Modular Induction Welding Fixture with Adjustable Support Structures
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Solution Overview
Problem
Existing induction welding fixtures are expensive and tedious to set up, requiring multiple fixtures or multi-station setups for welding multiple joints, which limits their versatility and efficiency.
Innovation Solution
A modular induction welding system with adjustable bottom and top support structures, heat sinks, and actuators that can accommodate various workpiece configurations and geometries, allowing for secure positioning and efficient welding of multiple joints with a single fixture setup.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple fixtures or multi-station setups are used to weld multiple joints, then welding capability is improved, but device complexity and cost increase
Solution Approach 1:
The fixture is designed with multiple adjustable support structures (first and second support structures with adjustable positions) and multiple induction coils (first and second induction coils) that can be configured to weld different joints on the workpiece. This single fixture can perform multiple welding operations at different locations, eliminating the need for multiple separate fixtures or complex multi-station setups.
Solution Approach 2:
The fixture is divided into modular components including adjustable support structures, removable spacers, and separate induction coils. These segmented elements can be independently positioned and configured to accommodate different workpiece geometries and welding requirements, providing versatility without increasing overall system complexity.
2Adaptability or versatility
If multiple fixtures or multi-station setups are used to weld multiple joints, then welding capability is improved, but manufacturing cost increases
Solution Approach 1:
By designing a single fixture that can weld multiple joints through adjustable support structures and multiple induction coils, the invention eliminates the need to manufacture and maintain multiple separate fixtures. This reduces manufacturing costs while maintaining the capability to weld various joints on the workpiece.
3Device complexity
If a single fixture is used for multiple joints, then device complexity is reduced, but adaptability to different workpiece configurations decreases
Solution Approach 1:
The fixture incorporates adjustable support structures that can be repositioned along the workpiece, and removable spacers that can be exchanged to accommodate different workpiece thicknesses and geometries. This dynamic adjustability allows a single simple fixture to adapt to various workpiece configurations without increasing inherent system complexity.
Solution Approach 2:
The fixture uses modular, independently adjustable components including support structures, spacers, and induction coils that can be configured in different positions and combinations to suit different workpiece configurations, maintaining simplicity while providing adaptability.
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
The system enables flexible and efficient induction welding of multiple joints on different workpiece configurations without the need for multiple fixtures, reducing setup time and costs while maintaining consistent weld quality.
Implementation Method 1
an induction welding coil arranged in a channel between the first and second beams
Implementation Method 2
induction welding a workpiece
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
An assembly (20) is provided for induction welding. This induction welding assembly (20) includes a fixture (26). The fixture (26) includes a first support structure (48) and a second support structure (50). The second support structure (50) includes a frame (118A, 118B) and a plurality of trunks (100). Each of the trunks (100) is connected to and repositionable on the frame (118A, 118B). The fixture (26) is configured to secure a workpiece (22) vertically between the first support structure (48) and the second support structure (50) using the trunks (100) during induction welding of the workpiece (22).