Extension Arm for Resistance Welding Hand Piece
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Solution Overview
Problem
Resistance welding hand pieces lack the necessary flexibility and accessibility to reach confined workspaces, especially when exacting forces are required for complex geometries, as the high pressure handle is often too large and cannot access these areas effectively.
Innovation Solution
An extension arm is designed to attach to the resistance welding hand piece, featuring an elongated main body with an electrode at one end, which is electrically connected to the hand piece via a pathway, allowing the hand piece to be used in spaces inaccessible with the high pressure handle alone.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a high pressure handle is used to provide exact known force, then welding force precision is improved, but device size increases and accessibility to confined areas deteriorates
Solution Approach 1:
The welding system is divided into two separate components: a pistol grip hand piece that provides precise force control and an extension arm that provides reach. This segmentation allows each component to be optimized for its specific function - the hand piece for force precision and the extension arm for accessibility.
Solution Approach 2:
The extension arm acts as an intermediary between the pistol grip hand piece and the work piece. It transmits both mechanical force and electrical current from the hand piece to the electrode, enabling the operator to maintain precise force control while reaching confined areas that would be inaccessible with a direct high pressure handle connection.
2Ease of operation
If a pistol grip hand piece is used for flexibility, then ease of operation is improved, but ability to deliver exact known force deteriorates
Solution Approach 1:
The system separates the flexibility function (pistol grip hand piece) from the precise force control function (high pressure handle). The pistol grip provides ergonomic flexibility and ease of manipulation, while the high pressure handle connection through the extension arm delivers the required exact known force to the work piece.
3Ease of operation
If an extension arm is added to increase reach, then accessibility to confined areas is improved, but device complexity increases
Solution Approach 1:
The extension arm merges multiple functions into a single component: it provides mechanical extension for reach, transmits force from the hand piece, conducts electrical current to the electrode, and maintains structural integrity. This consolidation achieves extended accessibility without proportionally increasing complexity.
Solution Approach 2:
The extension arm serves multiple purposes simultaneously - it is both a mechanical lever for force transmission and an electrical conductor for current delivery. This multi-functionality reduces the need for separate components, thereby limiting the increase in overall device complexity.
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 extension arm enables the hand piece to access confined areas by providing the necessary reach and force for effective resistance welding in complex geometries, enhancing the versatility and accessibility of the welding process.
Implementation Method 1
heat is generated at the interface of two parts to be joined by passing an electrical current through the parts
Implementation Method 2
The electrode may be in electrical communication with the hand piece by way of at least one electrical pathway
Data Source
AI summary
An extension arm for attachment to a resistance welding hand piece is disclosed. The extension arm may include an elongated main body extending between a first end and a second end. The first end of the elongated main body may be attachable to the hand piece such that the second end of the elongated main body is spaced apart from the hand piece. The extension arm also may include an electrode extending from the second end of the elongated main body. The electrode may be in electrical communication with the hand piece by way of at least one electrical pathway.