Adjustable Blankholder Plates for Variable-Thickness Panel Welding
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Solution Overview
Problem
Existing welding apparatuses struggle to effectively clamp and align panels with variable thickness edges for successful welding, as they are designed for constant thicknesses and require complex temporary support structures, which are not economically or technically satisfactory.
Innovation Solution
A blankholder with movable plates and a linear actuator system that adjusts to variable panel thicknesses, allowing for independent movement of gripping surfaces to align upper surfaces coplanarly, enabling efficient clamping and welding of panels with different thicknesses without additional support structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed reference blankholder is used for welding panels, then welding of panels with constant thickness is achieved, but welding of panels with variable thickness is not effective
Solution Approach 1:
The blankholder incorporates movable gripping surfaces that can dynamically adjust their position along the thickness direction. The lower gripping element has movable plates that can independently adjust their height, and the upper gripping element can move vertically, allowing the blankholder to adapt to variable panel thicknesses while maintaining effective clamping force throughout the welding process
Solution Approach 2:
The blankholder is divided into multiple independent gripping elements: an upper gripping element and multiple lower gripping elements with movable plates. Each lower gripping element can adjust independently, allowing differential adaptation to various thickness profiles across the panel surface, enabling effective clamping of panels with complex variable thickness configurations
2Reliability
If temporary support structures are added to clamp panels with variable thickness, then clamping effectiveness is improved, but device complexity increases
Solution Approach 1:
Instead of adding static support structures, the invention uses dynamic movable gripping surfaces that automatically adapt to the panel thickness profile. The movable plates in the lower gripping elements and the vertically movable upper gripping element provide the necessary adaptability through controlled movement, eliminating the need for complex temporary support structures
Solution Approach 2:
The blankholder system performs its own adaptation function through the automatic adjustment of movable gripping surfaces. The system self-regulates to match the panel thickness profile without requiring external support structures or complex intervention mechanisms, simplifying the overall device design
3Adaptability or versatility
If the upper gripping element is made movable to adapt to panel thickness, then adaptability is improved, but alignment of coplanar surfaces becomes complex
Solution Approach 1:
The upper gripping element is designed to move vertically along guide means to adapt to variable panel thicknesses. This controlled movement along a defined path allows the gripping element to follow the panel surface profile while maintaining proper alignment, avoiding the complexity of completely movable or reconfigurable equipment arrangements
Solution Approach 2:
The blankholder employs asymmetric gripping mechanisms where the upper gripping element has different movement capabilities compared to the lower gripping elements. The upper element moves vertically along guides while lower elements have adjustable movable plates, creating an asymmetric but coordinated system that achieves both adaptability and simplified alignment
4Manufacturing precision
If welding is performed from bottom up with coplanar bottom surfaces, then panel alignment is achieved, but equipment arrangement becomes complex
Solution Approach 1:
Instead of aligning panels from the bottom up as in conventional welding, the invention inverts the approach by using movable gripping surfaces that adapt to the panel thickness from both upper and lower sides. This allows alignment to be achieved through the gripping mechanism itself rather than through complex equipment arrangement, simplifying the overall setup
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 allows for easy adaptation to panels with variable thicknesses, automates the welding process, and maintains the upper gripping element fixed, ensuring effective clamping and alignment of panels with different thicknesses, enhancing the efficiency and simplicity of the welding process.
Implementation Method 1
a linear actuator, which moves the movable plates independently of each other in a direction substantially perpendicular to the lower operating surface
Data Source
AI summary
A blankholder for a welding apparatus has an upper gripping element and a lower gripping element having longitudinal development along a longitudinal direction. The upper gripping element is movable between a closed position in which a panel is clamped between the upper and lower gripping elements and an open position in which the panel is slidable between the upper and lower gripping elements. The lower gripping element has a lower operating surface facing the upper gripping element and a plurality of movable plates. The movable plates are movable in a direction substantially perpendicular to the lower operating surface between a first position in which the movable plates do not protrude or protrude by a minimum height relative to the lower operating surface and a second position in which the movable plates protrude with respect to the lower operating surface by a predetermined maximum height and have a gripping surface.