Fabric Welding Device with Segmented Counter-Rollers
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Solution Overview
Problem
Existing fabric welding devices cannot simultaneously apply multiple tapes in parallel due to speed irregularities and uneven dragging, especially when dealing with wide fabric sectors and curvilinear movements, leading to inhomogeneous application.
Innovation Solution
A welding device with a C-shaped frame, multiple idle application rollers, and a motor-driven counter-track system that allows simultaneous, parallel application of tapes by maintaining uniform speed and alignment across the fabric width, ensuring perfect parallel paths and uniform movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single counter-roller is used for traditional tape application, then the structure is simple, but it cannot ensure homogeneous dragging along over the whole width of the fabric sector
Solution Approach 1:
The single counter-roller is segmented into multiple counter-rollers (first, second, third counter-rollers) arranged in parallel. Each counter-roller independently contacts a specific application roller, ensuring homogeneous dragging force distribution across the entire fabric width during simultaneous multi-tape application.
Solution Approach 2:
Multiple counter-rollers are merged into a coordinated system where each counter-roller works in conjunction with its corresponding application roller. The counter-rollers are driven by a common motor through a transmission system, combining individual rolling actions into a unified dragging mechanism that ensures uniform movement across all tapes.
2Productivity
If multiple tapes are applied simultaneously on wide fabric sectors, then productivity increases, but speed irregularities and feeding inconsistencies occur
Solution Approach 1:
The tape feeding system is segmented into independent feeding paths, with each application roller and its corresponding counter-roller forming an independent unit. This allows each tape to be fed and applied separately while maintaining uniform speed control, preventing feeding inconsistencies even when multiple tapes are applied simultaneously.
Solution Approach 2:
The transmission system incorporates feedback mechanisms where the motor controlling the counter-rollers receives information about the movement status of all tapes. This enables real-time adjustment of driving force distribution to maintain uniform feeding speeds across all tapes during simultaneous application on wide fabric sectors.
3Adaptability or versatility
If tapes are applied on curvilinear paths with different radii of curvature, then versatile pattern application is enabled, but different lengths of tapes cause speed variations
Solution Approach 1:
The roller system is designed with dynamic characteristics that allow automatic adaptation to curvilinear paths. The application rollers and counter-rollers can adjust their positions and maintain contact during curvilinear movement, while the motor-controlled transmission system dynamically adjusts the driving force to compensate for speed variations caused by different radii of curvature.
Solution Approach 2:
The system changes operational parameters (rotational speeds of individual rollers, motor power distribution) in real-time based on the curvature requirements of each tape path. This allows the device to maintain speed consistency across all tapes even when following different curvilinear trajectories with varying radii of curvature.
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 precise, quick, and homogeneous application of multiple tapes on large fabric sectors, addressing speed variations and ensuring uniform coverage without creases or excessive stretching, improving operations like waterproofing and pattern application.
Implementation Method 1
the heating member addresses the hot air flow onto the tape and the fabric that are inserted between the application roller and counter roller, enabling hot welding of the tape on the fabric
Implementation Method 2
A roller or other counter-member, generally motor-driven, is tangential to the application roller for retaining the tape and the respective fabric
Data Source
Figure 1
Figure 2
AI summary
A welding device for fabrics comprising means (8) for feeding at least two ribbons or tapes to be welded to at least one respective fabric and a heating unit (3) adapted to operate on a region of the fabric to be welded. Said feeding means (8) comprises an application roller (13) for each tape or ribbon.