Rotary Plastic Assembly Welding With Controlled Internal Compression
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Solution Overview
Problem
Existing methods for automatic welding of plastic parts are time-consuming, require complex devices with multiple pressure jigs and laser sources, and lack adaptability for different sizes and dimensions of parts.
Innovation Solution
A method and device for automatic welding of plastic parts that involves vertical lifting and rotation of the assembly, using a single welding unit and continuous pressure control, to minimize steps and maximize speed and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple pressure jigs and laser sources are used for welding, then welding precision can be improved, but device complexity and time consumption increase
Solution Approach 1:
A single pressure jig is designed to perform multiple functions: it applies pressure to the workpiece, positions it accurately, and works in conjunction with a single laser source to create precise welds. This multi-functional design eliminates the need for multiple specialized components while maintaining welding precision.
Solution Approach 2:
The patent combines multiple welding operations into a single continuous process using one pressure jig and one laser source. The laser source moves with the workpiece during rotation, merging what would otherwise require multiple stationary laser sources into a single integrated system that achieves the same welding precision with reduced complexity.
2Manufacturing precision
If multiple pressure jigs and laser sources are used for welding, then welding precision can be improved, but time consumption increases
Solution Approach 1:
The welding process is made continuous through the rotation of the workpiece on the rotating table while the single laser source follows the workpiece. This continuous action eliminates the time required to reposition multiple laser sources and pressure jigs, maintaining welding precision while significantly reducing total processing time.
Solution Approach 2:
The system transitions from static multiple laser sources to a dynamic single laser source that moves with the rotating workpiece. This dynamic configuration allows continuous welding without the time losses associated with repositioning multiple stationary components, while maintaining precision through controlled rotation and laser tracking.
3Device complexity
If spring pressure is used for clamping, then device simplicity is maintained, but clamping precision and reliability deteriorate due to wear
Solution Approach 1:
The patent replaces the spring-based mechanical clamping system with a hydraulic or pneumatic pressure application system. This substitution eliminates the wear problems inherent in spring mechanisms while maintaining relatively simple device architecture. The fluid pressure system provides consistent, wear-free clamping force that improves reliability without significantly increasing complexity.
4Adaptability or versatility
If a robotic arm with four clamp modules is used, then adaptability to different workpieces is improved, but device complexity and space requirements increase
Solution Approach 1:
A single pressure jig is designed to accommodate different workpiece sizes and types through adjustable positioning features and flexible pressure application. This universal design eliminates the need for multiple specialized clamp modules while maintaining adaptability. The single jig can be reconfigured for different workpieces, providing versatility without the complexity of four separate clamp modules.
Solution Approach 2:
The pressure jig incorporates dynamic adjustment capabilities that allow it to adapt to different workpiece dimensions and configurations. This dynamic adaptability replaces the need for multiple fixed clamp modules, reducing device complexity while maintaining versatility across different workpiece types.
5Device complexity
If wireless data transmission is used for load gauge signals, then device simplicity is improved, but signal reliability deteriorates due to industrial interference
Solution Approach 1:
The patent replaces wireless data transmission with a wired connection for the load gauge signals. This substitution eliminates susceptibility to industrial electromagnetic interference while maintaining relatively simple device architecture. The wired connection provides reliable, interference-free signal transmission without the complexity of shielding or interference mitigation required for wireless systems in industrial environments.
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 achieves high-speed, high-accuracy welding with minimal space requirements, reducing defects and operational complexity, and allowing for precise control of pressure and weld formation.
Implementation Method 1
Joining plastic parts using energy beam, e.g., ultrasound, laser, etc.
Implementation Method 2
where a welding unit (4), in particular a laser welding unit (4), is provided
Implementation Method 3
Joining plastic parts using energy beam, e.g., ultrasound, laser, etc.
Data Source
Figure 1~2
Figure 3~4
Figure 5~5a
AI summary
A method for automatic welding an assembly (1) of plastic parts (11), which comprises a hollow container or cylindrical housing (11a) and a plate cover (11c) or plate separating baffle (11b) and further an internal element (12) arranged between the two, wherein the assembly (1) is automatically moved from the pick-up point (10) to the welding position (20) by vertical lifting, and the cover (11c) or the separating baffle (11b) is pressed by a force (Fp) through the internal element (12) into the hollow container or cylindrical housing (11a), whereupon the compressed assembly (1) is rotated about its vertical axis (14) and welding (13) started, thereby welding the circumference of the assembly (1) with defined compression of the internal element (12). The internal element may be a valve flap or filter filling, such as activated carbon. An automatic welding device (2, 3, 4) for carrying out this method is also disclosed.