Elastic-Guided Welding Positioning for Friction-Free Force Control
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Solution Overview
Problem
Current welding devices experience friction losses and hysteresis, leading to non-reproducible welding results and potential component destruction when applying small forces, particularly in welding filigree components like foils for in-ear headphones, due to mechanical losses in existing guides and drives.
Innovation Solution
A welding device positioning arrangement utilizing a static and movable section connected by an elastic guiding system and a moving coil drive, which allows precise control of force and axial length without mechanical friction, enabling high-precision positioning and force application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional mechanical guides and drives are used in welding devices, then the device structure is simple and easy to manufacture, but friction losses and hysteresis occur leading to non-reproducible welding results
Solution Approach 1:
The patent replaces conventional mechanical guiding systems with magnetic field-based positioning. Magnets are embedded in the lifting table and corresponding magnets are positioned above them, creating magnetic attraction forces that eliminate the need for mechanical contact and friction-prone guides. This substitution of mechanical fields with magnetic fields resolves the contradiction by achieving high positioning precision without the hysteresis and friction of mechanical systems.
Solution Approach 2:
The patent introduces a pneumatic cushioning system that generates an air layer between the lifting table and the upper tool. This pneumatic cushion eliminates direct mechanical contact during positioning, preventing friction losses and hysteresis while maintaining precise control of small forces. The pneumatic field acts as an intermediary that preserves positioning accuracy without mechanical wear.
2Manufacturing precision
If friction-reducing measures are implemented, then welding precision improves, but device complexity and manufacturing cost increase
Solution Approach 1:
By replacing mechanical friction-based guides with magnetic field interaction, the patent achieves high positioning accuracy without complex friction-reducing mechanisms. The magnetic system embeds precision directly into the field interaction rather than requiring precision mechanical surfaces, simplifying manufacturing while maintaining accuracy.
Solution Approach 2:
The patent changes the fundamental parameter of force transmission from mechanical contact to magnetic attraction. This parameter change allows positioning accuracy to be controlled through magnetic field strength and distribution rather than mechanical surface precision, making the system easier to manufacture while maintaining high precision.
3Ease of operation
If conventional drives with mechanical contact are used, then the drive system is simple, but stick-slip effects occur causing noise and wear
Solution Approach 1:
The patent replaces mechanical drive contact with magnetic field-based force application. The lifting table uses embedded magnets that interact with magnets in the upper tool, eliminating stick-slip effects by removing direct mechanical contact during the drive cycle. This achieves smooth operation without the noise and wear characteristic of conventional mechanical drives.
4Reliability
If high forces are applied to ensure reliable welding, then welding reliability improves, but component destruction occurs in small applications
Solution Approach 1:
The patent uses a pneumatic cushioning system that provides compliant force transmission. The air layer acts as a soft interface that allows precise control of applied force, enabling reliable welding through controlled magnetic attraction while preventing excessive force that would damage small components. The pneumatic system absorbs force variations that would otherwise cause component destruction.
Solution Approach 2:
The patent changes the force application mechanism from rigid mechanical contact to compliant magnetic field interaction with pneumatic cushioning. This allows the force parameter to be precisely controlled and adjusted for small components, maintaining welding reliability while preventing the high-force damage associated with conventional mechanical systems.
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 prevents force peaks and ensures reproducible welding connections by eliminating hysteresis and stick-slip effects, allowing for precise control of small forces and movements, making it suitable for welding sensitive components like foils for in-ear headphones.
Implementation Method 1
at least one drive system which is connected at a first end to the first section and at a second end to the second section, wherein the at least one drive system comprises a moving coil drive
Implementation Method 2
at least one elastic guiding system by means of which the first section and the second section are connected to each other
Data Source
AI summary
A welding device with which two components can be pressed against each other comprises a static first section and a second section movable relative to the first section. At least one drive system is connected at a first end to the first section and at a second end to the second section, as well as at least one elastic guiding system by which the first section and the second section are connected to one another. The first section and the second section are movable relative to each other along only one axis due to at least one elastic guiding system, so that an axial length of the arrangement can be varied. A moving coil drive may be used or another drive without mechanical losses or with mechanical losses less than a clamping force to be applied during operation.