Automated Welding of Plastic Handles to Metal Canisters
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Solution Overview
Problem
Current methods for attaching plastic handles to metal containers are either excessively expensive and labor-intensive or limited in their ability to handle complex shapes, such as tulip cans, with low production rates and quality issues.
Innovation Solution
A method involving the selection, perforation, and bending of a plastic strip to form a handle, which is then securely fixed to the container using welding, allowing for automated installation on various shapes, including tulip cans, with a machine that unwinds, punches, cuts, and bends the strip to ensure precise and efficient attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the first technique (welding lugs or rivets and manually mounting handles) is used, then the handle attachment is secure and reliable, but the production rate becomes very low and labor costs become excessively high
Solution Approach 1:
The patent replaces manual mechanical operations (manual handle mounting) with an automated welding system. The welding device automatically welds the plastic handle directly to the metal can body at predetermined positions, eliminating the need for manual lug/rivet installation and handle mounting operations. This substitution maintains attachment reliability through controlled welding parameters while dramatically increasing production speed to 50-75 cans per minute.
2Productivity
If the second technique (automatically unrolling and riveting plastic strip) is used, then the production rate increases to 50 cans per minute, but the handle positioning becomes random and uncontrolled on complex-shaped cans
Solution Approach 1:
The patent employs a programmable control system that automatically determines the precise positioning coordinates for handle attachment based on the can's geometric data stored in memory. The system self-adjusts the welding head position and orientation to accommodate various can shapes (cylindrical, conical, tulip-shaped) without manual intervention. This automated positioning ensures consistent, precise handle placement at predetermined locations while maintaining high production rates of 50-75 cans per minute.
3Extent of automation
If the second technique (automatically unrolling and riveting plastic strip) is used, then automation is achieved, but the technique is effective only for cylindrical cans and fails on complex shapes like tulip cans
Solution Approach 1:
The patent designs a universal welding apparatus with a programmable control system that can handle multiple can geometries (cylindrical, conical, tulip-shaped, and other complex forms). The system stores geometric data for different can types in memory and automatically adjusts welding parameters, head position, and orientation based on the detected can shape. This multi-functional capability allows the same automated device to precisely attach handles on various can shapes without requiring changeovers or manual reconfiguration.
Solution Approach 2:
The welding head is designed with dynamic positioning and orientation capabilities, allowing it to move freely in three-dimensional space and adjust its angle relative to the can surface. The programmable control system dynamically calculates the optimal welding trajectory and parameters based on real-time can geometry detection. This dynamic adaptability enables the automated system to successfully weld handles on complex-shaped cans like tulip cans, where fixed or rigid positioning systems would fail.
4Ease of operation
If handles are attached vertically above the opening on tulip cans, then the handle mounting appears simple, but the leverage effect of the tulip causes random positioning and poor attachment quality
Solution Approach 1:
The patent incorporates a feedback mechanism where the programmable control system continuously monitors the can's position, orientation, and geometry during the welding process. Sensors detect the actual can shape and dimensions, and the control system automatically adjusts the welding head position and parameters in real-time based on this feedback. This closed-loop control ensures that handles are precisely positioned and welded with consistent quality on tulip-shaped cans, eliminating the random positioning problems associated with simple vertical mounting approaches.
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 method enables high production rates, up to 75 equipped packages per minute, with improved precision and quality, and can handle complex shapes without the drawbacks of existing techniques.
Implementation Method 1
a fixing means is welded into the perforated orifice in each of said ends of the tape
Data Source
Figure 1
Figure 2A~3
Figure 4
AI summary
The method involves selecting a portion of a plastic strip (1) of length for forming a plastic handle (A) of a metallic canister (B), and perforating an orifice on the ends of the portion of the strip to receive fixation units e.g. rivet, where the units fix ends on walls of the package. The portion is bent in a horizontal plane using a bending device, and the portion is oriented with respect to walls of the package by displacing the device. A fixation unit is welded on the perforated orifice in two positions on the walls of the package for integrating with the walls so as to form the handle.