Arched Indentation Projection Welding Sheet Connection
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Solution Overview
Problem
The existing method for connecting sheet elements through projection welding requires complex setup and skilled operators due to the rectilinear shape of indentations, which can lead to deformations and surface imperfections, especially in the automotive industry for assembling composite panels.
Innovation Solution
The method employs arched-shaped indentations and corresponding tongues, eliminating the need for recesses at the base of the tongues, ensuring optimal contact and a reliable mechanical connection without complex setup, using a welding process where the arched indentations and tongues provide a larger contact surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rectilinear-shaped indentations are used for projection welding, then the welding process can be performed, but complex setup and skilled operators are required to avoid deformations and surface imperfections
Solution Approach 1:
The patent applies curvature by changing the indentation shape from rectilinear to arched form. The arched shape with rounded contours eliminates the need for complex setup procedures and skilled operator intervention, while ensuring reliable welding results without deformations or surface imperfections. This curved geometry naturally guides the welding process and accommodates variations in sheet positioning.
2Manufacturing precision
If rectilinear indentations with recesses at the base of tongues are used, then contact between sheets can be achieved, but additional complex operations are required
Solution Approach 1:
The arched shape of the indentation eliminates the need for additional recess formation operations at the base of tongues. The curved geometry provides sufficient contact surface area and optimal contact conditions without requiring extra manufacturing steps, thereby simplifying the overall manufacturing process while maintaining precise contact between the sheets during welding.
3Reliability
If complex setup procedures are followed to avoid deformations, then welding quality is maintained, but production time and costs increase
Solution Approach 1:
The arched indentation shape is designed in advance to inherently prevent deformations and surface imperfections during the welding process. This preliminary design feature eliminates the need for complex setup procedures and skilled operator interventions, thereby maintaining high welding quality while significantly reducing production time and operational costs.
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
This approach simplifies the setup process, ensures a strong and reliable mechanical connection, and reduces production costs by avoiding the need for skilled operators and additional operations, while maintaining aesthetically pleasing results.
Implementation Method 1
the indentations undergo a pressure and heat owing to the flow of a current, until the fusion thereof is achieved
Implementation Method 2
resistance welding operation, particularly a welding of the so-called projection type, in which one of the sheets to be welded has one or more projections or indentations for concentrating the welding current
Data Source
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AI summary
A method for connecting of a pair of sheets (12, 18), comprises the steps of forming in a first sheet (12) a series of indentations (14a) of substantially triangular cross-section, forming in a second sheet (18) a series of tongues (22a) which extend from the peripheral edge thereof, overlapping the sheets (12, 18) and connecting them by seaming, compressing the tongues (22a) of the second sheet (18) against the indentations (14a) of the first sheet (12) by pressure means, and welding the sheets (12, 18) by projection welding means using a current impulse. The indentations (14a) and the profile of the tongues (22a) have an arched shape so that they extend along a bent path.