Electromagnetic Welding Fixture for Precise Blank Alignment
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Solution Overview
Problem
Conventional fixture assemblies for laser welding often result in misalignment of blanks due to minor variations in dimensions, leading to gaps that require additional material and time to weld successfully.
Innovation Solution
A fixture assembly utilizing electromagnets and intensifiers to securely hold and adjust blanks in place, with adjustable pins and electromagnet adjusters to eliminate gaps and ensure precise alignment for efficient welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If conventional clamps are used to hold blanks in place, then the blanks are secured during welding, but minor variations in blank dimensions cause misalignment and gaps between blanks
Solution Approach 1:
The patent replaces conventional mechanical clamps with an electromagnetic holding system. Electromagnets are used to hold the blanks in place during welding, providing more precise and adjustable positioning that accommodates dimensional variations without causing misalignment or gaps between blanks.
Solution Approach 2:
The electromagnetic holding system allows for dynamic adjustment of blank positions during the welding process. The electromagnets can be activated and deactivated, and their strength can be adjusted, enabling real-time positioning corrections to maintain precise alignment despite blank dimension variations.
2Reliability
If gaps exist between misaligned blanks, then additional welding material and time are required, but the welding process becomes less efficient and more costly
Solution Approach 1:
The electromagnetic holding system performs preliminary positioning of the blanks before the welding process begins. By securing the blanks in precise alignment beforehand, the system prevents gap formation that would otherwise require additional filler material and rework, thereby improving both welding reliability and productivity.
3Device complexity
If conventional fixtures are used, then the setup is simple, but adjustments for dimensional variations are difficult and time-consuming
Solution Approach 1:
The electromagnetic holding system provides dynamic adjustability through electrical control. The electromagnets can be easily activated, deactivated, and adjusted in strength via electrical signals, allowing quick compensation for blank dimensional variations without complex mechanical adjustments, thus improving ease of operation while maintaining relatively simple device structure.
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
The solution allows for quick and efficient adjustment and secure holding of blanks during welding, eliminating gaps and enhancing the efficiency of laser welding operations by enabling precise alignment and effective use of welding material.
Implementation Method 1
A plurality of electromagnets are positioned on the frame for supporting the blanks and for drawing the blanks toward the electromagnets to inhibit relative movement between the blanks and the electromagnets upon being activated
Implementation Method 2
A plurality of intensifiers are moveably connected to the frame for selectively overlying the electromagnets for being drawn toward the electromagnets over the blank to clamp the blank in place and to intensify a magnetic force provided by the electromagnets when the electromagnets are activated
Data Source
AI summary
A fixture assembly for supporting a plurality of blanks during a welding operation. The fixture assembly includes a frame. A plurality of electromagnets are positioned on the frame for supporting the blanks and for drawing the blanks toward the electromagnets to secure the blanks into a desired position. A plurality of intensifiers are moveably connected to the frame for selectively overlying the top face of one of the electromagnets for clamping the blank against the electromagnet to intensify a magnetic force provided by the electromagnet. A plurality of electromagnet adjusters are each coupled with the frame and with at least one of the electromagnets for moving the electromagnets relative to the frame. A plurality of adjusting pins are each connected to the frame and moveable relative to the frame for adjusting a position of the blanks.