Butt-Welding Deburring Control for Mismatched Workpiece Dimensions
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Solution Overview
Problem
Existing butt welding devices face issues with damage to workpieces and deburring tools due to mismatched geometric dimensions, particularly when deburring tools act on the side with the smaller wire diameter, leading to incorrect deburring settings and residual burrs.
Innovation Solution
A butt welding device equipped with sensors to determine the geometric dimensions of workpieces, allowing the control unit to adjust the movement of clamping members and deburring tools, ensuring deburring occurs from the side with the larger dimensions, thus preventing damage and optimizing the deburring process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the deburring tool acts on the side with the smaller wire diameter, then the deburring opening can be set based on that smaller dimension, but the wire with larger diameter and the deburring tool are damaged due to incorrect opening setting
Solution Approach 1:
The patent applies preliminary action by measuring the geometric dimensions of both workpieces before the deburring operation and using this information to determine which side should be deburred. The control unit receives dimension data from sensors and pre-determines the correct deburring side and parameters, preventing damage before it occurs. This advance preparation ensures the deburring tool is properly configured based on actual workpiece dimensions rather than assumptions.
Solution Approach 2:
The patent implements feedback by using sensors to continuously monitor the geometric dimensions of the workpieces and providing this information to the control unit. The control unit uses this feedback to adjust the deburring process parameters and select the appropriate deburring side. This closed-loop control ensures that the deburring operation adapts to the actual dimensions of the workpieces, preventing damage to both the workpiece and tool.
2Productivity
If automatic deburring is implemented without dimension sensing, then productivity increases, but damage to workpiece and tool occurs due to mismatched geometric dimensions
Solution Approach 1:
The patent implements feedback by using sensors to continuously monitor the geometric dimensions of the workpieces and providing this information to the control unit. The control unit uses this feedback to adjust the deburring process parameters and select the appropriate deburring side. This closed-loop control ensures that the deburring operation adapts to the actual dimensions of the workpieces, preventing damage to both the workpiece and tool.
Solution Approach 2:
The patent applies self-service by enabling the system to automatically measure its own workpiece dimensions and self-adjust the deburring parameters without external intervention. The sensors and control unit work together to allow the system to determine the correct deburring configuration autonomously, maintaining high productivity while ensuring reliability through adaptive control.
3Manufacturing precision
If sensors and control systems are added to determine geometric dimensions, then deburring accuracy improves, but device complexity increases
Solution Approach 1:
The patent applies universality by designing a control unit that handles multiple functions: it receives signals from various sensors, processes dimension data, determines deburring parameters, and controls the deburring tool operation. This multi-functional approach consolidates complexity into a single control unit rather than requiring separate control systems for each function, thereby improving precision while managing device complexity.
Solution Approach 2:
The patent replaces manual measurement and adjustment mechanisms with automated sensors and electronic control systems. Instead of mechanical gauges and manual setting procedures, the system uses optical or electronic sensors to measure dimensions and electronically controls the deburring process. This substitution improves manufacturing precision while the integration of these systems into a unified control unit helps manage overall device complexity.
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 prevents damage to workpieces and deburring tools by ensuring accurate deburring based on geometric dimensions, maintaining high-quality welds and reducing burr residues.
Implementation Method 1
at least one sensor is provided to determine the geometric dimensions of the workpieces that are to be joined
Implementation Method 2
a control unit controls the movement of the clamping members and/or of the deburring tool as a function of the geometric dimension
Implementation Method 3
at least one deburring tool for deburring the welded workpiece ends
Data Source
AI summary
A butt-welding device and a method for butt welding workpieces, especially for double-upset resistance-pressure butt-welding of workpieces, particularly wires, strands and profiles, has first and second clamping members for receiving the ends of the workpieces that are to be joined. At least one clamping means can be moved between a starting position and a welding position. At least one deburring tool is provided for deburring the welded workpiece ends. In addition, at least one sensor is provided to determine the geometric dimensions of the workpieces that are to be joined, especially the diameter, the width or the height in the joining plane or substantially parallel thereto, wherein a control unit controls the movement of the clamping members and/or of the deburring tool as a function of the geometric dimension.