Displaceable Heating Element for Welding Motor Vehicle Light Panes
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Solution Overview
Problem
Existing welding tools for motor vehicle lights are limited in accessing joining surfaces with undercuts or complex geometries due to the fixed position of heating elements, which restricts the ability to warm and weld surfaces with limited accessibility, particularly in multi-part automotive rear lights where design demands tight gap dimensions and proximity of lighting elements to the joining surfaces.
Innovation Solution
A displaceable heating element on the welding tool allows for additional translational freedom, enabling the heating element to be moved between an idle and heating position, allowing access to undercuts or geometrically restricted areas by orienting the displacement direction at right angles or obliquely, and using a guide body with an angled or curved shape to bypass protruding components, combined with a pneumatic cylinder or servomotor for precise movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed heating element is used in the welding tool, then the structure is simple and reliable, but the tool cannot access joining surfaces with undercuts or complex geometries
Solution Approach 1:
The heating element is made displaceable between a retracted position and a forward position, allowing it to dynamically adapt to different joining surface geometries. This dynamic capability enables the heating element to access undercuts and complex areas while maintaining structural simplicity through a single degree of freedom movement mechanism.
2Temperature
If the heating element is positioned close to the joining surface, then heating efficiency is high, but protruding components obstruct access to the joining surface
Solution Approach 1:
The displaceable heating element can be positioned in a retracted state during approach to avoid collision with protruding components, then moved forward to achieve optimal heating distance once the path is clear. This dynamic positioning resolves the conflict between avoiding obstructions and achieving close proximity for efficient heating.
Solution Approach 2:
The heating element is preliminarily positioned in a retracted state before the welding tool approaches the joining surface. This preliminary retraction prevents collision with protruding components, and the heating element is subsequently advanced to the optimal heating position once the path is verified clear.
3Adaptability or versatility
If the heating element is moved laterally to access undercuts, then accessibility to complex geometries is improved, but the displacement mechanism increases device complexity
Solution Approach 1:
A simple linear displacement mechanism is implemented that moves the heating element laterally between retracted and forward positions. This single-degree-of-freedom dynamic system provides the necessary adaptability to access undercut geometries without introducing complex multi-axis movement mechanisms.
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
Enables effective warming and welding of joining surfaces in complex geometries, overcoming the limitations of prior art tools by allowing the heating element to bypass obstructing components and achieve the necessary working distance for efficient plasticization and joining, even in areas with restricted accessibility.
Implementation Method 1
The functional principle is based on plasticizing the joining surfaces of the molded parts with a heating element by contact or without contact by means of heat radiation
Implementation Method 2
welding them together under a joining pressure... by contact or without contact by means of heat radiation
Data Source
AI summary
A tool for welding a light pane to a housing of a motor vehicle light, the tool comprising a base body and at least one heating element arranged on the base body, wherein the heating element is displaceable relative to the base body between an idle position and a welding position.