Sensor-Guided Butt Welding Deburring for Mixed Wire Diameters
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Solution Overview
Problem
Existing butt welding devices face issues with deburring, where the deburring tool can damage workpieces and itself due to incorrect settings, especially when dealing with wires of different diameters, as the tool often targets the smaller diameter side, leading to incomplete removal of burrs.
Innovation Solution
A butt welding device equipped with sensors to determine the geometric parameters of the workpieces, allowing the control device to adjust the movement of clamping means and deburring tools accordingly, ensuring deburring occurs from the side with the larger diameter to avoid damage and ensure proper burr removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the deburring tool acts on the weld point from the side with the smaller wire diameter, then the deburring opening can be adjusted according to the smaller diameter, but this causes damage to the workpiece and the deburring tool due to incorrect opening adjustment
Solution Approach 1:
The patent measures the geometric dimensions of both workpieces before the deburring operation and identifies which side has the larger diameter. This preliminary measurement and identification action allows the control device to subsequently direct the deburring tool to act on the correct side (the side with the larger diameter), preventing damage that would occur if the tool acted on the smaller diameter side with an incorrectly adjusted opening.
Solution Approach 2:
The patent employs sensors to detect the geometric dimensions of the workpieces and feeds this information back to the control device. The control device then uses this feedback information to determine which side should receive the deburring action, ensuring the deburring tool is directed to the correct side based on real-time measurement data, thereby avoiding damage to both the workpiece and tool.
2Manufacturing precision
If the deburring opening is adjusted according to the wire diameter during deburring, then the tool can be optimized for the smaller diameter wire, but this results in incomplete burr removal from the larger diameter wire
Solution Approach 1:
The patent performs preliminary measurement of both workpiece diameters before deburring and identifies the side with the larger diameter. This allows the system to prepare the appropriate deburring parameters in advance, ensuring the deburring tool is configured to handle the larger diameter workpiece, thereby preventing incomplete burr removal.
Solution Approach 2:
The patent changes the operational parameters of the deburring tool based on the measured geometric dimensions of the workpieces. Specifically, the control device adjusts the deburring opening and other parameters according to the larger diameter measured, ensuring the tool is optimally configured for the larger diameter workpiece rather than being constrained by the smaller diameter, thus achieving complete burr removal.
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 solution prevents damage to the workpieces and deburring tools by accurately determining the geometric sizes and adjusting the deburring process, ensuring consistent and high-quality welds with reduced risk of tool and wire damage.
Implementation Method 1
the at least one sensor is designed as a displacement measuring sensor
Implementation Method 2
at least one sensor for determining the geometric dimensions of the workpieces to be joined, in particular the diameter, width or height
Implementation Method 3
at least one clamping means is displaceable between a starting position and a welding position
Implementation Method 4
double-up resistance butt welding of workpieces
Implementation Method 5
the material of the wire ends is compressed, and burrs form at the weld or seam
Implementation Method 6
These burrs can be removed, for example, using a planer-like device
Data Source
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AI summary
The invention relates to a butt-welding device and a method for butt-welding, in particular for dual-upset resistance-pressure butt-welding workpieces, in particular wires, strands and profiles, comprising first and second clamping means for receiving the workpiece ends to be joined. At least one clamping means can be shifted 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 in the joining plane or substantially parallel thereto for determining the geometric variables of the workpieces to be joined, in particular the diameter, the width or the height, wherein a control device controls the movement of the clamping means and/or the deburring tool on the basis of the geometric variables.