Location Pin Lever Mechanism for Welding Electrode Orientation

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Solution Overview

Problem

Conventional welding assemblies face issues with detecting proper orientation of weld fasteners, leading to destruction of electrodes, fasteners, and tooling, resulting in production delays and rejections due to mis-orientation or incorrect fasteners.

Innovation Solution

An apparatus with a housing, location pin, lever, and sensor system that converts linear motion of the location pin into angular position, using various sensors like limit switches, voltage detectors, and optical sensors to monitor the orientation and presence of the weld part, immune to electromagnetic fields, and adaptable to existing welding assemblies.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If position sensing is added to welding electrodes to detect fastener orientation, then welding reliability is improved, but device complexity increases

Engineering Contradiction:

Improvewelding reliabilityVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces complex electronic position sensing systems with a mechanical lever and limit switch mechanism. The location pin's linear motion is converted to angular lever motion, which actuates a limit switch to detect fastener presence and orientation. This mechanical substitution achieves reliable position detection while avoiding the complexity of electronic sensors in the welding electrode environment.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a lever as an intermediary mechanism between the location pin and the limit switch. The lever converts the linear displacement of the location pin into angular motion that can reliably actuate the limit switch. This intermediary mechanism amplifies and transforms the position signal, enabling reliable detection while keeping the overall system simple and robust.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Measurement precision

If conventional position sensing is used, then fastener orientation can be detected, but the sensing system is vulnerable to electromagnetic interference from welding currents

Engineering Contradiction:

Improvefastener orientation detectionVSAvoidelectromagnetic interference

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The patent replaces electronic position sensing systems that are vulnerable to electromagnetic interference with a purely mechanical detection mechanism. The location pin, lever, and limit switch form a mechanical system that converts fastener position into a mechanical signal (limit switch actuation) that is immune to electromagnetic fields generated during welding operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Measurement precision

If advanced sensors are used for position detection, then measurement precision is improved, but manufacturing cost increases

Engineering Contradiction:

Improveposition detection precisionVSAvoidmanufacturing cost

Core Design Contradiction:

Measurement precisionVSEase of manufacture

Solution Approach 1:

The patent employs inexpensive mechanical components (location pin, lever, limit switch) instead of expensive electronic sensors. These simple mechanical parts are cost-effective to manufacture and replace, achieving reliable position detection without the high cost of advanced electronic sensing systems.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent substitutes expensive electronic position sensors with a simple mechanical detection system using a location pin, lever, and limit switch. This mechanical substitution dramatically reduces component costs while maintaining adequate measurement precision for fastener orientation detection.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 accurate monitoring of weld part orientation and presence, preventing electrode destruction, reducing rejections, and facilitating easy maintenance by integrating low-cost sensors that match the height of conventional electrodes, ensuring proper welding processes.

Implementation Method 1

The lever may be rotatably attached to the housing and configured to convert a linear position of the location pin relative to the housing into an angular position of a shaft relative to the housing

Methodology Applied

Scientific EffectLever mechanism: Lever

Implementation Method 2

incorporate an electrical angle sensor

Methodology Applied

Scientific EffectElectrical angle sensor: Electromagnetic Induction

Implementation Method 3

incorporate an optical angle sensor

Methodology Applied

Scientific EffectOptical angle sensor: Optical Fibre

Data Source

PatentUS9789562B1Position sensing a location pin in a welding electrode

Publication Date: 2017.10.17 NBN INNOVATIONS LLC

AI summary

An apparatus having a housing, a location pin, a lever and a sensor is disclosed. The housing may be configured to receive a weld head. The location pin may be configured to move linearly in the housing in response to a force between the location pin and a part to be welded. The lever may be rotatably attached to the housing and configured to convert a linear position of the location pin relative to the housing into an angular position of a shaft relative to the housing. The sensor may be coupled to the shaft and configured to generate a value representative of the linear position of the location pin by a measurement of the angular position of the shaft.