Composite Sealing Element Length Deviation Compensation
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Solution Overview
Problem
The production of composite sealing elements for vehicle windows faces significant reject rates due to large fluctuations in the length of extruded element sections, leading to deviations in desired dimensions and subsequent rejection during the cutting process.
Innovation Solution
The method involves adjusting the insertion length of the extruded element section into a molding tool based on detected deviations, using a detector device and control unit to ensure the injection-molded element parts compensate for these deviations, thereby maintaining the composite sealing element within a predetermined tolerance range, reducing reject rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the length of extruded element sections is subject to fluctuations due to various influences, then the manufacturing process becomes more flexible and easier to operate, but the manufacturing precision of the composite sealing element deteriorates, leading to large deviations in desired dimensions and high reject rates
Solution Approach 1:
The invention measures the actual length of the extruded element section before injection molding and uses this information to adjust the positioning of the element section in the mold chamber. This preliminary measurement and adjustment action ensures that even if the extruded section has dimensional fluctuations, it can be positioned correctly to achieve the desired final dimensions of the composite sealing element, thereby maintaining manufacturing precision while accepting varied input dimensions
Solution Approach 2:
The invention changes the positioning parameter (insertion depth) of the extruded element section in the mold chamber based on its measured actual length. By adjusting the insertion depth according to the actual length L, the system compensates for dimensional fluctuations in the extruded sections, ensuring that the final composite sealing element meets the desired dimensional specifications despite variations in the extruded section lengths
2Ease of manufacture
If the dimensions of extruded element sections deviate from desired values, then the ease of manufacture increases by accepting varied inputs, but the productivity decreases due to high reject quotas and recycling requirements
Solution Approach 1:
The invention implements a feedback mechanism where the actual length of each extruded element section is measured, and this measurement feeds back to control the positioning system. The control unit adjusts the insertion depth based on the measured length, creating a closed-loop system that automatically compensates for dimensional variations. This feedback approach allows the system to process varied extruded sections without manual intervention or rejection, thereby maintaining high productivity
Solution Approach 2:
The system performs self-adjustment by automatically measuring the extruded section length and positioning it correctly in the mold chamber without requiring manual measurement or adjustment. The automated feedback control system handles the compensation for dimensional variations, allowing the production process to continue efficiently without stopping to recycle rejected parts, thus maintaining high productivity
3Manufacturing precision
If the insertion length of extruded element sections is adjusted based on measured deviations, then the manufacturing precision of the composite sealing element is improved, but the device complexity increases due to the need for detector devices and control systems
Solution Approach 1:
The invention replaces complex manual measurement and adjustment mechanical systems with automated detector devices and control systems. Instead of requiring manual measurement tools and operator intervention to adjust positioning, the system uses automated length measurement devices that optically or mechanically detect the extruded section length and automatically control the positioning mechanism, reducing the complexity of manual operations while maintaining high precision
Solution Approach 2:
The invention changes the control parameter from fixed insertion depth to variable insertion depth based on measured length. By making the insertion depth a variable parameter that adjusts according to the actual extruded section length, the system achieves high manufacturing precision without requiring overly complex mechanical adjustment mechanisms, as the adjustment is driven by simple length measurement and proportional positioning control
Data Source
AI summary
A method for producing a composite sealing element, in particular for forming a seal at a retractable pane of a vehicle window, wherein the composite sealing element is produced from at least one extruded element portion and at least one element part formed by injection molding in a mold cavity of a mold, with the element part being molded onto an end face, bounding the mold cavity, of the extruded portion. A change in the dimensions of the composite sealing element as a result of the length of the extruded element portion differing from the nominal value is counteracted by changing the arrangement of the end face of the extruded element portion with respect to the mold cavity.