Magnet Projection Welding Electrode Cooling to Prevent Demagnetization
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Solution Overview
Problem
Water-cooled electrodes experience insufficient cooling and temperature demagnetization of permanent magnets due to low water pressure and flow rate, leading to overheating and reduced attractive force, as the existing designs with thin heat insulating guide sleeves and large cooling water passage areas result in stagnant water regions and increased heat transfer to the magnets.
Innovation Solution
A magnet-equipped projection welding electrode with a cylindrical metal main body, a heat insulating guide sleeve having minor and major diameter holes, an annular cooling water passage, and a magnetic force transmission member, where the depth of the cooling water passage is set smaller than the thickness of the heat insulating portion to promote turbulent water flow and reduce heat transfer to the permanent magnet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the cooling water passage has a large sectional area, then the cooling capacity is improved, but the water pressure and flow rate become insufficient resulting in stagnant portions
Solution Approach 1:
The patent applies the dynamics principle by designing the cooling water passage to transition from laminar flow to turbulent flow. The passage cross-sectional area varies along the flow direction, being smaller at the inlet and larger at the outlet, which dynamically adapts the flow characteristics to maintain turbulent flow throughout the passage even with limited water supply, preventing stagnant portions while ensuring adequate cooling capacity.
2Device complexity
If the heat insulating guide sleeve has a thin wall, then the structural complexity is reduced, but the permanent magnet experiences temperature demagnetization
Solution Approach 1:
The patent applies the local quality principle by providing heat insulating portions only in specific locations where the permanent magnet is positioned, rather than insulating the entire guide sleeve. The heat insulating guide sleeve has heat insulating portions at locations corresponding to the permanent magnet positions, which locally reduces heat transfer to the magnet while maintaining overall structural simplicity.
3Temperature
If the cooling water passage has a large volume, then the cooling efficiency is improved, but the water pressure decreases due to the narrow and complicatedly bent water passage
Solution Approach 1:
The patent applies the dynamics principle by designing the cooling water passage to transition from laminar flow to turbulent flow. The passage cross-sectional area varies along the flow direction, being smaller at the inlet and larger at the outlet, which dynamically adapts the flow characteristics to maintain turbulent flow throughout the passage even with limited water supply, preventing stagnant portions while ensuring adequate cooling capacity.
Solution Approach 2:
The patent applies the parameter changes principle by varying the cross-sectional area parameter of the cooling water passage along the flow direction. The passage has a smaller cross-sectional area at the inlet and a larger cross-sectional area at the outlet, which changes the flow parameters to promote turbulent flow and improve cooling efficiency while managing water pressure constraints.
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
This configuration enhances cooling efficiency by ensuring turbulent water flow over the entire passage, preventing overheating and demagnetization of the permanent magnet, maintaining a strong attractive force even under conditions of low water pressure or flow rate, and improving the durability of the magnet.
Implementation Method 1
the depth dimension of the cooling water passage as viewed in the diameter direction of the main body is set to be smaller than a thickness dimension of the heat insulating portion... ensuring turbulent water flow over the entire passage
Implementation Method 2
a heat insulating guide sleeve made of an insulation material... reduce heat transfer to the permanent magnet
Implementation Method 3
a permanent magnet disposed in the heat insulating guide sleeve... maintaining a strong attractive force
Data Source
Figure 1
Figure 2~3B
Figure 4A1~5
AI summary
A main body made of metal and an end cover made of metal are provided. A major diameter hole and a minor diameter hole that communicates with the through hole of the end cover are provided in a heat insulating guide sleeve made of an insulation material and inserted into the main body. A cooling water passage having an annular shape is formed in the heat insulating guide sleeve. A portion of the heat insulating guide sleeve located at an inner side of the cooling water passage serves as a heat insulating portion. A container of a permanent magnet is slidably inserted into the heat insulating portion. A magnetic force transmission member is slidably inserted into the minor diameter hole. The permanent magnet, the heat insulating portion, and the cooling water passage are arranged in a diameter direction of the main body. A depth dimension of the cooling water passage is set to be smaller than a thickness dimension of the heat insulating portion.