach 1:
The patent enables independent movement control of multiple tools, allowing them to follow different trajectories and angles. This asymmetry in control allows mirror-symmetric components to be welded simultaneously from their respective optimal angles, doubling productivity for symmetric assemblies while maintaining simplified lifting table control through independent tool actuation
3Reliability
If a preheating arrangement is added, then welding quality improves, but the device complexity and cost increase
Solution Approach 1:
The patent incorporates a preheating arrangement that heats components before welding occurs. This preliminary thermal preparation improves welding quality and reliability by ensuring components are at optimal temperature for bonding, while the integrated design keeps the added complexity manageable within the overall system
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 easy and quick welding of components with complex undercuts, reducing the risk of damage and simplifying control, while allowing for precise positioning and cost-effective operation, including the ability to weld mirror-symmetric components simultaneously.
Implementation Method 1
the preheating arrangement can be moved from a rest position into an alignment position between the components... the lifting table is moved vertically again to position the unit in a preheating position so that the two components can be heated at the points to be welded
Implementation Method 2
The first component is then welded to the second component by friction welding or by pressing the preheated components together
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The plastic welding device according to the invention comprises a first tool and a second tool. The first tool is arranged on a first support, and the second tool is arranged on a second support. The first tool is furthermore movable relative to the first support in a first direction in a straight line between a first position and a second position by means of a first drive. The movement along the first direction is defined by a first imaginary spherical coordinate system, the origin of which is located at the first position of the first tool. The z-axis, as a first z-axis, extends in the direction of the second support. For a first angle of inclination between the first z-axis (positive in the direction of the second support) and the first direction, 0 ≤ υ1 ≤ π/2 applies, whereby a first component in the first tool can be brought into engagement with a second component in the second tool.