Ceramic Insulating Washer for Welding Electrode Positioning
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Solution Overview
Problem
Existing electrical processing devices, such as welding and soldering devices, face challenges in ensuring reliable electrical insulation and precise positioning of electrodes, which affects the quality and consistency of the joining process, especially in automated production systems.
Innovation Solution
A modular electrical processing device with a ceramic insulating disk that provides pressure-resistant and dimensionally stable insulation, allowing for precise force transmission and electrical isolation, along with a multi-part adjusting device for fine adjustment and compensation of positional tolerances, and a guide device with a movably guided drive element for axial movement, ensuring accurate and controlled electrode positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical insulation measures are implemented (insulating plastic film or insulation on electrode holders), then electrical insulation is provided, but the technical complexity increases or reliability is insufficient
Solution Approach 1:
The patent combines the electrical insulation function and the mechanical support function into a single ceramic insulating washer. This washer is integrated into the common supporting part and provides both structural support for the electrode holder and reliable electrical insulation, eliminating the need for separate insulation components and reducing overall device complexity.
Solution Approach 2:
The patent employs ceramic material for the insulating washer, which combines electrical insulation properties with mechanical strength and pressure resistance. This composite material approach provides superior electrical insulation reliability compared to plastic films while maintaining structural integrity under welding pressures.
2Manufacturing precision
If individual structures are designed for specific applications, then specific processing requirements are met, but adaptability to different applications is reduced
Solution Approach 1:
The patent designs a common supporting part that serves multiple functions across different welding applications. This single component provides mechanical support, electrical insulation, and positioning capabilities that can be adapted to various electrode configurations and welding processes, enabling the same basic structure to serve multiple purposes while maintaining processing quality.
Solution Approach 2:
The patent segments the welding device into modular components, with the common supporting part as a standardized base that can accommodate different electrode holders and tools. This segmentation allows the core supporting structure to remain consistent while enabling customization for specific application requirements.
3Reliability
If insulation measures are implemented, then electrical isolation is provided, but force transmission may be affected
Solution Approach 1:
The ceramic material used in the insulating washer provides both excellent electrical insulation properties and high mechanical strength. This allows the component to effectively isolate electrical currents while simultaneously transmitting welding forces accurately without deformation, resolving the contradiction between electrical isolation and force transmission.
Solution Approach 2:
The insulating washer is designed to perform both electrical insulation and mechanical force transmission functions simultaneously. By integrating these two functions into a single component with appropriate material properties and structural design, the patent ensures that electrical isolation does not compromise force transmission accuracy.
Data Source
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AI summary
The invention relates to an electrical processing device (1), in particular a welding or soldering device, comprising a tool (2), in particular an electrode (2), which is supplied with electric current and subjected to a contact force, and a tool holder (5), in particular an electrode holder, which transmits the contact force, wherein the processing device (1) has a feed device (9) for a tool (2), in particular for an electrode. The feed device (9) and a relatively stationary tool holder (6) are arranged on a common carrier (8), which is designed as a slide and is movably mounted on a frame (7), wherein an adjustment device (12) is arranged between the carrier (8) and the frame (7), which pre-positions or feeds the carrier (8).