Joining Head Alignment Detection for Curved Workpiece Surfaces
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Solution Overview
Problem
Existing joining processes, such as stud welding and drawn arc welding, face challenges in accurately aligning the joining tool with respect to curved workpiece surfaces, leading to potential misalignments and reduced joint quality.
Innovation Solution
A joining device equipped with a detection device integrated into the supporting device, which contacts the workpiece surface, and a control device that automatically corrects the orientation of the joining axis to ensure perpendicular alignment with the workpiece surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual alignment of the joining tool is used, then the device complexity is low, but the manufacturing precision deteriorates on curved surfaces
Solution Approach 1:
The patent replaces manual mechanical alignment with an optical detection system. A detection device with sensors (e.g., laser sensors, cameras) automatically detects the position and orientation of the joining tool relative to the workpiece, substituting human visual and manual adjustment processes with automated optical measurement and control.
Solution Approach 2:
The detection device enables the system to self-align by automatically detecting misalignment and providing feedback for correction. The system performs its own alignment verification and adjustment without requiring external manual intervention, achieving self-service alignment functionality.
2Manufacturing precision
If alignment detection devices are integrated on the joining tool, then the manufacturing precision is improved, but the weight of moving object increases
Solution Approach 1:
The patent employs thin-film sensor technologies and flexible circuit boards to minimize the mass of the detection device. By using thin-film sensors and flexible interconnections, the system achieves accurate alignment detection while keeping the added weight to a minimum, allowing the detection device to be integrated without significantly increasing the joining tool's weight.
3Manufacturing precision
If alignment detection devices are integrated on the joining tool, then the manufacturing precision is improved, but the volume of moving object increases
Solution Approach 1:
The detection device is nested within or integrated into the existing structure of the joining tool. Sensors, processing units, and related components are arranged in a compact, space-efficient manner, utilizing available spaces within the tool housing and integrating detection functionality into existing structural elements rather than adding external bulk.
4Manufacturing precision
If automated alignment correction is implemented, then the manufacturing precision is improved, but the device complexity increases
Solution Approach 1:
The patent implements a feedback control system where the detection device continuously monitors the alignment between the joining tool and workpiece, and the control unit automatically adjusts the tool position based on detected deviations. This closed-loop feedback mechanism maintains precise alignment throughout the joining process, compensating for any drift or misalignment that occurs.
Data Source
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Figure 3
AI summary
Joining method and joining device comprising a joining head having: - a retaining device (16) by which the joining element can be moved along a joining axis toward the workpiece for joining the joining element to on a workpiece surface, - a supporting device (18) adapted to contact against the workpiece, - detection device (28) for determining the relative orientation of the joining axis with regard to the workpiece surface, - a control device (42) which is set up to control the orientation of the joining axis, wherein the detection device is arranged on the supporting device and automatically correct the orientation of the joining axis (x) with regard to the workpiece surface.