Rotary Indexing Blade Welding for Scalable Razor Production
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Solution Overview
Problem
Existing apparatuses and methods for welding blades in wet-shave razors face limitations in scalability and availability, leading to restricted production capacity and frequent shutdowns during maintenance or servicing.
Innovation Solution
An apparatus with a rotary indexing table and multiple processing stations, including a blade-supply device and welding station, allows for improved scalability and availability by enabling efficient feeding, welding, and processing of blades on a carrier frame, utilizing a torque rotary table and synchronized positioning wings for precise blade placement and handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a rotary indexing table with multiple processing stations is used, then productivity is improved through continuous operation, but device complexity increases
Solution Approach 1:
The welding installation is segmented into multiple independent processing stations (blade supply station, welding station, removal station) arranged around a rotary indexing table. Each station performs a specific function, allowing continuous operation while maintaining manageable complexity through functional decomposition.
Solution Approach 2:
The rotary indexing table serves multiple functions: it positions carrier frames for welding, transfers blades between stations, and coordinates the timing of different operations. This multi-functional component enables continuous production without requiring separate dedicated systems for each operation.
2Reliability
If traditional welding apparatus is used, then device complexity is low, but availability deteriorates due to complete shutdown during maintenance
Solution Approach 1:
The welding installation is divided into modular processing stations that can be independently accessed and maintained. The holder device can be removed and serviced without affecting other stations, allowing partial maintenance operation and improving overall availability.
Solution Approach 2:
The rotary indexing table operates in periodic cycles, allowing maintenance to be performed on one station while other stations continue operating. This periodic access to different stations enables maintenance without complete shutdown.
3Productivity
If blade supply and welding are performed sequentially, then device complexity is low, but productivity deteriorates due to restricted scalability
Solution Approach 1:
The processing stations are arranged in a circular dimension around the rotary indexing table rather than in a linear sequence. This spatial reconfiguration allows multiple operations to occur simultaneously at different angular positions, enabling parallel processing and improved scalability.
Solution Approach 2:
The rotary indexing table enables continuous circulation of carrier frames through all processing stations. While one station is welding, another is receiving blades, and a third is preparing the next carrier frame, ensuring continuous useful action without idle time between operations.
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 production capacity and reduces downtime by enabling continuous operation and precise blade placement, improving the efficiency and scalability of cutting unit production while maintaining high availability of the welding installation.
Implementation Method 1
the welding apparatus is a constituent part of a welding station, of the rotary indexing table wherein the apparatus has suitable means for feeding a carrier frame into the operating region of the welding station
Data Source
AI summary
The invention relates to a device and a method for welding blades, in particular in order to produce a cutting unit for a wet razor. According to the invention, a rotary indexing table is used so that an adaptable and easily scalable device or an adaptable and easily scalable method for welding blades is provided for this purpose.