Contact Tip Reforming with Polygonal Guide Hole and Lower Force
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Solution Overview
Problem
Existing contact tip reforming devices require high force and are costly due to the need for a high-capacity mechanism to reform worn contact tips, and they have a short maintenance cycle due to wear and deformation of the core metal, leading to instability in welding quality and frequent replacement.
Innovation Solution
A contact tip reforming device with a first and second die that plastically deforms the contact tip using projecting portions and recessed surface portions, reducing the force required and preventing deformation of the core metal, allowing for a polygonal guide hole shape that maintains welding stability and extends maintenance cycles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the collet holder with slits is used to plastically deform the contact tip, then the guide hole shape is reformed to stabilize welding quality, but a large force is required increasing device cost
Solution Approach 1:
The reforming die is divided into multiple segment members that can move independently. The slits in the collet holder are positioned to align with these segment members, allowing the contact tip to be divided into multiple regions during deformation. This segmentation enables more efficient force distribution and reduces the overall force required while maintaining the polygonal guide hole shape for welding stability.
Solution Approach 2:
The reforming die transitions from a static structure to a dynamic one where segment members can move relative to each other during the reforming process. This dynamic structure allows the die to adapt to the deformation process, reducing resistance and the force needed to achieve the desired guide hole shape, thereby lowering device cost while maintaining welding quality.
2Manufacturing precision
If the core metal is made hexagonal in cross section to conform to the guide hole, then the contact tip is reformed effectively, but the core metal deforms due to wear shortening maintenance cycle
Solution Approach 1:
Instead of making the core metal hexagonal to match the guide hole shape, the invention inverts the approach by making the guide hole itself polygonal through the slit alignment and segment member movement. The core metal remains circular, eliminating wear-induced deformation while still achieving the desired polygonal guide hole shape for contact tip reforming precision.
Solution Approach 2:
The polygonal shape is created locally in the guide hole region through the coordinated movement of segment members and slit alignment, rather than requiring the entire core metal to be hexagonal. This localized shaping preserves the circular cross-section of the core metal, preventing wear deformation while achieving the necessary guide hole geometry for manufacturing precision.
3Strength
If the slits in the collet holder are eliminated during reforming, then the contact tip is compressed effectively, but there is no escape space for deformed material requiring high device capability
Solution Approach 1:
The reforming die is segmented into multiple movable members that create controlled deformation zones. The slits align with these segments, allowing material to be compressed effectively in each zone while providing escape paths through the segment interfaces. This maintains compression effectiveness while reducing the overall force and capability requirements of the device.
Solution Approach 2:
The segment members move dynamically during the reforming process, creating and closing deformation zones in sequence. This dynamic segmentation allows effective compression of the contact tip while providing temporary escape spaces for deformed material, reducing the force requirements and simplifying device capability needs.
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 device reduces the force needed for reforming, prevents core metal deformation, and stabilizes welding quality by creating a polygonal guide hole shape, resulting in a low-cost, efficient, and prolonged maintenance cycle.
Implementation Method 1
the projecting portions plastically deform the head end side of the contact tip by, when the contact tip is inserted into the plastic processing hole by the approach of the first and second dies to each other by the processing machine, pressing the head end side of the contact tip toward the hole center line
Implementation Method 2
while being in sliding contact with a head end side outer peripheral surface of the contact tip
Data Source
AI summary
A device is provided with a first die, a second die and a pressing machine. The second die is provided with a plastic processing hole where a core metal is disposed on a hole center line. On the inner peripheral surface of the plastic processing hole, three projecting portions are provided at regular intervals in the circumferential direction of the hole center line. By the approach of the first and second dies to each other, the core metal is inserted into a guide hole of a contact tip, and the projecting portions plastically deform the head end side of the contact tip by pressing it until it is in contact with the core metal.