Magnetic Ring Positioning for Laser-Welded Strut Assemblies
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Solution Overview
Problem
Existing methods for welding lattice-shaped structures, such as wire mesh products, require high-cost, type-specific devices and are labor-intensive due to complex manual insertion of rings and limited adaptability to various geometries, especially when using laser welding for wire-shaped parts with punctiform or short linear contact.
Innovation Solution
A device and method utilizing a spreading mechanism with magnetic force to precisely position rings on struts, combined with laser welding that directs the beam through the upper part to focus on the joint, ensuring efficient and adaptable welding with reduced manual effort and device complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If resistance or capacitor discharge welding is used for lattice-shaped structures, then welding strength is achieved, but device complexity and manufacturing cost increase due to type-specific welding devices
Solution Approach 1:
The patent employs a universal holding device with magnetic strips that can accommodate rings of various geometries and sizes through a single standardized design. The magnetic holding mechanism provides a general-purpose solution that eliminates the need for multiple type-specific welding devices, thereby reducing device complexity while maintaining welding strength through laser welding.
Solution Approach 2:
The patent replaces complex mechanical welding devices with a laser welding system combined with a simple magnetic holding device. The laser beam provides the welding function without requiring complex mechanical pressure application mechanisms, while the magnetic strips provide positioning without complex mechanical clamping systems, thereby reducing overall device complexity.
2Adaptability or versatility
If laser welding is used for wire-shaped parts with punctiform contact, then adaptability to various geometries is improved, but manual insertion of rings becomes labor-intensive and time-consuming
Solution Approach 1:
The patent implements a spreading mechanism that automatically positions and spreads multiple rings onto the holding device in a predetermined arrangement before welding begins. This preliminary action eliminates the need for manual insertion of each ring individually, significantly reducing insertion time while maintaining the adaptability to handle various ring geometries through the standardized magnetic holding structure.
Solution Approach 2:
The magnetic strips on the holding device automatically hold and position the rings in place without requiring manual intervention during the positioning process. The rings are attracted and secured by the magnetic force, enabling the system to service itself by automatically maintaining ring positions during the welding operation, thereby reducing labor-intensive manual insertion.
3Manufacturing precision
If complex manual insertion methods are used for rings, then positioning precision is achieved, but productivity decreases due to labor-intensive processes
Solution Approach 1:
The patent replaces complex mechanical positioning and insertion mechanisms with a laser welding system combined with magnetic holding. The laser provides precise welding at the point of contact without requiring complex mechanical positioning, while the magnetic strips provide sufficient holding force and basic positioning, thereby maintaining manufacturing precision while dramatically improving productivity through automation.
Solution Approach 2:
The universal magnetic holding device with standardized strips can handle various ring types and sizes through a single design, eliminating the need for multiple specialized positioning devices. This universality maintains positioning precision across different geometries while improving productivity by reducing the complexity and time required for setup and operation.
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
Significantly simplifies the insertion and positioning of rings, reduces welding time, and achieves high-quality connections with lower repositioning forces, allowing for efficient production of wire-shaped parts with varied geometries using laser welding technology.
Implementation Method 1
a positioning device having at least one radially arranged magnetic strip for positioning the at least one ring on the at least one strut
Implementation Method 2
a laser beam is used
Data Source
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AI summary
A device (14) for transferring at least one ring into a holding device (21), a holding device (21) for at least one ring to be fixed to at least one strut and a method for positioning at least one ring on at least one strut are proposed, in which a time-consuming manual insertion of the rings into a device (holding device (21)) is significantly simplified and thereby also shortened in time and a position-accurate arrangement of a ring on a strut, which is supported by magnetic force, is made possible.