Adjustable Welding Tip Layout for Multi-Spec Battery Welding
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Solution Overview
Problem
Existing welding tooling systems are not compatible with batteries of different specifications, leading to high use costs due to the fixed installation positions of welding tips and dust extraction pipes, limiting their adaptability in battery production and other batch welding scenarios.
Innovation Solution
A welding tooling system with a carrier, driving assemblies, guide rails, and sliders that allow for adjustable spacing of welding tip assemblies along multiple directions, enabling flexible arrangement and compatibility with various product specifications, and incorporating dust extraction pipes for improved efficiency and quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If welding tip assemblies are fixedly installed on the carrier, then the structure is simple and stable, but the adaptability to different product specifications deteriorates
Solution Approach 1:
The welding tip assemblies are designed to be movable rather than fixed, allowing dynamic adjustment of their positions along the carrier. The driving assemblies enable the welding tips to move to different locations, providing adaptability to various product specifications while maintaining a relatively simple overall structure.
Solution Approach 2:
The welding tooling is designed with universal adaptability through the movable welding tip assemblies that can be repositioned along the carrier. This allows the same device to accommodate different battery pack sizes and welding patterns, making it multi-functional and suitable for various product specifications.
2Adaptability or versatility
If welding tip assemblies are fixedly installed, then the manufacturing cost is low, but the use cost increases due to inability to accommodate different specifications
Solution Approach 1:
The welding tip assemblies incorporate movable mechanisms with driving assemblies that allow dynamic repositioning. This design enables the tooling to adapt to different battery specifications without requiring multiple dedicated fixtures, thereby reducing long-term use costs while maintaining reasonable manufacturing simplicity.
Solution Approach 2:
The system allows for parameter changes in the positions of welding tip assemblies along the carrier through the driving mechanisms. This capability enables the same manufacturing equipment to handle various battery pack dimensions and welding requirements, reducing the need for multiple specialized tools and lowering overall costs.
3Productivity
If the spacing among welding tip assemblies is fixed, then the device is simple to operate, but the productivity decreases when adapting to different product specifications
Solution Approach 1:
The spacing among welding tip assemblies is made dynamic through the driving assemblies that can adjust positions automatically. This allows the system to optimize welding efficiency for different product specifications while the automation reduces operational complexity, as the adjustments are made through controlled mechanisms rather than manual reconfiguration.
Solution Approach 2:
The manual adjustment of welding tip positions is replaced with automated driving assemblies that control the spacing and movement of welding tips. This substitution of mechanical adjustment with automated control systems improves productivity while maintaining ease of operation through centralized control.
4Productivity
If multiple welding tip assemblies are used for batch welding, then the productivity increases, but the device complexity increases due to multiple driving and guide components
Solution Approach 1:
Multiple welding tip assemblies are merged onto a single carrier structure, sharing common guide rails and control systems. This consolidation allows batch welding of multiple battery packs simultaneously or sequentially, improving productivity while reducing overall device complexity through resource sharing and integrated design.
Solution Approach 2:
The carrier and guide rail system serves multiple functions by supporting and guiding numerous welding tip assemblies. This multi-functional design enables the system to handle various batch welding scenarios with different numbers and arrangements of welding tips, improving productivity without proportionally increasing complexity.
Data Source
AI summary
A welding tooling includes a carrier, a first driving assembly disposed on the carrier, a first guide rail disposed on the carrier and extending along a first direction, a first slider slidably assembled with the first guide rail and configured to be driven by the first driving assembly to move along the first guide rail, and a plurality of welding tip assemblies arranged in an array. At least one column of welding tip assemblies arranged in a second direction among the plurality of welding tip assemblies is assembled on the first slider and is configured to move along with the first slider to change a spacing from other columns of welding tip assemblies. The second direction intersects the first direction.