Rotatable Helical Weld Tool for Continuous Pocketed Spring Production
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Solution Overview
Problem
Existing methods for producing pocketed springs are limited by the need to pause production for ultrasonic welding, leading to inefficiencies in energy use and production speed.
Innovation Solution
A rotatable welding apparatus with a helical welding contact portion is used to weld webs of pocketing material continuously, allowing for uninterrupted web movement and precise control over weld spacing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If reciprocating pairs welding tools are used to weld webs, then welding can be performed, but production speed is limited due to the need to pause web movement
Solution Approach 1:
The welding tool is made rotatable about an axis, transforming it from a static reciprocating tool to a dynamic rotating tool. This allows the welding contact portion to continuously engage with the moving web, eliminating the need for pausing the web during welding operations and thereby increasing production speed.
Solution Approach 2:
The rotating welding tool enables continuous welding action along the length of the web as it moves through the apparatus. The helical welding contact portion ensures uninterrupted engagement with the web material, maintaining continuous useful action without interruptions or pauses that would otherwise limit productivity.
2Use of energy by moving object
If reciprocating pairs welding tools are used to weld webs, then welding can be performed, but energy efficiency deteriorates
Solution Approach 1:
The continuous rotation of the welding tool eliminates idle pause time where energy would be consumed without performing welding functions. The welding action is maintained continuously as the tool rotates and the web moves, ensuring that energy input is always productive and thereby improving energy efficiency.
Solution Approach 2:
The dynamic rotating mechanism allows the welding tool to maintain optimal engagement with the moving web, preventing energy waste associated with starting and stopping reciprocating motion. The continuous rotational movement ensures steady-state operation that is more energy-efficient than intermittent reciprocating motion.
3Productivity
If a rotatable weld tool with helical welding contact portion is used, then continuous welding is achieved, but device complexity increases
Solution Approach 1:
The welding tool employs a cylindrical surface with a helical welding contact portion, using curved geometric forms to achieve continuous welding. The helical shape naturally provides continuous engagement with the linearly moving web, and the cylindrical rotation simplifies the mechanical implementation compared to more complex reciprocating mechanisms with multiple actuators.
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
Enables faster and more efficient production of pocketed springs by eliminating the need for pauses during welding, enhancing production speed and energy efficiency.
Implementation Method 1
The welding of the leaves of pocketing material is usually performed using reciprocating pairs welding tools, such as ultrasonic welding tools
Data Source
AI summary
An apparatus for welding together webs, the apparatus comprising first and second weld tools, wherein at least the first weld tool is rotatable about an axis of rotation and has a substantially cylindrical surface on which is located a welding contact portion, and wherein the welding contact portion extends at least partly circumferentially around the cylindrical surface and at least partly axially along the cylindrical surface.