Tube Body Welding Alignment Control
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Solution Overview
Problem
Existing methods for manufacturing circumferentially closed tubular tube bodies face challenges in maintaining the precise alignment of the contact region during the welding process, leading to defective tube bodies due to fluctuations in web tension, slippage, and position deviations, which require costly and time-consuming manual interventions.
Innovation Solution
A device with first and second sensor means and control means is employed to detect the substrate web position and adjust the positioning means to maintain the contact region's alignment with the welding position, using ultrasonic sensors and optical image capture to ensure precise alignment and automatic correction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual adjustment of web edge position is used to maintain contact region alignment, then welding quality is improved, but production cost increases and productivity decreases
Solution Approach 1:
The patent replaces manual mechanical adjustment with an automated control system that uses sensors to detect web position and automatically adjusts the positioning mechanism, eliminating the need for operators to manually intervene and maintain alignment during the welding process
Solution Approach 2:
The patent implements a closed-loop feedback system where sensors continuously monitor the web edge position and provide real-time data to the control system, which then automatically adjusts the positioning mechanism to maintain proper alignment between the contact region and welding position
2Manufacturing precision
If manual adjustment of web edge position is used to maintain contact region alignment, then welding quality is improved, but time consumption increases
Solution Approach 1:
The patent ensures continuous monitoring and adjustment of web position throughout the entire welding process, eliminating intermittent manual interventions and maintaining constant alignment without stopping production or losing time
3Device complexity
If only edge position monitoring is used without considering web alignment angle, then edge position control is simplified, but contact region alignment at welding position deteriorates
Solution Approach 1:
The patent extends the monitoring from a single edge position measurement to include angular alignment detection, adding a dimensional aspect to the control system that accounts for the web's orientation and angle relative to the welding position, thereby achieving comprehensive alignment control
4Stability of the object's composition
If positioning means are used to correct edge position deviations, then edge position stability is improved, but contact region alignment at welding position deteriorates due to unaccounted influences
Solution Approach 1:
The patent implements a comprehensive feedback system that monitors not only edge position but also the actual contact region position at the welding location, using this feedback to automatically adjust positioning and compensate for all influencing factors including web tension fluctuations, slippage, and alignment angle variations
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 enables the production of high-quality tube bodies with improved resilience by maintaining the contact region's alignment automatically, reducing waste and eliminating the need for manual interventions, thereby enhancing the efficiency and quality of the weld seam.
Implementation Method 1
ultrasonic sensors are used for example, which detect at least one longitudinal edge of the substrate web
Data Source
AI summary
A device for manufacturing circumferentially closed tubular tube bodies, comprising conveying means for conveying the substrate in a conveying direction, and also comprising tube-forming means which are designed to form a web-like substrate, which has a first and a second longitudinal edge, into a tubular form in which, in the circumferential direction, the first and the second longitudinal edge form or delimit a contact region, in particular abutting or overlapping region, which extends in the conveying direction, wherein the tube-forming means effect the shaping of the substrate into the tubular form in a shaping region and comprise welding means for welding the tubular form at a weld circumferential position, first sensor means, which are upstream of the shaping region; in the conveying direction, for detecting the position of the substrate web, setting means for setting the position of the substrate web transversely with respect to the conveying direction, and first control means which are designed to actuate the setting means, taking into consideration the measurement values from the first sensor means, such that the web-like substrate is held in a setpoint position transversely with respect to the conveying direction or such that the web-like substrate is adjusted in the direction of the setpoint position.