Segmented Heating Bar Welder for Adjustable Weld Widths
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Solution Overview
Problem
Existing material welders are limited by fixed weld beam widths, requiring replacement or different machines for varying weld widths, which increases costs and operator time.
Innovation Solution
A material welder with adjustable heating elements and an actuator device that allows for selective heating and width control, enabling the same machine to produce welds of different widths by heating either the first or second heating elements, or both, and using an actuator to apply force, eliminating the need for multiple machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a material welder uses a weld beam with a predetermined width, then the welding process is simple and reliable, but the weld width cannot be adjusted for different situations
Solution Approach 1:
The weld beam is divided into multiple independent heating elements (first heating element and second heating element) that can be selectively activated. This segmentation allows the welder to produce different weld widths by controlling which heating elements are active, transforming a single fixed-width beam into a multi-functional heating system.
Solution Approach 2:
The system transitions from a static, fixed-width weld beam to a dynamic configuration where heating elements can be selectively activated. The controller enables dynamic adjustment of weld width by activating different combinations of heating elements based on the required weld width, making the system adaptable to various welding situations.
2Adaptability or versatility
If multiple weld beams with different widths are used to accommodate varying weld width requirements, then all weld width requirements can be met, but the cost and operator time increase due to replacing beams or using different machines
Solution Approach 1:
A single weld beam structure is designed to perform multiple functions by incorporating several independent heating elements. This universal design allows one beam to replace multiple specialized beams, enabling the same machine to produce welds of different widths without requiring physical beam replacements or different machines.
Solution Approach 2:
The heating elements are pre-configured in the weld beam structure, ready for selective activation. The controller can immediately switch between different heating element combinations to produce different weld widths, eliminating the time required for beam replacement that would be necessary in a system requiring multiple physical beams.
3Adaptability or versatility
If multiple weld beams with different widths are used, then all weld width requirements can be met, but the overall cost increases due to purchasing and maintaining multiple beams or machines
Solution Approach 1:
The weld beam is designed as a universal component with multiple heating elements that can accommodate various weld width requirements. This single multi-functional beam replaces the need for multiple specialized beams or machines, reducing the overall equipment investment and maintenance costs while providing the same level of weld width versatility.
Solution Approach 2:
Multiple heating functions are merged into a single weld beam structure. By combining several heating elements into one integrated beam with a common support structure and control system, the design achieves the functionality of multiple beams while reducing the total number of components, simplifying the machine configuration, and lowering costs.
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 efficient welding of various widths with a single machine, reducing costs and operator time by allowing adjustable weld widths without the need for multiple machines or beam replacements.
Implementation Method 1
heating the first heating element of the first top bar assembly and first heating element of the bottom bar assembly
Implementation Method 2
fluid or air is circulated through the holes and/or channels and through a cooling device to cool the heating elements
Data Source
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AI summary
A material welder for welding at least two portions of a weldable material together, including: a top bar assembly and a bottom bar assembly, a portion of the top bar assembly directly above a portion of the bottom bar assembly, the top bar assembly including a first and second heating element substantially in the same plane and the bottom bar assembly including a first and second heating element substantially in the same plane, at least one heating device adapted to selectively heat the first heating elements and/or second heating elements, an actuator device adapted to move the top bar assembly towards the bottom bar assembly and/or the bottom bar assembly towards the top bar assembly, such that the first heating element of the top bar assembly aligns with the first heating element of the bottom bar assembly and the second heating element of the top bar assembly aligns with the second heating element of the bottom bar assembly; a contact surface of the top bar assembly and a contact surface of the bottom bar assembly adapted to contact the material during a welding process.