Modular Clamping Module with Flexure Joints for Sheet Metal Welding
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Solution Overview
Problem
Existing clamping devices for welding sheet metal components are limited in flexibility and accuracy, particularly when dealing with non-flat shapes, and are costly due to complex structures, restricting their ability to weld components with varying joint geometries and requiring extensive setup times.
Innovation Solution
A modular clamping module with adjustable clamping jaws and a lever mechanism that provides a constant clamping force across varying sheet metal thicknesses, allowing for flexible positioning and heat transfer, along with interchangeable clamping jaws and a restoring element for efficient operation, enabling the clamping of diverse sheet metal components with high precision and speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a large number of circular clamping jaws are arranged next to one another to flatten out waviness in sheet metal blanks, then the welding edges come to rest evenly, but the structural complexity of the device increases and becomes expensive
Solution Approach 1:
The clamping device is divided into multiple independent clamping modules, each with its own clamping jaw. This segmentation allows each module to independently adjust and clamp portions of the sheet metal blank, achieving even distribution of clamping force across the entire workpiece without requiring a monolithic complex structure.
Solution Approach 2:
The clamping jaws are designed to be adjustable and movable rather than fixed. Each clamping jaw can be individually positioned and angled to match the specific geometry of the workpiece, allowing the device to adapt dynamically to different sheet metal configurations and maintain even contact without increasing overall structural complexity.
2Adaptability or versatility
If each clamping jaw is individually accommodated via a spring element and can be positioned relative to the workpiece, then flexibility is improved, but the device complexity and cost increase
Solution Approach 1:
The clamping modules are designed as universal, interchangeable units that can be used in various positions and configurations. Each module contains all necessary components (clamping jaw, lever mechanism, spring element) to function independently, allowing the same basic design to serve multiple purposes and reducing overall system complexity through standardization.
Solution Approach 2:
The spring elements automatically adjust each clamping jaw to the appropriate force and position based on the workpiece geometry. The lever mechanisms provide self-regulating clamping action that adapts to varying thicknesses and shapes without requiring complex external control systems, enabling the device to self-adjust to different workpiece configurations.
3Adaptability or versatility
If the clamping device is designed to handle non-flat sheet metal components with varying joint geometries, then versatility is improved, but the structural complexity and cost increase significantly
Solution Approach 1:
Each clamping jaw is designed with specific local characteristics (shape, angle, surface geometry) that can be optimized for particular joint types or workpiece features. This local customization of individual jaws allows the overall device to handle diverse geometries without requiring a completely different structure for each application.
Solution Approach 2:
The clamping device allows for adjustment of multiple parameters including jaw position, angle, and clamping force. These parameters can be modified to accommodate different sheet metal thicknesses, joint geometries, and material properties, providing versatility through parameter variation rather than structural redesign.
4Productivity
If setup times are reduced for welding different components, then productivity is improved, but the precision and accuracy of clamping may be compromised
Solution Approach 1:
The clamping modules are pre-configured with adjustable mechanisms that allow quick setup for different workpiece types. Templates, guides, or pre-set positions are provided that enable operators to rapidly configure the device for new components without sacrificing clamping accuracy, thereby reducing setup time while maintaining precision.
Solution Approach 2:
Manual adjustment mechanisms are replaced or supplemented with automated or semi-automated positioning systems that can quickly and accurately set clamping parameters for different workpieces. This substitution reduces the time and skill required for setup while maintaining or improving clamping precision through more consistent, repeatable positioning.
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 enables high flexibility and repeat accuracy in welding processes, allowing for the efficient clamping and welding of components with different joint geometries, reducing setup times and operational costs, while maintaining consistent clamping force and heat transfer efficiency.
Implementation Method 1
A compensating spring element is connected between the pressure piece and the clamping lever, which elastically supports the pressure piece on the clamping lever
Implementation Method 2
The flat support of the clamping jaw also serves to transfer heat in the form of thermal conduction from the component to the clamping jaw
Data Source
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AI summary
Clamping module (11) comprises: a housing (12); a path generating element (14) in the housing, where path generating element moves at least one clamping jaw (18) from a starting position to a clamping position; and at least one solid body joint between the path generating element and at least one clamping jaw, which is elastically resilient in a direction of a clamping movement of the clamping jaw. Independent claims are also included for: (1) a positioning module for a clamping device, comprising housing, path generating element in the housing, a gear mechanism, and an alignment element controlled with gear mechanism such that the alignment element can be moved from a starting position to an alignment position with a sliding-pivoting movement; and (2) a clamping device for clamping at least one component for a subsequent welding operation with at least one clamping module and at least one positioning module, where an accommodating pin and at least two clamping jaws are arranged freely projecting on a base plate, at least two clamping jaws and accommodating pin are positioned in triangular arrangement to one another on the base plate, at least one clamping module is arranged on each clamping beam, and at least one clamping jaw of the clamping module arranged on the clamping beam is assigned to the accommodating pin for fixing the component to the accommodating pin.