Element Nest Feeding With Mechanical Self-Alignment for Set Welding
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Solution Overview
Problem
Existing setting welding devices have complex element feeding systems that require multiple drives and sensors, leading to increased construction and control efforts, and are prone to interference due to large interfering contours and tolerance issues.
Innovation Solution
A simplified element feeding device using a linear drive with a movable element nest that can be positioned via mechanical stops and a mechanical direction-changing coupling component, allowing for efficient alignment and movement of auxiliary welding joining parts without additional sensors or drive technology, utilizing resilient element jaws and a floating mounting system to compensate for tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple drives and sensors are used to feed welding auxiliary components, then positioning accuracy is improved, but device complexity increases
Solution Approach 1:
The element nest is designed with self-aligning features including a mechanical stop that engages with the electrode punch and resilient element jaws that automatically adjust to positioning tolerances. This self-service mechanism eliminates the need for external sensors and multiple drives, achieving accurate positioning through the nest's own structural features
Solution Approach 2:
The invention extracts and eliminates the complex sensor and drive systems from the feeding mechanism. By using a single linear drive combined with the self-aligning element nest, the system removes unnecessary components while maintaining positioning accuracy through the nest's mechanical stop and resilient jaw features
2Device complexity
If a single linear drive is used to simplify the system, then device complexity is reduced, but positioning precision deteriorates
Solution Approach 1:
The element nest acts as an intermediary between the single linear drive and the welding auxiliary component. It features a mechanical stop that engages with the electrode punch to define the precise stopping position, and resilient element jaws that automatically adjust to accommodate tolerances, thereby achieving precise positioning through mechanical mediation rather than complex control systems
Solution Approach 2:
The resilient element jaws provide dynamic adjustment capability, allowing the system to adapt to positioning variations automatically. This dynamic feature compensates for the simplicity of the single linear drive, maintaining positioning precision through elastic deformation and automatic adjustment rather than requiring complex control mechanisms
3Ease of manufacture
If mechanical stops and floating mounting are used for tolerance compensation, then ease of manufacture is improved, but positioning accuracy worsens
Solution Approach 1:
The mechanical stop on the element nest automatically engages with the electrode punch to define the precise stopping position, while the floating mounting allows the nest to self-align within tolerance ranges. The resilient element jaws further self-adjust to ensure accurate positioning, creating a self-service system that achieves precision through its own structural features rather than requiring complex external adjustment mechanisms
Solution Approach 2:
The floating mounting and resilient element jaws enable parameter changes in position and orientation to accommodate manufacturing tolerances. The system absorbs dimensional variations through elastic deformation and mechanical play, transforming fixed precision requirements into adaptable parameter ranges that are easier to manufacture while maintaining functional accuracy
Data Source
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AI summary
An element feed device 3 of a welding machine 1 for a welding auxiliary joining part 2 with a head and a shaft, which has the following features: a linear drive 10, which can be attached to the welding machine 1 and which has an element nest 30 at a movable end 12 in which a welding auxiliary joining part 2 can be detachably received from a transfer unit 7, and the element nest 30 is movable by a linear movement of the linear drive 10 in a first direction of movement R10 at least to a joining point of the welding auxiliary joining part 2, wherein the element nest 30 is floatingly mounted in a plane approximately perpendicular to a joining direction RF in order to be positioned below the electrode punch S in the joining direction RF by means of a mechanical stop alignment, and/or wherein the element nest 30 is connected to the movable end 12 of the linear drive 10 by means of a mechanical stop alignment direction-changing coupling component 20 is connected,so that the element nest 30 can be moved by means of the linear movement of the linear drive 10 in the first direction of movement R10 into a second direction of movement R30, so that the welding aid joining part 2 can be positioned at the joining point, wherein the second direction of movement R30 is oriented at an angle other than 0° and other than 180° to the first direction of movement R10.