Ultrasonic Suture Cogging Machine Tension Control
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Solution Overview
Problem
Existing methods for forming cogs on sutures using ultrasonic waves face challenges such as suture breakage due to cross-section reduction, difficulty in controlling temperature, and maintaining fine shapes of cog formations, leading to non-uniform quality and residual stress in the sutures.
Innovation Solution
A suture processing machine and method utilizing ultrasonic waves, which includes a supply roll, distal-end transferer, tension controller, mold with an intagliated pattern, ultrasonic wave generator, and blade portions to control tension, form cogs, and separate the suture, thereby preventing residual stress and improving suture quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If ultrasonic waves are used to heat and press the suture in a mold to form cogs, then cogs can be formed on the suture surface, but residual stress is generated between the central portion and surface portion of the suture causing non-uniform quality
Solution Approach 1:
The suture processing is divided into distinct stages: tension application stage, ultrasonic heating stage, and cooling stage. During ultrasonic heating, tension is specifically removed to prevent residual stress, while during cooling, tension is reapplied. This segmentation of processing stages allows independent optimization of each stage's parameters to avoid cumulative adverse effects.
Solution Approach 2:
Tension is applied in advance during the suture feeding stage to maintain suture stability and positioning. Then tension is removed before ultrasonic heating to prevent residual stress generation. This preliminary action of adjusting tension status before the main processing step ensures optimal conditions for each stage.
2Manufacturing precision
If the suture is heated to melt the surface portion to form cogs, then cogs are formed on the suture, but the suture may break due to reduction in cross-section
Solution Approach 1:
The ultrasonic wave parameters (frequency, power, duty cycle) are optimized to achieve localized surface melting without excessive heat penetration that would weaken the core. The heating temperature is controlled to be sufficient for surface melting and cog formation but below the point where significant cross-sectional weakening occurs. This precise parameter control resolves the contradiction between forming precision and strength retention.
3Productivity
If the mold is repeatedly heated and cooled to form cogs on multiple sutures, then productivity increases, but temperature control becomes difficult and suture quality becomes non-uniform
Solution Approach 1:
The mold undergoes periodic heating and cooling cycles corresponding to batch processing of multiple sutures. Each cycle is carefully controlled with defined heating duration, cooling duration, and temperature ranges. This periodic action allows high productivity through batch processing while maintaining temperature stability through controlled cycle parameters and rest periods between cycles.
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
The solution effectively prevents residual stress in sutures, improves their quality by maintaining uniformity, and addresses issues related to temperature control and suture breakage, ensuring consistent and durable cog formations.
Implementation Method 1
an ultrasonic wave generator (300) configured to come in contact with the suture (10) in the mold (200) and transmit ultrasonic waves thereto
Data Source
AI summary
The present disclosure provides a suture processing machine using ultrasonic waves, the suture processing machine including: a supply roll around which a suture to be processed is wound; a distal-end transferer configured to grip and transfer a distal end of the suture supplied from the supply roll; a tension controller configured to control tension of the suture between the distal-end transferer and the supply roll; a mold having an intagliated pattern to form cogs on the suture; both-end transferers installed at both sides of the mold to move the suture to the intagliated pattern of the mold or separate the suture from the intagliated pattern between the supply roll and the distal-end transferer; an ultrasonic wave generator configured to come in contact with the suture in the mold and transmit ultrasonic waves thereto; a first blade portion configured to remove a part of the suture that protrudes to an upper surface of the mold; a separation roller configured to support the suture from a lower side and assist in separation of the suture while the suture is being separated from the intagliated pattern by the both-end transferers; and a second blade portion configured to cut a tip of the suture transferred from the distal-end transferer.