Metal Web Splicing by Synchronized Electric Welding
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Solution Overview
Problem
In the tobacco processing industry, existing devices for connecting metal-containing webs of material interrupt the production process when replacing bobbins, as they require stopping the movement of material webs during splicing, which is undesirable, especially when intermediate storage is not used.
Innovation Solution
A device with two segments that can be moved into a working position to connect metal-containing webs using electric welding, allowing for a seamless connection without interrupting the production process, utilizing an electric welding device with synchronized movement and a control system to ensure precise alignment and welding of the webs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If material webs are stopped during splicing, then connection reliability is improved, but productivity deteriorates
Solution Approach 1:
The device employs movable segments that can dynamically adjust their position and speed to match the material web flow. The segments are designed to move synchronously with the material webs during the welding process, allowing continuous production without stopping. This dynamic adaptation enables the system to maintain both connection reliability through proper alignment and productivity through continuous operation.
2Productivity
If electric welding is used to connect metal webs quickly, then productivity is improved, but harmful factors worsen due to heat generation
Solution Approach 1:
The device introduces cooling intermediaries in the form of cooling channels and cooling elements integrated into the segment structure. These intermediaries actively remove heat generated during the electric welding process, preventing excessive temperature buildup that could damage the material webs or surrounding components. This allows the system to maintain high productivity through quick welding while mitigating the harmful thermal effects.
3Manufacturing precision
If segments are moved synchronously with material webs, then connection precision is improved, but device complexity increases
Solution Approach 1:
The device incorporates feedback mechanisms through sensors and control systems that monitor the position and speed of both the segments and material webs. This feedback enables real-time adjustments to maintain synchronous movement and precise alignment during the welding process. The control system processes this information and automatically adjusts segment positioning to ensure manufacturing precision while managing the inherent complexity through automated control.
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 a secure and efficient connection of metal webs in a short time without generating excessive heat, ensuring continuous production by synchronizing the movement of the segments with the material webs, thus maintaining production flow.
Implementation Method 1
an electric welding device with a first electrode arrangement of one polarity and a second electrode arrangement of the other polarity
Implementation Method 2
the electric welding device is designed to bring about a welding process for connecting the material webs
Data Source
Figure 1a~1b
Figure 1c
Figure 2a
AI summary
A device for the tobacco processing industry is described for joining an outgoing old, metal-containing material web (12a) with an incoming new, metal-containing material web, comprising an arrangement (24) of two segments (32, 34) which are separated from each other by forming a space for receiving an arrangement of superimposed material webs (12a, 12b) to be joined, and each have an end face (32a, 34a), wherein at least one of the segments (32, 34) is movably mounted and can be moved into a working position in which its end face (32a) is opposite the end face (34a) of the other segment (34) at a minimal distance, including the arrangement of the material webs (12a, 12b) to be joined, a drive device (38, 39) for moving the at least one segment (32, 34), and an electric welding device.wherein the end face (32a) of one segment (32) is provided with the first electrode arrangement (40) and the end face (34a) of the other segment (34) with the second electrode arrangement (41), and the electric welding device is configured to perform a welding process for joining the material webs (12a, 12b) in the working position of the segments (32, 34), and a control device configured for controlling the drive device (38, 39) such that the at least one movably mounted segment (32, 34) is moved into the working position and subsequently the at least one movably mounted segment is removed from the working position.