Interlocking Plate Edge Structure for Tack-Free Welding
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Solution Overview
Problem
The existing welding processes for large and long regular structural members, such as straight and circular structures, are hindered by the time-consuming and inefficient 'tack welding-polishing' process, which results in poor quality, high costs, and low efficiency due to the use of tack-welds.
Innovation Solution
A meshing structure for plate welding is introduced, where the plates are cut and shaped to create interlocking edges that restrain the plates in specific dimensions, eliminating the need for tack-welds. This is achieved through a tack-free welding device and method that uses a cutting mechanism to remove the meshing structures before formal welding begins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If tack-welds are used to restrain plates during welding, then the stability and alignment of plates are improved, but the production time and cost increase due to the need for multiple tack-welds and subsequent polishing
Solution Approach 1:
The meshing structures are prepared in advance on the plate edges through cutting and shaping operations. These pre-formed interlocking features eliminate the need for time-consuming tack-welding and polishing operations during the welding process, while still providing the necessary plate restraint and alignment stability.
Solution Approach 2:
The patent extracts and eliminates the unnecessary polishing operation from the traditional welding process. By using meshing structures that provide both restraint and alignment functions, the harmful or unnecessary action of polishing tack-welds is removed, reducing production time and cost while maintaining plate stability.
2Reliability
If many tack-welds are used to prevent cracking, then the weld quality and structural integrity are improved, but the material waste and processing time increase
Solution Approach 1:
The meshing structures are pre-formed on the plate edges before the welding process begins. These structures provide the necessary restraint and alignment to prevent welding defects such as cracking, eliminating the need for multiple tack-welds and subsequent polishing operations, thereby reducing processing time while maintaining weld quality.
Solution Approach 2:
The patent discards the traditional tack-welding approach that requires subsequent polishing removal. Instead, meshing structures are used that provide the necessary function during welding and can be removed or are left as part of the final structure, eliminating material waste from excessive reinforcement at tack-weld locations.
3Manufacturing precision
If a special welding fixture is used to align plates, then the alignment precision is improved, but the equipment cost and device complexity increase
Solution Approach 1:
The meshing structures feature asymmetric interlocking profiles (such as triangular, trapezoidal, or sawtooth shapes) that provide precise alignment and restraint functions. These asymmetric geometries ensure proper plate positioning and alignment during welding without requiring complex external fixtures, thereby reducing device complexity while maintaining manufacturing precision.
Solution Approach 2:
The meshing structures on the plate edges serve the dual function of both alignment and restraint during the welding process. The plates self-align through the interlocking meshing features, eliminating the need for external alignment fixtures and reducing overall device complexity while maintaining precise alignment.
4Manufacturing precision
If manual polishing of tack-welds is performed, then the appearance quality is improved, but the labor cost and production time increase
Solution Approach 1:
The patent extracts and eliminates the polishing operation from the welding process by using meshing structures that do not require post-welding removal or leveling. The interlocking structures provide the necessary restraint function without creating excessive reinforcement that would need to be polished away, thereby improving labor efficiency while maintaining appearance quality.
Solution Approach 2:
The meshing structures are pre-formed with precise geometries that eliminate the need for subsequent polishing operations. By preparing the interlocking features in advance through cutting and shaping, the patent avoids the time-consuming manual polishing step while ensuring the final weld appearance meets quality requirements.
Data Source
AI summary
A meshing structure for plate welding, and a tack-free welding device and method are provided. The device comprises a connecting frame, a welding gun, and a cutting mechanism, the welding gun is fixed on the connecting frame, and the cutting mechanism is connected to the connecting frame. The meshing structures are disposed on welded plates, and after being assembled, the two plates can be restrained by the meshing structures in multiple dimensions. Before welding, edges of the plates are cut according to the form of the meshing structures, then the plates are assembled and meshed; after the position of the welding gun is adjusted, the cutting mechanism and the welding gun are driven by a welding robot or a special welding machine to move along a weld; and the meshing structures are removed by the cutting mechanism, and then normal welding is performed by the welding gun.