Simultaneous Ball Resistance Welding for Precise Multi-Point Joining
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Solution Overview
Problem
Existing methods for welding multiple balls to each other or to components are inefficient and lack the capability to produce high-quality connections simultaneously.
Innovation Solution
The method employs resistance or electric welding with a high electrical current to simultaneously weld multiple balls and a component, using a holding device to maintain precise alignment, and can be performed without a protective gas atmosphere, allowing for complex ball connections in a single process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple balls are welded separately to the component, then each welding connection can be made with sufficient quality, but the total welding time and process complexity increase significantly
Solution Approach 1:
The patent combines multiple separate welding operations into a single simultaneous welding process. Multiple balls are positioned on the component using a holding device, and all welding connections are established at the same time through one welding operation, rather than welding each ball separately in sequence.
Solution Approach 2:
The holding device is used to pre-position multiple balls on the component in the correct locations and orientations before the welding process begins. This preliminary positioning ensures that when welding occurs, all balls are already in their final positions, enabling simultaneous welding without requiring complex positioning during the welding operation itself.
2Manufacturing precision
If a holding device is used to position multiple balls precisely, then welding alignment is improved, but the device complexity and setup time increase
Solution Approach 1:
The holding device acts as an intermediary tool that simplifies the positioning task. Instead of requiring complex positioning mechanisms during welding, the holding device provides a simple structure with positioning elements (such as slots or clamps) that hold the balls in place. The holding device is removed after positioning, having served its purpose as a temporary aid.
3Reliability
If traditional welding methods are used for multiple balls, then each connection can be made individually, but the overall process time and energy consumption increase
Solution Approach 1:
Multiple welding operations are merged into a single simultaneous welding process. The holding device positions multiple balls on the component, and all welding connections are established at the same time through one welding operation, rather than welding each ball separately in sequence.
Solution Approach 2:
The welding process performs useful action continuously on all balls simultaneously. While traditional methods would weld one ball at a time with idle time between operations, this method maintains continuous welding action across multiple connection points at the same time, eliminating idle time and reducing total process duration.
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 method produces high-quality welded connections efficiently, capable of welding multiple balls to each other and to components with precision, as demonstrated by tests using steel balls and components.
Implementation Method 1
an electrical voltage is applied such that a current flow through the at least two balls and through the component occurs. The voltage is high enough that a sufficiently large current flows through the at least two balls and through the component, which current results in simultaneous welding of the at least two balls and in simultaneous welding at least of the first of the at least two balls to the component.
Data Source
AI summary
A method for welding balls provides a component, provides at least two balls, places at least one first ball of the at least two balls on the component, and applies an electrical voltage in such a manner that a current flows through the at least two balls and through the component, wherein the at least two balls are simultaneously welded together and the first ball is simultaneously welded to the component.