Strapping Machine Welding Head Gripper Buffer Design
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Solution Overview
Problem
The existing welding heads for strapping machines using coil springs suffer from cyclical breakages due to high compression forces and limited space, leading to unnoticed failures and increased costs, as traditional materials only offer limited improvements in durability.
Innovation Solution
The design incorporates a welding unit with gripper units featuring a buffer made of elastically yieldable material, such as rubber or elastomers, and a return spring, which provides robust and adjustable compression, eliminating the need for coil springs and enhancing the machine's operational reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If coil springs are used to provide closing force for grippers, then the desired elastic force is achieved, but cyclical breakages occur due to high compression forces and limited space
Solution Approach 1:
The patent replaces the coil spring mechanical system with a cup spring system. The cup spring is a simplified mechanical element that provides the necessary elastic force while being more resistant to cyclical breakage. The cup spring is seated in a recess and works in conjunction with a cam mechanism to provide the closing force to the gripper, eliminating the complexity and failure points of traditional coil springs.
2Reliability
If the size of springs is increased to improve resistance, then durability is enhanced, but the limited space in the gripper unit makes this solution impracticable
Solution Approach 1:
The cup spring design provides a more space-efficient mechanical solution compared to traditional coil springs. The cup spring's compact geometry allows it to deliver the required elastic force within the limited space of the gripper unit, eliminating the need to increase spring size while maintaining or improving durability.
Solution Approach 2:
The patent changes the fundamental parameters of the spring system by transitioning from coil springs to cup springs. This parameter change includes altering the spring geometry, material properties, and mounting configuration, which together enable the system to achieve higher reliability within the same spatial constraints.
3Ease of manufacture
If traditional materials are used for coil springs, then cost is reduced, but useful life is prolonged only to a limited extent
Solution Approach 1:
The cup spring system replaces the traditional coil spring mechanism, offering a design that inherently resists cyclical breakage. This substitution maintains manufacturing simplicity while dramatically extending the useful life of the spring component, as the cup spring's geometry and material selection optimize it for repeated compression cycles without the failure modes of traditional springs.
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 solution effectively prevents spring breakage, maintains high elastic force, and reduces maintenance costs by using elastomeric buffers, which are more durable and space-efficient compared to traditional coil springs.
Implementation Method 1
a buffer (26) made of an elastically yieldable material (advantageously rubber or a suitable elastomer) is arranged between the end of the pivot opposite the cam and the bottom of the seat (25) that receives the pivot
Implementation Method 2
In order to improve the return speed of the gripper and to maintain the roller (23) against the cam, a return spring (30) is also advantageously provided
Data Source
Figure 1
Figure 2
AI summary
A welding unit for a strapping machine comprises at least a gripper unit with a gripper (15, 16, 17) that is movable towards a corresponding counter gripper (19) for clamping a strap part. Gripper movement means acts on a thrust pivot (22) that protrudes from the body of the gripper. This pivot (22) is received axially slidable in a seat (25) in the body of the pivot and between ends of the pivot inside the seat and the bottom of the seat a buffer (26) is arranged that is made of an elastically yieldable material. Buffer compression adjusting means can be provided.