Inflatable Product Preassembly for Automated Tensioning Structure Welding
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Solution Overview
Problem
Current inflatable product manufacturing is manual, time-consuming, expensive, and prone to human error, particularly when producing inflatable mattresses that require individual welding of tensioning structures to upper and lower sheets.
Innovation Solution
An automated system and method that includes an upstream tensioning structure production subsystem and a downstream preassembly production subsystem to simultaneously produce and couple tensioning structures to sheets, using welders to efficiently weld the structures to the sheets in an automated, efficient, and repeatable manner.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual production methods are used for inflatable products, then flexibility and adaptability are maintained, but production time increases and productivity decreases
Solution Approach 1:
The patent replaces manual mechanical welding operations with automated welding systems. The controller automatically controls the welding process, positioning, and operation, substituting human labor with automated machinery that can perform welding operations consistently and efficiently without manual intervention for each tensioning structure attachment.
2Manufacturing precision
If manual welding of tensioning structures is performed, then adaptability to different configurations is maintained, but production time increases and consistency decreases
Solution Approach 1:
The controller automates the welding process, ensuring consistent welding parameters and positioning for each tensioning structure. This eliminates variability in manual welding techniques while maintaining the ability to produce different configurations through programmed control, thereby improving welding consistency without sacrificing adaptability.
Solution Approach 2:
The system performs preliminary positioning and preparation of tensioning structures before the actual welding process. The automated system pre-positions multiple tensioning structures and prepares the welding parameters in advance, which streamlines the production process and reduces overall production time while ensuring consistent results.
3Productivity
If individual welding of each tensioning structure is performed manually, then quality control is possible, but production costs increase and productivity decreases
Solution Approach 1:
The automated system is designed with multi-functionality to handle various welding operations, positioning tasks, and control functions within a single integrated platform. The controller can manage different welding parameters, accommodate various tensioning structure configurations, and perform quality monitoring, thereby reducing the need for multiple separate devices and processes while improving productivity.
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
The automated system enables the production of inflatable products in a more efficient and error-free manner, reducing production time and costs while ensuring consistent quality.
Implementation Method 1
The pair of sheet members are spread on a pair of working bases. A lower electrode of a high frequency welding apparatus is disposed between the bases, and an upper electrode is disposed opposite to the lower electrode. The crosslinking member is doubled with a weldable sheet to be welded as a core. The welding position is agreed with the upper electrode. The upper electrode is pressed down and generates heat, and the pair of sheet members and crosslinking member are welded.
Implementation Method 2
When processing using a hot-fusing machine or high-frequency machine, the upper and lower pull strap sheets are simultaneously jointed with the upper and lower fixing sheets.
Data Source
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AI summary
An automated system and method are disclosed for producing an inflatable product(100) having a first sheet, a second sheet, and a plurality of tensioning structures(1031) between the first and second sheets. The system includes an upstream tensioning structure production subsystem that produces the tensioning structures and a downstream preassembly production subsystem that couples the tensioning structures to the first and second sheets. The subsystems may operate simultaneously to produce the inflatable product in an automated, efficient, and repeatable manner.