Electrode Roller Angle Control for Seam Welding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In seam-welding, maintaining a constant pressing direction of workpieces by electrode rollers is challenging, especially when the workpieces are round or have non-uniform thickness, leading to variations in the welding state.
Innovation Solution
A seam-welding method and system that measures the distance to the workpieces using a predetermined positional relationship and adjusts the angle between the electrode rollers and the workpieces to maintain a preset inclination angle, ensuring a consistent pressing direction through continuous movement and electricity application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If seam-welding is performed on round or non-uniform workpieces using conventional electrode rollers, then welding can be completed, but the pressing direction changes导致焊接状态不稳定
Solution Approach 1:
The electrode rollers are designed with dynamic adjustment capability through a tilt mechanism that allows real-time correction of the roller axis orientation. The system continuously measures the workpiece surface inclination and adjusts the roller pressing direction dynamically to maintain perpendicular contact, resolving the contradiction between handling varied workpiece geometries and maintaining stable welding conditions.
Solution Approach 2:
A feedback control system is implemented where sensors measure the actual pressing direction and workpiece surface orientation, and this information is used to automatically adjust the electrode roller tilt angle. This closed-loop control ensures the pressing direction remains consistent despite variations in workpiece shape or position, directly addressing the reliability issue.
2Manufacturing precision
If additional measurement components are added to detect workpiece position and adjust electrode rollers, then pressing direction can be maintained, but system complexity increases
Solution Approach 1:
The measurement system is designed to serve multiple functions: it detects workpiece position, determines surface inclination, and provides data for roller orientation adjustment. By making the measurement means multi-functional, the system achieves high pressing direction accuracy without requiring separate dedicated components for each function, thus limiting the increase in system complexity.
Solution Approach 2:
The measurement and control functions are merged into an integrated system where the same measurement apparatus that detects workpiece position also provides the data needed for inclination correction. This consolidation reduces the number of separate components needed while maintaining precision in pressing direction control.
Data Source
AI summary
Distance to the upper face of workpieces W sandwiched between electrode rollers 15 and 16 is measured by a range sensor 41 that has a predetermined positional relationship with the electrode rollers 15 and 16 (STEPs 1, 3). Correction is made based on the distance found by the range sensor 41 by moving the pair of electrode rollers 15, 16 with reference to the workpieces W so that an angle Rx between a straight line L0 connecting centers of the pair of electrode rollers 15, 16 and the surface of the plurality of workpieces W is preset angle (STEP 5).