Electrode Holder Electromagnet Contact Pressure Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing welding devices for electrical resistance welding face challenges in controlling electrode contact pressure quickly, precisely, and economically, with complex and expensive linear drives required for both fast movement and pressing force, and electromagnets leading to direct dependence on welding current control.
Innovation Solution
A combined electrode drive system using a simple and inexpensive linear drive for closing and opening movements, supplemented by an electromagnet for precise control of contact pressure, allowing fast and dynamic force build-up with optimized profiles, and optionally using two electromagnets for individual force control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a linear drive is designed for both fast closing movements and required pressing force, then the welding device can perform both functions, but the linear drive becomes complex and expensive
Solution Approach 1:
The patent divides the drive system into two separate components: a linear drive for fast closing movements and an electromagnet for applying pressing force. This segmentation allows each component to be optimized for its specific function, reducing overall system complexity and cost while maintaining dual functionality.
Solution Approach 2:
The patent combines two different actuation mechanisms (linear drive and electromagnet) to achieve multiple functions from a single integrated system. The linear drive provides rapid positioning while the electromagnet provides controlled pressing force, together enabling both fast closing and force application capabilities.
2Extent of automation
If an electromagnet is used to drive the electrode holder, then the electrode holder can be actuated, but the infeed movement cannot be adjusted finely and welding current control becomes dependent on electromagnet control
Solution Approach 1:
The patent separates the actuation function (electromagnet) from the positioning function (linear drive). The linear drive handles precise infeed movement while the electromagnet is dedicated solely to applying pressing force, eliminating the control dependency and precision issues associated with using an electromagnet for both purposes.
3Force
If the electromagnet is arranged parallel to the linear drive on the same electrode holder, then the electromagnet can act on the electrode holder, but the connection becomes structurally complex and space-consuming
Solution Approach 1:
Instead of arranging the electromagnet parallel to the linear drive on the same electrode holder, the patent inverts the arrangement by placing the electromagnet on the opposite electrode holder. This allows the electromagnet to act through the linear drive mechanism, simplifying the structural connection and reducing space requirements.
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
Enables precise and programmable control of contact pressure during welding, achieving rapid force build-up (e.g., 5 kN in 20 ms) and maintaining contact pressure during melting, reducing the complexity and cost of the linear drive system.
Implementation Method 1
at least one of the two electrode holders can be acted upon by an electromagnet with a force F acting in the electrode closing direction
Implementation Method 2
at least one of the two electrode holders can be moved via a linear drive in such a way that the welding electrodes to be welded are interposed
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present invention relates to a welding device (1) for electric resistance welding, comprising two electrode holders (10, 12) for two welding electrodes (14, 16) that can be supplied with an electric welding current. One of the two electrode holders (10) is movable via a linear drive (18) such that the welding electrodes (14, 16) can be brought together in a closing direction (22) with the components to be welded (20) interposed. At least one of the two electrode holders (10, 12) can be subjected to a force (F) acting in the electrode closing direction (22) via an additional electromagnet (30).