Electrode Tip Remover Structure for Thin-Nail High Rigidity
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrode tip removers for spot welding guns face issues with nail rigidity, leading to deformation and damage due to lower section modulus designs, which result in a bulky apparatus when attempting to increase rigidity.
Innovation Solution
The electrode tip remover design eliminates step portions, utilizing a pair of removing members with nails and protrusions that move symmetrically, supported by arm members with curved and slot-shaped support portions, allowing for pivotal movement and coil spring biasing to maintain rigidity and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the nail thickness is increased to improve rigidity, then the removing member can withstand greater load, but the nail cannot be inserted into the gap between the large-diameter portion and electrode tip
Solution Approach 1:
The removing member features a localized thickened portion (reinforcement rib) that extends from the nail toward the base end, concentrating structural reinforcement only where needed near the nail-root connection. This allows the nail itself to remain thin for gap insertion while the thickened portion provides the necessary rigidity and section modulus to withstand removal loads.
2Ease of operation
If step portions are added to the removing members to enable separation movement, then the arm members can pivotally move the removing members apart, but the section modulus at the nail connection portions decreases, reducing rigidity
Solution Approach 1:
Instead of reducing section modulus at the nail connection, the invention introduces a localized thickened portion (reinforcement rib) that extends from the nail toward the base end of the removing member. This reinforcement rib is positioned specifically at the nail-root connection area, maintaining high section modulus where the nail connects to the removing member, while still allowing step portions to enable separation movement.
3Reliability
If the removing members are designed with higher rigidity to prevent deformation, then the apparatus can withstand repeated removal actions, but the overall apparatus size increases becoming bulky
Solution Approach 1:
The invention applies reinforcement locally through thickened portions (reinforcement ribs) only at critical stress concentration points near the nail-root connections, rather than uniformly thickening the entire removing member. This localized reinforcement provides the necessary rigidity to withstand repeated removal actions while keeping the overall apparatus size compact and avoiding bulkiness.
Solution Approach 2:
The removing member is segmented into distinct functional zones: a thin nail portion for gap insertion, a thickened reinforcement rib portion for structural strength, and a standard thickness portion for flexibility. This segmentation allows each zone to be optimized for its specific function without compromising overall performance.
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 configuration reduces the size of the remover while enhancing rigidity, preventing deformation and damage, enabling smooth and efficient removal of electrode tips with reduced operational load and automatic resetting for repeated use.
Implementation Method 1
coil spring biasing to maintain rigidity and efficiency
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
In the present disclosure, a pair of removing members (5) are provided to be able to move toward and away from each other. Each of the removing members (5) includes a nail (5A, 5B) capable of being inserted into a gap (S1) between a large diameter portion (11a) and an electrode tip (12), and a protrusion (54) extending in a direction intersecting with a direction of insertion of the nail (5A, 5B) into the gap. The protrusions (54) of one and the other one of the removing members (5) are axially supported respectively by first and second support portions (81a, 81b) provided on one end of an arm member (8). The first support portion (81a) is in the shape of a groove that is shaped to be gradually closer to the other one of the removing members as progressing toward the other end of the arm member (8).