Outlet Element Welding with Movable Anvil Support
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Solution Overview
Problem
Existing welding devices for attaching outlet elements to packaging materials face challenges in achieving precise and compact designs, particularly in maintaining the anvil's position during the welding process, which affects the quality and efficiency of the welding operation.
Innovation Solution
The welding device incorporates a support unit with a movably mounted support element that exerts a holding force on the anvil, allowing it to be positioned and maintained during the welding process, and includes a punching unit for perforating the packaging material, enabling precise welding and efficient processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a welding device uses a simple holding element to hold the anvil, then the device complexity is reduced, but the manufacturing precision and reliability of the welding process deteriorate due to inconsistent anvil positioning
Solution Approach 1:
The support element is designed to be movably mounted on the holding element, allowing it to move along a movement axis perpendicular to the holding element's main axis. This dynamic positioning capability enables the support element to adapt to variations in packaging material thickness and welding conditions, maintaining consistent anvil positioning and welding pressure without requiring an overly complex fixed structure
Solution Approach 2:
The patent replaces simple mechanical holding with a more sophisticated support system that uses controlled movement along a defined axis. The support element's ability to move and exert controlled force substitutes for complex multi-component mechanical positioning systems, achieving precise anvil positioning through streamlined mechanical means
2Reliability
If the anvil is held firmly during welding, then the welding reliability improves, but the packaging material may be damaged due to excessive holding force
Solution Approach 1:
The movably mounted support element can dynamically adjust its position and applied force during the welding process. This allows the system to exert sufficient holding force on the anvil for reliable welding while automatically adapting to prevent excessive force that could damage the packaging material, achieving force control without complex sensing systems
Solution Approach 2:
The support element's ability to move along the movement axis enables dynamic adjustment of the holding force parameter. By changing the position of the support element relative to the anvil, the system can modulate the applied force to match the specific welding conditions and material properties, maintaining reliability while preventing damage
3Manufacturing precision
If the support element is aligned perpendicular to the holding element, then the anvil positioning precision is improved, but the device complexity increases due to the additional movement mechanism
Solution Approach 1:
The support element is movably mounted to move along a movement axis that is substantially perpendicular to the main axis of extension of the holding element. This perpendicular movement capability provides precise control over the support element's position relative to the anvil, achieving accurate positioning through a single degree of freedom rather than requiring complex multi-axis positioning mechanisms
Solution Approach 2:
The welding device is segmented into distinct functional components: the holding element for support, the movably mounted support element for positioning, and the anvil for welding. This segmentation allows each component to be optimized for its specific function, with the support element's perpendicular movement providing positioning precision without requiring the entire system to be complex
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
This configuration ensures precise welding of outlet elements to packaging materials while maintaining a compact device design, allowing for easy processing and minimizing complications post-welding.
Implementation Method 1
a movably mounted support element which is set up to exert a holding force on the anvil when the welding stamp is in a welding operating state
Implementation Method 2
at least one welding stamp, in particular a sonotrode, which is designed to cooperate with the anvil for welding the outlet element to the packaging material
Implementation Method 3
The support unit is designed, for example, as a hydraulic unit, a pneumatic unit, a servo drive unit or the like
Implementation Method 4
The support unit is designed, for example, as a hydraulic unit, a pneumatic unit, a servo drive unit or the like
Data Source
Figure 1
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AI summary
The invention relates to a welding device (10a; 10b) for welding an outlet element (12a; 12b), in particular a valve, to a packaging material (14a; 14b), with at least one anvil (16a; 16b) which comprises at least one receiving area (18a; 18b) for receiving the outlet element (12a; 12b) to be welded, with a holding element (20a; 20b), in particular a cantilevered one, on which the anvil (16a; 16b) is arranged, and with at least one welding punch (22a; 22b), in particular a sonotrode, which is configured to cooperate with the anvil (16a; 16b) for welding the outlet element (12a; 12b) to the packaging material (14a; 14b).It is proposed that the welding device (10a; 10b) comprises at least one support unit (24a; 24b) for supporting the anvil (16a; 16b), which includes at least one movably mounted support element (26a; 26b) which is configured to exert a holding force on the anvil (16a; 16b) in a welding operating state of the welding punch (22a; 22b).