Concentric Clamping and Welding Electrode for Datum Spot Welding

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Solution Overview

Problem

Conventional resistance spot welding systems cause workpiece deformation due to the need for electrodes to apply compressive forces at non-datum locations, leading to reduced vehicle dimensional accuracy, assembly cell congestion, increased tooling costs, and longer cycle times.

Innovation Solution

A system and method that involves clamping workpieces at predetermined datum locations using a clamping element and applying electric current through an electrode substantially adjacent these locations to produce radially symmetric welds, minimizing deformation and optimizing clamping force.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If electrodes apply compressive welding forces at locations spaced from datum locations, then welding can be performed, but workpiece deformation increases

Engineering Contradiction:

Improveworkpiece deformationVSAvoidwelding operation

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

The patent combines the clamping function and welding function into a single integrated apparatus. The clamping element and electrode are positioned to perform both clamping and welding operations at or near the same location (the datum location), eliminating the need for separate clamping and welding robots. This integration allows the welding forces to be applied at the datum location where clamping occurs, preventing workpiece deformation while maintaining welding effectiveness.

Inventive Principle:

Principle #5Merging (Combining)

2Ease of operation

If separate clamping and welding robots are used, then clamping and welding can be performed independently, but assembly cell congestion increases

Engineering Contradiction:

Improveindependent clamping and weldingVSAvoidassembly cell space

Core Design Contradiction:

Ease of operationVSArea of stationary object

Solution Approach 1:

The patent merges the functions of separate clamping and welding robots into a single integrated apparatus that performs both operations. This consolidation reduces the number of robots and equipment needed in the assembly cell, thereby reducing floor space requirements and three-dimensional space congestion while maintaining the ability to perform both clamping and welding operations.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If multiple robots are used for clamping and welding, then specialized functions are achieved, but tooling costs increase

Engineering Contradiction:

Improvespecialized clamping and welding functionsVSAvoidtooling costs

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent integrates clamping and welding functions into a single apparatus, reducing the total number of robots and tooling elements required. This consolidation decreases tooling costs by eliminating redundant equipment while maintaining specialized functions through the integrated design of the clamping element and electrode assembly.

Inventive Principle:

Principle #5Merging (Combining)

4Adaptability or versatility

If multiple separate apparatuses are used, then specialized operations are performed, but cycle time increases

Engineering Contradiction:

Improvespecialized operationsVSAvoidcycle time

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The patent combines clamping and welding operations into a single integrated apparatus that can perform both functions in sequence or simultaneously at the same location. This integration eliminates the need for workpiece transfer between separate clamping and welding stations, reducing cycle time and improving productivity while maintaining the capability to perform specialized clamping and welding operations.

Inventive Principle:

Principle #5Merging (Combining)

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 approach reduces workpiece deformation, improves dimensional accuracy, decreases assembly cell congestion, and lowers production costs by ensuring even force distribution and efficient welding.

Implementation Method 1

These systems function to transmit an electric current through a plurality of adjacently secured workpieces, such that the resistance of the workpieces generates sufficient heat energy to produce a spot weld therebetween

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

A clamping element is provided for engaging the workpieces at a first location centered at a predetermined datum point, so as to secure the workpieces in a fixed position

Methodology Applied

Scientific EffectCompression: Compression

Data Source

PatentUS7633032B2System and method for clamping and resistance welding

Publication Date: 2009.12.15 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

An improved spot welding system for clamping and welding a plurality of workpieces at predetermined datum locations includes a clamping element, and at least one electrode. The preferred electrode(s) and element are concentrically alignable during engagement, and configured to produce an annular weld about the datum location. More preferably, the workpieces define an opening at the datum location, the element includes an insulated pin at least a portion of which is configured to pass-through the opening, and the electrode defines an inner space configured to receive the portion of the pin, when the electrode and element fully engage the workpieces.