Electromagnetic Welding Fixture Assembly for Blank Gap Elimination
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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, intensifiers, and adjustable supports to quickly and efficiently align and hold blanks in precise positions during welding, allowing for magnetic force adjustment and hydraulic actuation to close gaps and maintain alignment.
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 field-based system. Electromagnets mounted on the fixture assembly generate magnetic fields that attract and hold the blanks in precise positions. This substitution eliminates the misalignment issues caused by mechanical clamps because the electromagnetic field can accommodate minor dimensional variations while maintaining precise alignment through controlled magnetic attraction forces.
Solution Approach 2:
The patent employs adjustable electromagnets that can be dynamically repositioned along the fixture assembly using adjusting pins and hydraulic actuators. This dynamic capability allows the system to adapt to variations in blank dimensions by adjusting the position and strength of individual electromagnets, thereby maintaining precise alignment and eliminating gaps between blanks during welding operations.
2Reliability
If gaps between blanks are created due to misalignment, then additional filler material and time are required for successful welding
Solution Approach 1:
The patent implements preliminary alignment action by using electromagnets to secure blanks in their precise final positions before the welding process begins. The electromagnets hold the blanks firmly against the fixture assembly, ensuring that no gaps or misalignments exist when welding commences. This preliminary securing action eliminates the need for filler material and additional welding time, as the blanks are already perfectly positioned for direct welding.
3Ease of operation
If conventional fixture assemblies are used, then blanks can be held in place, but adjustments for alignment are difficult and time-consuming
Solution Approach 1:
The patent incorporates hydraulic actuators that work in conjunction with the electromagnets and adjusting pins. These hydraulic systems provide powered adjustment capabilities, allowing operators to easily reposition electromagnets and adjusting pins along the fixture assembly with precise control. This hydraulic assistance eliminates the manual effort required for conventional mechanical adjustments while maintaining high alignment precision through controlled, incremental positioning.
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 alignment and efficient welding operations by eliminating gaps between blanks, reducing the need for filler material and minimizing operation time.
Implementation Method 1
Each of the electromagnets has a top face for supporting the blank and for drawing the blank toward the top face
Implementation Method 2
A plurality of intensifiers overlie the top faces of the electromagnets such that, when the electromagnets are activated, they are drawn toward the top faces of the electromagnets over the blanks to clamp the blanks in place in order to intensify the magnetic force provided by the electromagnet
Data Source
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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.