Wound Hose Device With Force Decoupling Unit
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Solution Overview
Problem
Existing methods for producing wrapped tube products in motor vehicle exhaust systems are inefficient, as they often require complex sequential processes and can lead to disturbances during the winding and cutting stages due to unmanaged forces, and lack flexibility in handling non-round cross-sections.
Innovation Solution
A device comprising a winding machine, a converting machine, and a force decoupling unit, along with a packaging machine equipped with movable operating heads capable of laser welding and cutting, which allows for flexible processing and optimal settings for both separation and joining operations, including the use of a beam switch for efficient laser energy distribution and a force decoupling unit to absorb and manage forces during the winding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If complex sequential processes are used for producing wrapped tube products, then manufacturing precision can be maintained, but process efficiency deteriorates and production time increases
Solution Approach 1:
The patent combines multiple sequential operations (welding, cutting, separating) into a single integrated device with multiple operating heads that work simultaneously on the winding tube, thereby maintaining precision while improving process efficiency and reducing production time
Solution Approach 2:
The device enables continuous production by maintaining the winding tube in a constant state of motion while performing multiple operations without interruption, eliminating idle time between sequential processes and improving overall productivity
2Device complexity
If traditional winding and cutting methods are used, then process simplicity is maintained, but disturbances occur during winding and cutting stages due to unmanaged forces
Solution Approach 1:
The patent introduces a force decoupling unit that acts as a counterbalancing mechanism to compensate for forces generated during winding and cutting operations, thereby stabilizing the process and preventing disturbances without significantly increasing overall system complexity
Solution Approach 2:
The force decoupling unit serves as an intermediary element between the winding machine and the packaging machine, absorbing and managing forces to ensure stable operation during both winding and cutting stages
3Stability of the object's composition
If fixed processing methods are used, then manufacturing consistency is maintained, but flexibility deteriorates when handling non-round cross-sections
Solution Approach 1:
The patent employs movable operating heads that can dynamically adjust their position and orientation to accommodate different cross-sectional shapes, allowing the system to maintain manufacturing consistency while adapting to various product geometries including non-round sections
4Ease of operation
If multiple separate machines are used for welding and cutting, then operational simplicity is maintained, but device complexity and space requirements increase
Solution Approach 1:
The patent integrates welding and cutting operations into a single unified device with multiple operating heads, reducing the number of separate machines required while maintaining operational simplicity through centralized control
Solution Approach 2:
The integrated device performs multiple functions (welding, cutting, separating) simultaneously using a single system, thereby reducing overall device complexity and space requirements while maintaining ease of operation through unified management
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 enables continuous production of wrapped tube products with improved process efficiency, reduced disturbances, and the ability to handle non-round cross-sections by synchronizing the movement of the operating head with the winding tube and using a force decoupling unit to manage forces, resulting in higher production speed and product quality.
Implementation Method 1
The welding and cutting technology is primarily based on laser technology
Implementation Method 2
a radially continuously circumferential laser seam is produced
Implementation Method 3
a laser-based separating cut is made
Data Source
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AI summary
The invention relates to a device and a corresponding method for manufacturing coiled tube products, comprising a coiling machine (3100) for coiling a strip into a coiled tube (WS) and a finishing machine (3200) for cutting pieces of desired length from the coiled tube (WS) and for joining strip layers in the end regions of the coiled tube product by a joining operation, wherein the finishing machine includes a movable operating head and/or a force decoupling unit (3300).