Induction Welding Fixture for Multi-Curvature Workpiece Support
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Solution Overview
Problem
Existing induction welding fixtures are expensive and tedious to set up, and require multiple fixtures or multi-station setups for welding multiple joints on a workpiece, lacking versatility.
Innovation Solution
A versatile induction welding station and system that uses a gantry and support structures to securely hold a workpiece with varying curvatures, allowing a single fixture to weld multiple joints without retooling, using a moveable induction welder and adjustable support surfaces to accommodate different curvature geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple different fixtures are used to weld multiple joints on a workpiece, then welding coverage is improved, but device complexity and cost increase
Solution Approach 1:
The patent implements a universal fixture system with a reusable base structure and interchangeable curved support surfaces. Each support surface is designed for a specific curvature radius, allowing the same fixture base to accommodate multiple workpiece geometries by simply changing the support surface component, thereby achieving multi-joint welding capability without requiring multiple complete fixtures
Solution Approach 2:
The fixture system is divided into modular components: a reusable base structure and separate interchangeable curved support surfaces. This segmentation allows the support surfaces to be independently selected and replaced based on the specific curvature requirements of different workpieces, enabling versatile application with a single fixture platform
2Adaptability or versatility
If a single fixture is configured with multiple stations, then welding coverage is improved, but setup time and complexity increase
Solution Approach 1:
The fixture employs a dynamic, adjustable support surface that can be repositioned and reconfigured for different curvature radii. Instead of fixed multi-station configurations, the support surface can be adjusted to match various workpiece geometries, reducing setup time by eliminating the need to retool or reposition entire fixture assemblies
3Manufacturing precision
If fixtures are specifically tailored for single joints, then manufacturing precision is improved, but adaptability decreases
Solution Approach 1:
The fixture design applies local quality by providing specific curved support surfaces with predetermined curvature radii that match specific workpiece geometries. Each support surface is optimized for its specific curvature application, ensuring welding precision, while the overall fixture system maintains versatility through the ability to interchange these locally-optimized components
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 efficient and cost-effective induction welding of complex workpieces with varying curvatures without the need for retooling, increasing production efficiency and reducing setup time.
Implementation Method 1
an induction welder (56) moveably mounted to the induction welder track (52) and configured for induction welding the workpiece (20)
Implementation Method 2
a first support structure (36) and a second support structure (44) of the gantry (38) configured to hold the workpiece (20) in a predetermined orientation
Data Source
Figure 1
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Figure 3
AI summary
An induction welding system includes a first gantry (38), a second gantry (38), and a support structure (36, 44). The first gantry (38) includes a first frame and a first plurality of trunks. The first plurality of trunks defines a first curved inner support surface (42) of the first gantry (38). The first curved inner support surface (42) has a first curvature geometry. The second gantry (38) includes a second frame and a second plurality of trunks. The second plurality of trunks defines a second curved inner support surface (42) of the second gantry. The second curved inner support surface (42) has a second curvature geometry which is different than the first curvature geometry. The support structure (36, 44) includes at least one tooling member (40) defining a curved outer support surface (50) of the support structure (36, 44). The support structure (36, 44) is longitudinally moveable relative to the first gantry (38) and the second gantry (38).