Intelligent Welding Platform for Flat Flexible Electronic Skins
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Solution Overview
Problem
Flexible electronic skins are prone to non-uniform stretching or torsional deformation during welding, leading to defects such as weak welding joints, discontinuous weld seams, and cracks, which compromise product reliability and service life.
Innovation Solution
An integrated intelligent welding platform with a stretching unit, welding unit, and control unit, incorporating flatness and welding monitoring components, and actuators to apply precise stretching and compression forces, ensuring uniformity and stability during the welding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If clamps are used to fix flexible electronic skins before welding, then the skins can be held in position, but the skins are prone to non-uniform stretching or torsional deformation due to their thin and pliable nature
Solution Approach 1:
The system performs preliminary stretching of the flexible electronic skin before welding to pre-establish uniform tension and flatness. The stretching unit applies controlled stretching forces in advance, and the flatness monitoring component verifies the stretching effect, ensuring the skin is properly prepared before the welding process begins.
Solution Approach 2:
The flatness monitoring component continuously monitors the flatness of the flexible electronic skin during stretching and provides real-time feedback to the stretching unit. This closed-loop feedback system allows dynamic adjustment of stretching forces to maintain optimal flatness and prevent deformation during the welding process.
2Ease of manufacture
If a welding device is used on flexible electronic skins, then welding can be performed, but the skins deform non-uniformly or torsionally during the welding process
Solution Approach 1:
The system performs preliminary stretching of the flexible electronic skin before welding to pre-establish uniform tension and flatness. The stretching unit applies controlled stretching forces in advance, and the flatness monitoring component verifies the stretching effect, ensuring the skin is properly prepared before the welding process begins.
Solution Approach 2:
The flatness monitoring component continuously monitors the flatness of the flexible electronic skin during stretching and provides real-time feedback to the stretching unit. This closed-loop feedback system allows dynamic adjustment of stretching forces to maintain optimal flatness and prevent deformation during the welding process.
3Productivity
If existing welding devices are used on flexible electronic skins, then welding can be completed, but defects such as weak welding joints, discontinuous weld seams, or cracks occur
Solution Approach 1:
The system performs preliminary stretching of the flexible electronic skin before welding to pre-establish uniform tension and flatness. The stretching unit applies controlled stretching forces in advance, and the flatness monitoring component verifies the stretching effect, ensuring the skin is properly prepared before the welding process begins.
Solution Approach 2:
The flatness monitoring component continuously monitors the flatness of the flexible electronic skin during stretching and provides real-time feedback to the stretching unit. This closed-loop feedback system allows dynamic adjustment of stretching forces to maintain optimal flatness and prevent deformation during the welding process.
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
Ensures high-quality welding by maintaining precise flatness and seam regulation, reducing defects, enhancing product reliability, and minimizing production costs and cycle time.
Implementation Method 1
the stretching component is configured to receive a stretching control signal and apply a stretching force perpendicular to the first direction to the flexible electronic skin
Implementation Method 2
the lifting component is configured to receive a welding control signal and apply a compression force parallel to the first direction to the flexible electronic skin
Data Source
AI summary
The invention provides an integrated intelligent welding platform and a welding method. The welding platform includes a stretching unit, a welding unit, and a control unit. The stretching unit includes a flatness monitoring component and a stretching component. The stretching component is configured to receive a stretching control signal and apply a stretching force to a flexible electronic skin. The welding unit includes a welding monitoring component and a lifting component. The welding monitoring component is configured to obtain welding information, and the lifting component is configured to receive a welding control signal and apply a compression force to the flexible electronic skin. The control unit includes a first and second control components. The first control component is configured to receive the flatness information and transmit the stretching control signal. The second control component is configured to receive the welding information and transmit the welding control signal.