Weld-Imaging Strapping Joint Control for Consistent Seal Strength
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Solution Overview
Problem
Current strapping devices often form suboptimal welded strap joints due to wear and usage, leading to weaker joints that can break, and these issues are not detected until they fail, requiring trial-and-error adjustments to restore optimal welding.
Innovation Solution
A strapping device equipped with a weld imager that images the strap joints and generates data for analysis by a controller to determine if a weld-adjustment condition is met, automatically adjusting weld parameters for subsequent sealing cycles to maintain optimal joint formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sealing modules are used to weld strap joints, then strap loops can be formed around loads, but over time wear and usage cause suboptimal welded joints with melted areas outside the designated range, leading to weaker joints that break
Solution Approach 1:
The patent implements an imaging system that captures images of welded strap joints and analyzes the melted area to determine if it falls within the designated range. This feedback mechanism allows the system to detect suboptimal welds caused by sealing module wear and automatically trigger adjustments to welding parameters, maintaining joint strength throughout the sealing module's service life.
Solution Approach 2:
The patent automatically adjusts welding parameters (such as heating element temperature, clamp force, or welding time) based on the analyzed image data. When suboptimal welds are detected, the system modifies these parameters to compensate for sealing module wear, ensuring that melted areas remain within the designated range and joint strength is maintained over time.
2Manufacturing precision
If trial-and-error adjustments are made to restore optimal welding, then weld quality can be improved, but this process is time-consuming and requires operator intervention
Solution Approach 1:
The imaging and analysis system provides immediate feedback on weld quality by measuring the melted area of each joint. This eliminates the need for operators to perform time-consuming trial-and-error adjustments, as the system automatically identifies when weld quality deviates from specifications and triggers appropriate parameter changes.
Solution Approach 2:
The system performs self-diagnosis and self-adjustment by automatically analyzing weld images and modifying welding parameters without operator intervention. This autonomous capability restores optimal welding conditions quickly, eliminating the time loss associated with manual trial-and-error adjustment processes.
3Reliability
If automated imaging and analysis systems are implemented, then suboptimal welds can be detected and corrected, but device complexity increases
Solution Approach 1:
The patent introduces an imaging system as an intermediary between the welding process and the control system. This intermediary captures visual data of the welded joints, which is then analyzed to determine melted area dimensions. This approach provides reliable weld quality detection without requiring complex direct measurement sensors, thereby limiting the increase in device complexity.
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 device automatically detects and corrects suboptimal welds, ensuring consistently strong strap joints and reducing the likelihood of breakage by adjusting weld parameters in real-time without operator intervention.
Implementation Method 1
the heating element is heated up and positioned between the overlapping portions of the strap, and a clamp forces the overlapping portions of the strap into contact with the heating element, which melts the strap
Implementation Method 2
a clamp forces the overlapping portions of the strap into contact with the heating element, which melts the strap
Implementation Method 3
a weld shoe clamps the overlapping portions of the strap against a weld plate while oscillating at a high frequency. This high-frequency oscillation locally melts the strap
Implementation Method 4
a weld shoe clamps the overlapping portions of the strap against a weld plate while oscillating at a high frequency
Data Source
AI summary
Various embodiments of the present disclosure provide a strapping device configured carry out a sealing cycle to form a strap joint by welding two overlapping portions of strap together based at least in part on a weld parameter. A weld imager of the strapping device is configured to image the strap joint and generate image data based on the imaged strap joint. A controller of the strapping device is configured to receive the image data; determine, based on the image data, whether a weld-adjustment condition is met; and responsive to determining that the weld-adjustment condition is met, automatically adjust the weld parameter for a later sealing cycle.