Horizontal Plate Lamination Welding to Prevent Deflection

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Solution Overview

Problem

The existing welding device for plate laminated bodies is prone to deflection and inclination due to thermal distortion, leading to poor welding quality and constraints on the number of laminations.

Innovation Solution

A welding device with a chuck that grips the plate laminated body in a horizontal position and a support extending along the lamination direction to provide equal support reaction forces to each plate, correcting deflection and inclination during welding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the welding torch is positioned horizontally to weld outer peripheral edges of laminated plates, then the welding device can process non-circular plates with varying curvature, but deflection and inclination occur due to thermal distortion and gravity affecting the welding bead

Engineering Contradiction:

Improveability to weld non-circular plates with varying curvatureVSAvoidwelding quality and plate alignment

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent inverts the conventional welding approach by positioning the welding torch vertically from above rather than horizontally from the side. This inversion allows gravity to work in favor of the welding process, preventing bead sag while the torch rotates with the plate to maintain constant angular relationship with the plate surface, thereby welding both circular and non-circular plates with high precision

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent changes the spatial parameter of the welding torch from horizontal to vertical position, and dynamically adjusts the torch angle relative to the plate surface during rotation. This parameter change enables the welding process to adapt to varying plate curvatures while maintaining welding quality and preventing thermal distortion-induced deflection

Inventive Principle:

Principle #35Parameter changes

2Productivity

If multiple plates are laminated in the vertical direction, then the plate structure can achieve greater height and capacity, but thermal distortion during welding causes inclination and constraint on the number of laminations

Engineering Contradiction:

Improvenumber of laminations in plate structureVSAvoidplate alignment and structural stability

Core Design Contradiction:

ProductivityVSStability of the object's composition

Solution Approach 1:

The patent inverts the lamination approach by positioning plates horizontally during welding rather than vertically. This inversion allows the welding torch to vertically approach from above, applying weld heat symmetrically to both plates at the joint. The horizontal positioning during welding prevents cumulative thermal distortion and inclination, enabling stable lamination of multiple plates without constraint on the number of laminations

Inventive Principle:

Principle #13The other way round (Inversion)

3Manufacturing precision

If the plate laminated body is positioned vertically during welding, then gravity affects the welding bead causing sag and poor welding, but repositioning requires complex device configuration

Engineering Contradiction:

Improvewelding bead qualityVSAvoiddevice configuration for position change

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent inverts the conventional vertical welding configuration by positioning the plate laminated body horizontally and the welding torch vertically from above. This single inversion eliminates the need for complex position-changing mechanisms, as the horizontal plate position naturally prevents gravity-induced bead sag while allowing the torch to rotate with the plate for consistent welding quality

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent employs a support that automatically adjusts to maintain the plate laminated body in horizontal position during welding. The support system self-regulates to compensate for any positional variations, eliminating the need for complex external positioning devices while ensuring consistent welding quality

Inventive Principle:

Principle #25Self-service

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 effectively suppresses deflection and inclination, ensuring high-quality welds and allowing for increased number of laminations in the plate laminated body.

Implementation Method 1

deflection and inclination with respect to the lamination direction due to thermal distortion in welding

Methodology Applied

Scientific EffectThermal distortion: Thermal Expansion

Implementation Method 2

a subtle disturbance such as sag is likely to occur in a welding bead under the influence of gravity

Methodology Applied

Scientific EffectGravity: Gravitation

Data Source

PatentUS12202079B2Welding device for plate laminated body in horizontal orientation and producing method for plate structure thereof

Publication Date: 2025.01.21 MAYEKAWA MFG CO LTD

AI summary

A welding device for a plate laminated body according to an embodiment includes a welding torch, a chuck for gripping a plurality of laminated plates with a lamination direction being in a horizontal position, and at least one support extending along the lamination direction for supporting the plate laminated body from below.