Chain Welding Machine Programmable Upset System
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Solution Overview
Problem
Existing chain welding machines face challenges in process reliability, productivity, and energy efficiency, particularly when switching between different resistance butt welding processes or adapting to changes in chain link materials and geometries.
Innovation Solution
A chain welding machine with a freely programmable upsetting system that decouples the compression system from the control shaft, allowing for a definable relationship between the upsetting path and time, enabling flexible programming of the upsetting sequence independent of the control shaft. This system includes servo-hydraulic drives for precise force control and monitoring, ensuring consistent welding conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the compression system is mechanically coupled to the control shaft via cam discs and lever constructions, then the machine structure is simplified and mechanically robust, but the upsetting sequence cannot be flexibly programmed and adapted to different materials and geometries
Solution Approach 1:
The patent replaces the mechanical cam-disc and lever construction with a servo-driven mechanical system. The servo motor enables programmable control of the upsetting sequence through electronic means, allowing flexible adaptation to different chain link materials and geometries while maintaining a relatively simple mechanical structure. The servo drive can be controlled via a teach function or parameter storage, eliminating the need for complex mechanical reconfiguration.
2Adaptability or versatility
If hydraulic controls are used for the compression levers, then flexible control of the upsetting sequence is achieved, but the machine becomes more complex and less reliable
Solution Approach 1:
The patent replaces the hydraulic control system with a servo-driven mechanical system. This substitution eliminates hydraulic fluid, seals, and pressure control mechanisms that are prone to leakage and failure. The servo motor provides direct, reliable mechanical drive with programmable control, maintaining flexibility while significantly improving reliability through the elimination of hydraulic components.
3Productivity
If the upsetting sequence is fixed by mechanical cam discs, then the control system is simple and robust, but productivity and energy efficiency cannot be optimized for different welding processes
Solution Approach 1:
The patent introduces dynamic programmability to the upsetting sequence control through a servo motor. The system can adapt the upsetting sequence in real-time based on different chain link materials, geometries, and welding process requirements. The servo drive allows for variable speed and position control during the upsetting process, enabling optimization of welding quality and productivity for different applications while maintaining a relatively simple overall machine structure.
Solution Approach 2:
The patent enables changes in upsetting sequence parameters (speed, position, timing, force) through electronic programming of the servo motor. Different parameter sets can be stored and recalled for different welding processes, allowing rapid optimization without mechanical reconfiguration. This parameter flexibility directly improves productivity and energy efficiency by enabling process-specific optimization.
4Ease of manufacture
If mechanical retooling is required for different chain link materials and geometries, then the machine structure remains simple, but downtime and loss of productivity increase
Solution Approach 1:
The patent implements a teach function that allows the optimal upsetting sequence to be recorded and stored before production. Once the sequence is taught and stored in the control system's memory, it can be rapidly recalled for different materials and geometries without mechanical retooling. This preliminary programming action eliminates time-consuming reconfiguration operations while maintaining simple machine structure.
Solution Approach 2:
The patent uses parameter storage to create digital copies of optimal upsetting sequences for different chain link types. Instead of physically reconfiguring the machine, the system retrieves stored parameter sets that replicate the optimal settings for each material and geometry combination. This digital copying approach eliminates retooling downtime while preserving mechanical simplicity.
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 enhances process reliability and productivity by allowing for customizable upsetting processes based on material and geometry, ensuring high-quality welds and reducing the need for mechanical retooling, while maintaining energy efficiency.
Implementation Method 1
The heat required for welding is generated by current flow via the electrical resistance of the weld joint
Implementation Method 2
a sufficiently large external force must be applied to bring about a more or less strong plastic deformation on both abutting surfaces during the heating phase
Data Source
Figure 1
Figure 2
Figure 3A~3D
AI summary
A chain welding machine (100) for resistance butt welding of chain links (180) by means of pressure butt welding has a machine frame (110), a control shaft for the timing control of kinematic functions of the chain welding machine, a chain transport device (150) for feeding unwelded chain links to a welding position (145) and for removing welded chain links from the welding position after a welding operation, an electrode arrangement with at least one pair of electrodes (130-1, 130-2) that can be positioned towards the ends of the chain links to be welded for supplying welding current, and two movable upsetting tool holders (212-1-212-2) that are arranged on opposite sides of the welding position (145) and carry upsetting tools (210-1, 210-2) on their facing sides for transmitting an upsetting force and an upsetting displacement to the chain link.A compression system (250) acting on the compression steel holders to provide the compression force and the compression path according to a predefinable compression sequence is designed as a freely programmable compression system for programming a compression sequence profile independent of the control shaft with a definable relationship between compression path and time sequence.