Quick-Change Electrode Head with Automatic Coolant Circuit
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing welding devices face challenges in flexibility and reduced downtimes, particularly due to complex electrode replacement processes, which hinder quick adaptation to changing production demands and result in significant operational interruptions.
Innovation Solution
A quick-change system for electrode heads, where the electrode and its holder form a unit that can be easily removed and replaced within minutes, with an automatic coolant circuit closure mechanism to minimize downtime and prevent coolant loss during replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If the electrode replacement process follows traditional methods with separate components, then the electrode can be replaced, but the replacement time is long (about 30 minutes) and operational interruption is significant
Solution Approach 1:
The electrode and electrode holder are merged into a single integrated electrode head assembly that can be replaced as one unit. This eliminates the time-consuming separate replacement steps and reduces operational interruption from 30 minutes to just a few minutes, directly addressing the time loss and productivity issue.
Solution Approach 2:
The welding device is segmented into modular components, with the electrode head designed as a detachable unit that can be quickly exchanged. This modular segmentation enables rapid replacement while maintaining system functionality, resolving the contradiction between replacement speed and production continuity.
2Reliability
If the electrode holder is designed with coolant channels and flexible hoses, then cooling can continue during electrode tip replacement, but the system complexity increases and coolant escape risk arises during disconnection
Solution Approach 1:
The coolant circuit is integrated into the electrode holder structure itself, with cooling channels built directly into the holder body. This eliminates the need for external flexible hoses and complex connections, simplifying the system while ensuring continuous cooling during electrode tip replacement.
Solution Approach 2:
The electrode tip is designed as a disposable component that can be quickly replaced without disconnecting the coolant circuit. The reusable electrode holder with built-in cooling channels maintains reliable cooling while eliminating the complexity and leak risks associated with detachable hose connections.
3Adaptability or versatility
If electrodes have different dimensions for different contact metal blanks, then versatility is improved, but the electrode replacement complexity and time expenditure increase
Solution Approach 1:
The electrode holder is designed with universal features including adjustable guide rails and interchangeable electrode tips, allowing a single holder design to accommodate electrodes of different dimensions. This provides versatility for processing various contact metal blanks while maintaining simple, consistent replacement procedures.
Solution Approach 2:
The guide rails incorporate adjustable positioning mechanisms that can dynamically adapt to different electrode dimensions. This dynamic adjustment capability enables the system to handle various electrode sizes without requiring complex replacement procedures, maintaining ease of operation alongside versatility.
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 solution significantly reduces operational interruptions, allowing for faster electrode changes and increased production capacity, enabling the welding device to produce quantities greater than 100 pieces per minute while maintaining efficient coolant management.
Implementation Method 1
A coolant supply and a coolant return of a respective coolant circuit are provided in each frame element for cooling the associated electrode
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The welding device for punching- and/or bending machine for loading carrier parts with contact metal through welding of contact metal blanks that are separated from a band material such as wire, comprises a base frame, an electrode pair with a first electrode movable between a reception position and a welding position relative to a second electrode, where the first and second electrodes (16, 18) are arranged to first and second frame elements that are pivotable relative to each other, and a contact metal supply with a feed device. The welding device for punching- and/or bending machine for loading carrier parts with contact metal through welding of contact metal blanks that are separated from a band material such as wire, comprises a base frame, an electrode pair with a first electrode movable between a reception position and a welding position relative to a second electrode, where the first and second electrodes (16, 18) are arranged to first and second frame elements that are pivotable relative to each other, and a contact metal supply with a feed device for the supply of contact metal blanks to the electrode pair. The electrodes are detachably connected by an electrode holder with an electrode reception in such a way that the electrode holder with the electrode is removable in interrupted operation of the welding arrangement from the welding device mounted on the punching- and/or bending machine. A coolant inflow and a coolant outflow of a coolant circuit are provided in the frame element for cooling the electrode. The electrode and/or the electrode holder are formed in such a way that the coolant circuit is automatically connected between the electrode holder and the frame element through the production of mechanical connection. The coolant circuit is a common emptying device in order to remove the coolant present in the circuit. The emptying device comprises a pneumatic line that is connected through a valve with the coolant inflow or the coolant outflow, where compressed air from a compressed air source is pumped into the coolant circuit. The emptying device comprises a flow valve associated to the coolant inflow, where the flow valve is connected during emptying the coolant circuit. The electrode holder is connected with the electrode reception of the frame element in positive-fit manner. The electrode holder and the electrode reception are formed on the frame element in such a way that a clamping connection is produced between the electrode holder and the frame element. The electrode holder comprises two guiding strips (20a, 22a) connected to each other in its interval. The guiding strips receive a frame section of the electrode reception in incorporated condition of the electrode. The guiding strips are connected to each other through a bolt, which is received in incorporated condition of the electrode in a corresponding opening in the frame section. The bolt is formed in such a way that it is positionable by a positioning screw so that the interval between the guiding strips is adjustable in order to detach the clamping connection between the electrode and the frame section. Independent claims are included for: (1) an electrode head for a welding device; (2) a punching- and/or bending machine for deformation of workpieces; and (3) a method for exchanging an electrode head.