Oscillating Weld Jaw Spring Support for Bale Strapping
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Solution Overview
Problem
Existing bale strapping systems using steel wires are cumbersome, costly, and prone to wear, while automatic systems with thermoplastic straps face inefficiencies in welding and handling, particularly in down-packer-type presses.
Innovation Solution
A method and apparatus for welding thermoplastic straps using oscillating weld jaws and connecting rods with integrated flat springs to form frictional welds, allowing for efficient and reliable strapping of bales and other materials, adaptable to both up-packers and down-packers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If pre-formed steel wires are used for strapping, then the strapping material is strong and reusable, but the material is cumbersome and dangerous to handle due to its weight and sharp edges
Solution Approach 1:
The patent employs disposable thermoplastic strapping material instead of reusable steel wires. The thermoplastic straps are lightweight, safe to handle, and discarded after use, eliminating the hazards of steel wire handling while providing sufficient strength for the strapping application.
Solution Approach 2:
The patent changes the material parameters from steel (high strength, high weight, sharp edges) to thermoplastic material (adequate strength, low weight, soft edges). This parameter change resolves the contradiction by selecting a material that provides sufficient functional strength while dramatically improving handling characteristics.
2Strength
If flat steel straps are used for strapping, then the strapping material is strong, but the machinery complexity and cost increase significantly
Solution Approach 1:
The patent uses disposable thermoplastic straps that can be easily fed through simple welding mechanisms, eliminating the need for complex steel strap handling and crimping machinery. The material's flexibility and safety make it ideal for automated welding systems.
Solution Approach 2:
The patent replaces complex mechanical steel strap crimping and insertion systems with a simpler friction welding system. The thermoplastic material's properties allow for direct welding without complex mechanical manipulation, reducing machinery complexity.
3Productivity
If automatic bale strapping systems are implemented, then productivity increases, but wear on moving parts increases and cycle time decreases
Solution Approach 1:
The patent employs friction welding through oscillating motion of the weld jaws. This vibrational mechanism creates sufficient friction heat to weld thermoplastic straps without requiring high-speed operation that would cause wear, thereby maintaining reliability while achieving automatic strapping.
Solution Approach 2:
The welding process uses periodic oscillating motion of the weld jaws rather than continuous high-speed operation. This periodic action generates the necessary friction heat for welding while allowing for controlled, reliable operation that reduces wear on moving parts.
4Ease of manufacture
If down-packer-type presses are used, then purchase and installation cost decreases, but cycle time increases and productivity decreases
Solution Approach 1:
The patent changes the welding parameters and material properties to optimize performance for down-packer systems. By using thermoplastic material with specific friction welding characteristics, the system achieves efficient welding that compensates for the slower cycle time inherent in down-packer design, maximizing productivity within the system's operational constraints.
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 solution enhances the efficiency and reliability of bale strapping by reducing wear and improving cycle time, making the process safer and more cost-effective with the use of thermoplastic straps, suitable for various strapping applications beyond cotton bales.
Implementation Method 1
forming a frictional weld at a location of the strap where the two ends are located between the upper and lower weld jaws
Data Source
AI summary
Strap welding system and method for welding two ends or sections of a strap around a bundle of articles or around a pressed bale. The strap welding system has a weld assembly for frictionally welding two ends of a plastic strap around a pressed bale. The weld assembly has a weld head with an upper weld jaw and a lower weld jaw, and wherein the lower weld jaw is supported, directly or indirectly, by a spring. A connecting piece for moving the lower weld jaw can optionally have a section with a connecting spring.