Mirror-Image Electrode Capsule Feeding Apparatus
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Solution Overview
Problem
Current electrode capsule feeding apparatuses for resistance spot-welding require lengthy assembly times, risk accidental capsule fall, and cannot close the welding gripper around capsules within the apparatus without damaging components, leading to coolant leakage and inefficient operations.
Innovation Solution
A feeding apparatus with two mirror-image withdrawal stations, guide ducts, prechambers, and pneumatic connections allows for simultaneous engagement of new electrode capsules on the gripper, reducing robot movement and eliminating the need for separate sensor detection, while maintaining a compact design and preventing coolant leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the welding gripper is moved to remote positions between capsule changes, then capsule replacement can be performed, but assembly time increases and productivity decreases
Solution Approach 1:
The patent combines both withdrawal stations into a single feeding apparatus structure, allowing the gripper to access both stations without moving to remote positions. The mirror-image arrangement enables simultaneous engagement of capsules from both stations, merging the replacement operations into one stationary location and significantly reducing assembly time.
Solution Approach 2:
The electrode capsules are pre-positioned in the guide ducts and prechambers before the gripper arrives. The retractable stop elements are pre-configured to release capsules at the appropriate moment, eliminating the need for the gripper to move to remote positions to retrieve capsules, thus reducing assembly time while maintaining replacement accuracy.
2Productivity
If the gripper closes around capsules within the apparatus, then assembly time is reduced, but components may be damaged and coolant may leak
Solution Approach 1:
The retractable stop elements are pre-positioned to release the electrode capsules from the prechambers into the withdrawal stations before the gripper closes. This preliminary action ensures that capsules are properly seated and secured in the withdrawal stations, allowing the gripper to close safely without damaging components or causing coolant leakage, while still enabling time-efficient assembly.
Solution Approach 2:
The withdrawal stations act as intermediary structures between the guide ducts and the gripper. They provide a controlled environment where capsules are released and positioned before the gripper engages them, mediating the interaction to prevent damage to components and ensure proper capsule placement, thus maintaining reliability while improving productivity.
3Reliability
If separate sensor detection is used for capsule engagement, then capsule placement can be verified, but device complexity and operation time increase
Solution Approach 1:
The feeding apparatus is designed to provide visual indication of capsule engagement through the transparent or translucent casing. The structure itself serves the verification function by allowing direct observation of capsule placement, eliminating the need for separate sensor detection systems. This self-service approach maintains reliability while reducing device complexity and operation time.
Solution Approach 2:
The transparent or translucent casing enables visual verification of capsule engagement by allowing operators to observe the capsules directly. This optical indication method replaces complex sensor systems, maintaining reliable verification while simplifying the device structure and reducing operational complexity.
4Ease of operation
If gravity feeding with vertical cartridge units is used, then capsule delivery is simple, but apparatus volume increases and collision risk increases
Solution Approach 1:
The patent transitions from vertical gravity feeding to horizontal pneumatic feeding. The guide ducts are arranged horizontally with inlet ends at one end and outlet ends at the other, allowing capsules to be delivered along the horizontal dimension using pneumatic pressure. This dimensional change reduces the vertical space required and minimizes the apparatus volume while maintaining simple capsule delivery operation.
Solution Approach 2:
The patent uses pneumatic pressure delivered through the guide ducts to move electrode capsules from the inlet ends to the outlet ends. This pneumatic mechanism replaces gravity-based vertical feeding, enabling compact horizontal arrangement of the apparatus while maintaining reliable capsule delivery. The pneumatic system reduces apparatus volume and minimizes collision risk with robot arms and sheet metal parts.
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 solution significantly reduces assembly time, ensures stable capsule placement, increases loading capacity, and minimizes coolant leakage by allowing the gripper to close around new capsules within the apparatus, enhancing operational efficiency and safety.
Implementation Method 1
two pneumatic connections (30a, 30b) are connected to two guide ducts (16a, 16b) in the proximity of the respective inlet ends, so as to introduce selectively and independently separate compressed-gas flows into either one of the guide ducts so that the compressed-gas flows directly push the electrode capsules contained in the chosen guide duct and cause it to advance towards the respective withdrawal station
Data Source
AI summary
Devices which shorten the time needed for the assembly of electrode capsules on welding grippers are provided. Such devices may have two stations for withdrawal of electrode capsules. The withdrawal stations may have a mirror-image arrangement with respect to a given intermediate plane and may be situated in a peripheral zone of the apparatus. Two guide ducts may house two respective rows of electrode capsules. Two prechambers can be provided, each one being arranged between the associated withdrawal station and an outlet end of the associated guide duct. A retractable stop pin may be mounted between each prechamber and the associated withdrawal station, said pin, when extracted, blocking an electrode capsule inside the withdrawal station. To transfer an electrode capsule from the prechamber to the associated withdrawal station, the apparatus may be provided with two positioning devices which can be selectively operated in order to accomplish this.