Modular Resistance Welding Power Supply for Versatile Thermoplastic Welds
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Solution Overview
Problem
Existing thermoplastic welding systems have limited capability and are often only capable of performing one type of weld operation, restricting their versatility in joining thermoplastic parts.
Innovation Solution
A modular resistance welding apparatus with a configurable power supply system, temperature sensors, and a weld controller that allows for multiple configurations and real-time feedback to execute customizable weld routines, enabling a wide range of welds by adjusting current, voltage, and internal resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If existing thermoplastic welding systems are designed for a single weld operation, then the device complexity is reduced and ease of manufacture is improved, but the adaptability and versatility are significantly limited
Solution Approach 1:
The patent implements a universal welding system that can perform multiple weld operations (protrusion welds, insert welds, recess welds, and welds with heating elements) using a single apparatus. The system achieves multi-functionality through configurable power supply connections and interchangeable tooling, allowing one device to replace multiple specialized welding systems.
Solution Approach 2:
The welding system is divided into modular components including separate power supply units, interchangeable heating elements, and configurable connection leads. This segmentation allows flexible reconfiguration of the system for different weld types without requiring complete system replacement, thereby improving versatility while managing complexity through modularity.
2Adaptability or versatility
If a modular power supply system with multiple configurations is implemented, then the adaptability and versatility are improved, but the device complexity and ease of operation increase
Solution Approach 1:
The system employs dynamic reconfiguration capabilities where the power supply connections can be adjusted between series and parallel configurations depending on the specific weld requirements. The heating elements and leads can be dynamically connected or disconnected to match the desired weld operation, allowing the system to adapt its electrical configuration in real-time.
Solution Approach 2:
The system incorporates temperature sensors that provide feedback during welding operations, allowing the controller to monitor and adjust the welding process parameters. This feedback mechanism simplifies operation by automatically optimizing weld parameters based on real-time temperature data, reducing the burden on the operator to manually configure all parameters.
3Power
If multiple power supply modules are connected in series or parallel, then the power output and welding capability are improved, but the device complexity and loss of time for configuration increase
Solution Approach 1:
The system is designed with pre-configured connection schemes where the leads and power supply modules are prepared in advance for specific weld types. The modular design allows operators to quickly connect pre-assembled units without performing complex wiring configurations during operation, thereby reducing configuration time while maintaining high power output capabilities.
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 apparatus provides a flexible and efficient method for welding thermoplastic parts by allowing multiple configurations and real-time control, enhancing the capability to perform various welds with precision and consistency.
Implementation Method 1
passing an electric current through an electrically resistive heating element placed between two substrates to generate localized heat at the interface
Implementation Method 2
sacrificial temperature sensors that may be disposed at the interface of the thermoplastic parts while they are being welded together to output a temperature signal representative of temperature of the weld interface
Data Source
AI summary
A resistance welding apparatus can employ a modular power supply system with multiple power supply modules and leads for electrically connecting the modular power supply system to a welding resistor. The resistance welding apparatus is selectively configurable in at least three of (i) a first configuration in which the leads connect the first power supply module to the resistor and the second power supply module is disconnected from the resistor; (ii) a second configuration in which the leads connect the second power supply module to the resistor and the first power supply module is disconnected from the resistor; (iii) a third configuration in which the leads connect the first and second power supply modules to the resistor in series; and (iv) a fourth configuration in which the leads connect the first and second power supply modules to the resistor in parallel.