Plastic Welding Device with Automatic Transfer Feeding
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Solution Overview
Problem
Conventional plastic welding devices are time-consuming and inefficient when welding multiple components, as they require manual loading and restarting the process for each additional component, which increases cycle time and costs.
Innovation Solution
A plastic welding device with a transfer device that automatically feeds components to the tools, allowing for the simultaneous welding of at least three components with reduced cycle time, using friction welding or infrared welding, and optionally preheating to enhance weld quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual loading and process restart is used for each additional component, then the welding process can be completed, but the cycle time increases and efficiency decreases
Solution Approach 1:
The transfer device pre-positions the third component in the lower tool before the welding process begins. After the first two components are welded, the transfer device automatically feeds the third component into position without requiring manual intervention or process restart, thereby reducing cycle time and improving productivity
Solution Approach 2:
The system uses an automatic transfer device that feeds components without human intervention. The device monitors the welding process and automatically introduces the third component when appropriate, allowing the system to serve itself rather than requiring manual loading for each component
2Ease of operation
If the housing opening is opened for loading components, then components can be loaded, but the process becomes time-consuming and safety risks increase
Solution Approach 1:
The transfer device automatically feeds the third component into the lower tool without requiring the housing opening to be opened. The device operates within the closed housing, maintaining safety while eliminating the time-consuming manual loading process
3Strength
If friction welding is used to weld multiple components, then strong welds are achieved, but the process must be restarted for each additional component
Solution Approach 1:
The transfer device pre-positions the third component in the lower tool before welding begins. After the first two components are welded together with strong friction welds, the transfer device automatically feeds the third component into position, allowing the welding process to continue without restart and maintaining both weld strength and productivity
Solution Approach 2:
The system maintains continuous welding action by using the transfer device to automatically introduce the third component during the welding process. This eliminates interruptions and process restarts, allowing friction welding to proceed continuously while achieving strong welds between all components
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 automatic feeding and welding process significantly reduces cycle time, increases efficiency, and allows for the welding of components of different shapes, resulting in cost savings and improved weld quality, particularly in the automotive and medical industries.
Implementation Method 1
at least one preheating device (134) arranged on opposite sides of the carrier (132), wherein the preheating device (134) is aligned with the tool (12, 22, 24) in a preheating position, so that the surface of a component (102, 104, 106) in the tool (12, 22, 24) in the welding area is heated at least partially
Implementation Method 2
The first component is now welded to the second component by means of friction welding
Data Source
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AI summary
A plastic welding device (1; 100) for automatically welding at least three components comprises at least one first tool (12; 112), at least one second tool (22; 122), and at least one transfer device (14; 114). A first component can be positioned on the first tool (12; 112). The first (12; 112) and the second tool (22; 122) are movable relative to each other to weld the first component to a second component (102). The transfer device (14; 114) is movable relative to at least one of the tools (12, 22; 112, 122) and can automatically feed at least one third component (106) to one of the tools. In this way, at least one third component (106) can be welded to the composite (104) of first and second component via the first (12; 112) and the second tool (22; 122) or via the first (12; 112) or the second tool (22; 122) in combination with a third tool (24; 124).