Arc Stud Welding Counterweight for Magnetic Field Compensation
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Solution Overview
Problem
Stud welding processes face irregularities due to the 'blow effect' caused by strong magnetic fields deflecting the arc, leading to uneven melting and increased rework, which affects cost-effectiveness and acceptance.
Innovation Solution
A welding device with a feeding and positioning system for ferromagnetic solid bodies to selectively influence the magnetic field, balancing the mass distribution and current conduction effects, reducing the blowout effect by bundling magnetic flux and using permanent magnets for enhanced compensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high current is used for stud welding, then welding speed and productivity are improved, but strong magnetic fields are generated that deflect the arc causing welding defects
Solution Approach 1:
The patent introduces a counterweight made of ferromagnetic material that generates a magnetic field opposing the arc-deflecting magnetic field. This counterweight is positioned on the workpiece to create a balancing magnetic field that cancels out the harmful arc blow effect, allowing high current welding without arc deflection.
Solution Approach 2:
The ferromagnetic counterweight acts as an intermediary element between the welding current and the arc. It modifies the magnetic field distribution in the workspace by concentrating and redirecting magnetic flux, thereby mediating the interaction between the welding current and the arc to prevent arc deflection.
2Ease of operation
If welding is performed near the edge of a workpiece, then accessibility and ease of operation are improved, but arc blow is intensified due to asymmetric current distribution
Solution Approach 1:
When welding near the edge, the patent positions a ferromagnetic counterweight on the opposite side of the workpiece to compensate for the asymmetric current distribution. This counterweight creates a balancing magnetic field that counteracts the intensified arc blow caused by the edge effect, maintaining weld quality despite the challenging position.
3Reliability
If multiple workpiece clamps are used to compensate for arc blow, then arc stability is improved, but device complexity and assembly time increase
Solution Approach 1:
The patent extracts the arc-stabilizing function from the workpiece clamps and transfers it to a dedicated ferromagnetic counterweight. This separation allows the clamps to be minimized or removed, as the counterweight alone can compensate for arc blow without requiring multiple clamps to be positioned strategically on the workpiece.
Solution Approach 2:
The ferromagnetic counterweight serves multiple functions: it compensates for arc blow, concentrates magnetic flux, and can be positioned to address different welding scenarios. This multi-functionality replaces the need for multiple specialized clamps, simplifying the overall device while maintaining arc stability.
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 effectively reduces the blowout effect, allowing for more predictable and efficient stud welding processes, even near edges, with reduced assembly time and improved joint quality.
Implementation Method 1
The high magnetic conductivity of the ferromagnetic solid causes the magnetic flux to be concentrated within the solid and a reduced magnetic field strength away from the workpiece position
Implementation Method 2
through which the magnetic field generated by the welding current in the area of the arc can be selectively influenced
Data Source
Figure 1
AI summary
Welding device for welding studs (2) onto a workpiece (3), comprising a welding tool (4) connectable to a welding power source with a stud holder (5), at least one mass clamp (6) attachable to the workpiece (3) to form a switching arrangement for arc stud welding, and a first feeding and positioning device (7) for moving the welding tool (4) and the workpiece (3) relative to each other to at least edge-adjacent workpiece positions (12) for welding studs (2), wherein a second feeding and positioning device (8) is provided with which individual ferromagnetic solids (10, ) are drawn from a supply (9).11) of selectable mass at least one solid body (11) can be removed and temporarily placed on the workpiece (3) facing away from the edge of the workpiece position (12) to change the mass distribution of the workpiece (3) relative to the mass clamp (6) for edge-adjacent workpiece positions (12).