Shelving Base Seam Welding for Higher Load Capacity
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Solution Overview
Problem
The existing manufacturing process for shelving components requires two separate welding stations, one for spot welding and another for laser beam welding, which is inefficient and limits the structural stability and loading capacity of the bases, particularly in professional settings like supermarkets where high loads and safety standards must be met.
Innovation Solution
A method using a single welding station that employs techniques like laser welding, plasma welding, or TIG welding, where the welding axis or band travels along the contact surfaces, allowing for deeper penetration and continuous seam welding parallel to the metal sheet's direction, enhancing the base's loading capacity and aesthetic appeal by minimizing visible welds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If spot welding is used to manufacture bases, then the base can support loads of 400-1300 kg, but the welding spots are clearly visible and the base requires a specific welding station
Solution Approach 1:
The patent combines the base manufacturing and post manufacturing operations into a single laser beam welding station. The metal sheet is bent to form the base with integrated post structures, and laser beam welding is used to weld both the base components and post components in one continuous process, eliminating the need for separate spot welding and post welding stations.
Solution Approach 2:
The patent replaces traditional spot welding mechanics with laser beam welding. Instead of using mechanical spot welding devices that create visible weld spots, the laser beam creates continuous weld seams with superior strength and aesthetic appearance, while maintaining the ability to support high loads.
2Productivity
If spot welding is used, then the base can be manufactured with visible welding spots, but the base requires multiple welding stations and has limited loading capacity
Solution Approach 1:
The patent implements continuous laser beam welding along the entire length of the base and post components in a single continuous operation. The laser beam moves continuously along the metal sheet, creating uninterrupted weld seams that provide superior structural integrity and loading capacity compared to discrete spot welding, while improving production efficiency by eliminating station changes.
3Strength
If laser beam welding is used with perpendicular direction, then the two metal sheets can be welded, but the welding direction is limited and visible weld seams are created
Solution Approach 1:
The patent changes the welding approach from perpendicular welding to parallel welding along the length of the metal sheet. The laser beam travels parallel to the main extension of the metal sheet, creating narrow, aesthetically pleasing weld seams that are less visible. This dimensional change in welding direction allows for both strong joints and improved appearance.
4Ease of manufacture
If two welding stations are used (one for bases, one for posts), then both components can be manufactured, but the production line is more complex and costly
Solution Approach 1:
The patent designs a universal laser beam welding station that can manufacture both base components and post components using the same equipment. The metal sheet is bent to form integrated base and post structures, and the laser welding station performs all welding operations for both component types in one continuous process, making the welding station multi-functional and eliminating the need for separate dedicated stations.
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
This approach reduces production costs by consolidating the welding stations, increases the base's loading capacity from 400-1300 kg to around 2000 kg without cracking, and improves safety and reliability while providing an aesthetically pleasing, invisible welding appearance.
Implementation Method 1
The laser beam heats up and melts the material, and therefore allows the two counterposed metal sheets or strips to weld
Implementation Method 2
The laser beam heats up and melts the material
Implementation Method 3
Laser beam welding can be used too, but this technique normally requires that the two metal sheet be in contact with each other
Data Source
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AI summary
1. Method for manufacturing components for points of sale shelving (1) or pieces of furniture, said components being obtained from at least a metal sheet suitably bent and welded along facing strips of metal sheet or sheets generated by the bending process so as to obtain a three-dimensional structure characterized in that - the said two strips show facing surfaces (120) to be joined one to the other which surfaces extend along at least one direction, preferably along the two directions defining the said surfaces and the extension of said surfaces along at least one of the said directions is greater than the thickness of the metal sheet; - the welding action is performed exercising a melting action of the material of the surfaces of the strips to be joined together along a welding axis or direction which is parallel to the facing surfaces (120) of the two strips to be welded and parallel to at least one of the directions defining the surfaces to be joined and along the extension of the said surfaces (120) in the said direction - Welding being carried out providing shifting speed along a direction transverse to the said welding axis and along the second of the said two directions defining the surfaces to be joined (120) of the two facing strips, so that the melting of the material of the two strips reaches for at least part of the said surfaces along the direction parallel to the said welding axis and for a length greater than the thickness of the metal sheet.