Resistance Welding Electrode Valve Body for Gas Control
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Solution Overview
Problem
Resistance welding electrodes face contamination from molten material residues, leading to decreased performance and quality of welded joints, with existing solutions either wasteful or requiring complex and costly control electronics for compressed air management.
Innovation Solution
An electrode design featuring a valve body that remains closed unless actuated by the bolt, allowing compressed air to be directed only during welding to remove molten material, reducing gas consumption and eliminating the need for complex control electronics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If compressed air is constantly introduced into the electrode, then molten material is continuously removed from the electrode and weld, but compressed air is wasted and the stud may be blown out of the electrode before welding
Solution Approach 1:
The patent applies a dynamic valve body that changes position based on welding state. The valve body is movable between a closed position (blocking the opening) and an open position (allowing compressed air flow). This dynamic adjustment ensures compressed air is only supplied during welding when molten material needs removal, eliminating waste during non-welding periods while maintaining effective contamination control.
Solution Approach 2:
The valve body automatically responds to welding conditions without external control. During welding, the valve body opens to allow compressed air flow; during non-welding, it closes to stop flow. This self-regulating mechanism eliminates the need for complex control electronics while optimizing compressed air usage based on actual welding needs.
2Loss of energy
If control electronics are used to synchronize compressed air introduction with welding process, then compressed air is only supplied during welding, but the control electronics are complicated and expensive with high maintenance
Solution Approach 1:
The valve body serves itself by automatically opening and closing in response to welding conditions without requiring external control signals. The welding process itself triggers the valve operation, creating a self-regulating system that eliminates complex control electronics while achieving optimal compressed air timing.
Solution Approach 2:
The valve body acts as an intermediary mechanism between the welding process and compressed air supply. It translates welding conditions into appropriate air flow control, replacing complex electronic control systems with a simple mechanical intermediary that performs the synchronization function.
3Stability of the object's composition
If the valve body is designed as a three-dimensional shaped body made of hard and impact-resistant material, then the valve body retains its shape over long period use, but the valve body may jam in the cavity
Solution Approach 1:
The valve body is designed as a sphere, utilizing spherical geometry to prevent jamming. The curved surface allows the valve body to rotate and move freely within the cavity without getting stuck on edges or corners. This spherical design maintains structural integrity and shape retention while ensuring reliable, jam-free movement during operation.
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 design effectively reduces gas consumption and maintains electrode performance by ensuring compressed air is only supplied during welding, preventing contamination and eliminating the need for costly control systems.
Implementation Method 1
During the welding process, compressed air is introduced into the electrode via the compressed air connection and fed to the welding point. Molten material is entrained in the air flow and removed from the electrode and the weld.
Implementation Method 2
When the gas pressure is applied, the valve body is in a closed valve position. The gas introduced into the cavity of the electrode cannot escape through the opening in the upper part of the electrode.
Implementation Method 3
The valve body is only moved into an open valve position by the action of the bolt. When the bolt is removed, the valve body is automatically moved back into its closed valve position by the applied gas pressure.
Data Source
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AI summary
The invention relates to an electrode (1) for resistance welding of studs (2), comprising an upper part (7) and a lower part (8) which are designed to be connectable to one another and, in the connected state, jointly provide a cavity (12), wherein the upper part (7) has an opening (11) for inserting a stud (2) and the lower part (8) has a gas connection (13) for a pressurized gas. A valve body (23) is arranged in the cavity (12) by which the opening (11) can be closed. This prevents the escape of compressed air. Compressed air escapes only when the valve body (23) releases the opening (11).