Flash Welding Carriage Alignment for Billet Head-Tail Joining
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Solution Overview
Problem
Existing flash welding machines for longitudinal metal products, such as billets and bars, face challenges in perfectly aligning the head and tail of the products to be welded, leading to misalignment issues that complicate the welding process and subsequent rolling operations.
Innovation Solution
A flash welding machine equipped with a carriage and adjustable structures that allow for precise alignment of the head and tail of the metal products through sliding and lifting mechanisms, utilizing clamping means and adjustment systems to ensure accurate positioning, potentially aided by sensors for height detection and automatic alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional welding machines are used, then the welding process can be performed, but the head and tail of the two products cannot be perfectly aligned
Solution Approach 1:
The patent applies dynamics by making the second structure movable relative to the first structure through sliding and lifting mechanisms. The second structure can slide along the feeding direction and be lifted vertically to adjust the position of clamping means, enabling dynamic alignment compensation for folded or misaligned product ends during the welding process.
Solution Approach 2:
The welding machine is segmented into two independent structures: a first structure fixed to the carriage and a second structure that can move relative to the first. This segmentation allows independent adjustment of the second structure's position through sliding and lifting, enabling precise alignment without requiring the entire machine to be complex and rigid.
2Reliability
If manual alignment methods are used, then the machine structure can be simple, but operator safety is compromised
Solution Approach 1:
The patent incorporates sensors that detect the position of the head and tail of the products to be welded. This feedback information is used by a control unit to automatically command the sliding and lifting mechanisms to adjust the second structure's position, achieving automatic alignment that eliminates operator exposure to hazardous areas and ensures consistent safety.
3Manufacturing precision
If the clamps are worn or incorrectly assembled, then the machine can operate, but the products become folded or misaligned
Solution Approach 1:
The patent performs preliminary alignment action by detecting the position of product ends with sensors before the welding process begins. The control unit then commands the sliding and lifting mechanisms to pre-adjust the second structure's position, compensating for any folds or misalignments caused by worn clamps before the actual welding occurs.
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 enables improved alignment of the metal products, reducing the formation of burrs and steps in the welded joint, thereby facilitating easier cleaning and rolling processes while enhancing operator safety through automated alignment.
Implementation Method 1
second adjustment means are provided for adjusting, along a plane transversal to said feeding direction, the position of the second structure with respect to the first structure by means of a lifting of the second structure
Implementation Method 2
first clamping means, provided on said first structure, for clamping the tail of the first metal product or the head of the second metal product; second clamping means, provided on said second structure, for clamping the head of the second metal product or the tail of the first metal product
Implementation Method 3
said second structure is connected to said first structure so as to slide, parallel to the feeding direction, with respect both to the first structure and the carriage
Data Source
Figure 1
Figure 2
Figure 3a~3b
AI summary
A welding machine for welding together the tail of a billet to the head of a second billet along a feeding direction, the machine comprising a carriage (1) adapted to slide along the feeding direction, said carriage (1) supporting a first structure integrally fixed to said carriage (1); first clamping means, provided on said first structure, for clamping the head of the second billet; a second structure (5) connected to the first structure and sliding, parallel to the feeding direction, with respect to both the first structure and the carriage (1); second clamping means (6, 7), provided on said second structure (5), for clamping the tail of the first billet; wherein first adjustment means are provided for adjusting the position of the second structure (5) with respect to the first structure along said feeding direction; and second adjustment means 20 are provided for adjusting the position of the second structure (5) with respect to the first structure on a plane transversal to the feeding direction, so as to align the second clamping means (6, 7) with the first clamping means along said feeding direction.