Adjustable Cooling Pipe Positioning for Resistance Welding Electrodes
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Solution Overview
Problem
The existing electrode devices for resistance welding face issues with reduced cooling efficiency due to non-adjustable cooling pipe positions, leading to electrode tip wear and increased welding failure rates, especially when shank lengths change during setting adjustments.
Innovation Solution
An electrode device with a movable and adjustable cooling pipe that can be positioned proximate to the electrode tip, allowing efficient water circulation and maintaining the electrode tip's form through a support member with a supply port and lock mechanism, ensuring consistent cooling performance across varying shank lengths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the shank length is increased to accommodate different welding settings, then the adaptability of the electrode device is improved, but the cooling performance deteriorates because the gap from the cooling pipe tip to the cap tip inner surface increases
Solution Approach 1:
The cooling pipe is designed to be movable in the axial direction rather than fixed, allowing its position to be dynamically adjusted. This enables the cooling pipe tip to maintain optimal proximity to the cap tip inner surface regardless of shank length variations, resolving the contradiction between adaptability and cooling performance
Solution Approach 2:
The electrode device is segmented into movable and fixable components, where the cooling pipe can be independently positioned and fixed at different locations. This segmentation allows the cooling system to adapt to varying shank lengths while maintaining effective cooling
2Device complexity
If the cooling pipe position is fixed during electrode replacement, then the device complexity is reduced, but the cooling efficiency deteriorates leading to faster electrode tip wear
Solution Approach 1:
The cooling pipe's movable and fixable design allows for simple adjustment during electrode replacement without requiring complex repositioning mechanisms. The pipe can be quickly moved and secured at the appropriate position, maintaining both simplicity and cooling efficiency
Solution Approach 2:
The cooling pipe structure enables operators to easily adjust and fix the pipe position during routine electrode replacement without requiring specialized tools or complex procedures, making the system self-adjusting to maintain optimal cooling
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 adjustable cooling pipe design ensures efficient water circulation to the electrode tip, reducing wear and maintaining welding quality by maintaining the electrode tip's form, thereby minimizing welding failures even with changes in shank lengths.
Implementation Method 1
Cooling water ejected from the tip opening of the cooling pipe cools the cap tip
Implementation Method 2
Cooling water ejected from the tip opening of the cooling pipe cools the cap tip
Implementation Method 3
flows through a gap between an outer peripheral surface of the cooling pipe and inner peripheral surfaces of the shank and the straight holder
Implementation Method 4
the Joule heat, which is the basis of the resistance welding, is proportional to the square of the current
Data Source
AI summary
An electrode device for water-cooling type resistance welding that constantly circulates cooling water efficiently to the proximity of an electrode tip, allowing the electrode to stably cool down. A cooling pipe 11 is inserted inside a device body 1 from a lower side thereof, and cooling water ejected from a tip opening 11a of the cooling pipe 11 cools a cap tip 10 placed on the tip of a shank 8. The cooling pipe 11 is movable in the axial direction of the device body 1 and fixable at any position. As a result, even with a change in the length of the shank 8, the tip opening 11a of the cooling pipe 11 can always be positioned in the proximity of the cap tip 10, allowing the cap tip 10 to cool down reliably and the form of the electrode tip to be maintained stably for a long time.