Electrode Cap Puller with Helical-Straight Clamping Retention
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Solution Overview
Problem
Existing devices for removing electrode caps from electrode shafts in resistance spot welding processes face challenges in ensuring process reliability and preventing uncontrolled loosening or loss of the electrode caps, particularly in automated production lines.
Innovation Solution
A pulling device is designed with a combination of straight-toothed and helical-toothed clamping means, where the helical toothing is angled in the axial direction to provide a form fit and prevent axial movement, while the straight-toothed clamping supports an earlier initiation of the rotary movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a pulling device uses only straight-toothed clamping means, then the structure is simple, but the electrode cap may uncontrolably loosen or be lost during removal
Solution Approach 1:
The patent combines straight-toothed clamping means and helical-toothed clamping means in the same pulling device. The straight-toothed means provide simple structural support while the helical-toothed means prevent uncontrolled loosening through their angled geometry, achieving both simplicity and reliability
Solution Approach 2:
Different portions of the clamping means have different toothing characteristics - straight toothing in some areas for simple clamping, and helical toothing in other areas for controlled retention. This local differentiation allows each region to perform its specific function optimally
2Reliability
If a pulling device uses only helical-toothed clamping means, then the electrode cap is securely held, but the initiation of rotary movement is delayed
Solution Approach 1:
The combination of straight-toothed and helical-toothed clamping means allows the straight-toothed portion to initiate rotary movement quickly while the helical-toothed portion maintains secure retention, resolving the time-delay issue
Solution Approach 2:
The straight-toothed clamping means prepares for and initiates the rotary movement earlier than helical-toothed means alone would allow, while the helical means are already in position to provide secure holding once rotation begins
3Ease of operation
If electrode caps are removed manually using pullers, then the removal process is simple, but worker safety is compromised in automated production lines
Solution Approach 1:
The pulling device is designed to be mounted on the welding robot itself, allowing the robot to perform the electrode cap removal operation autonomously without manual intervention, ensuring both safety and operational simplicity
Solution Approach 2:
The pulling device integrates multiple functions - clamping, rotating, and removing electrode caps - into a single automated tool that can be mounted on standard welding robots, making it universally applicable in automated production lines
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a system for drawing off electrode caps, consisting of at least one drawing off unit (1), which is rotatably mounted about a tool axis and comprises clamping means (2 and 3) for fixing the electrode caps to be drawn off, comprising a combination of straight-toothed and helically toothed clamping means (2 and 3).