Modular Spot Welding Tip Inspection Apparatus with Detachable Camera
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Solution Overview
Problem
Existing welding tip inspection apparatuses for spot welding guns are cumbersome to maintain and repair, particularly when replacing camera modules, and are prone to contamination from impurities on mirrors, leading to inaccurate image analysis.
Innovation Solution
A modular apparatus with a detachable camera module connection unit, light transmission portions, and a protective casing that prevents impurities from reaching the camera module, allowing for swift and clean replacement and inspection of welding tips.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the inspection apparatus is provided as a combined single package with fixed camera modules, then the structural integrity is maintained, but the ease of repair and camera module replacement deteriorates
Solution Approach 1:
The inspection apparatus is divided into separable modules: a housing containing the camera module connection unit, and a detachable camera module assembly. This segmentation allows the camera module to be replaced independently without disassembling the entire apparatus, resolving the contradiction between ease of repair and structural integrity.
Solution Approach 2:
The camera module connection unit is designed with detachable connections that allow dynamic reconfiguration. The camera module can be quickly connected and disconnected from the housing, enabling rapid replacement while maintaining a relatively simple overall apparatus structure when assembled.
2Reliability
If mirrors are provided between camera modules to face welding tips, then the inspection coverage is improved, but the reliability deteriorates due to impurity contamination on mirror surfaces
Solution Approach 1:
The mirror component is completely removed from the inspection apparatus. Instead of using mirrors to reflect images from welding tips, the design employs direct optical paths from the welding tip through the pressure plate to the camera module, eliminating the source of contamination-related reliability issues while maintaining inspection capability.
Solution Approach 2:
A protective casing is introduced as an intermediary component between the welding tip inspection area and the camera module. This protective casing prevents impurities from reaching the camera module while allowing optical information to pass through, resolving the contamination issue without sacrificing inspection reliability.
3Ease of operation
If the inspection apparatus uses a fixed integrated design, then the manufacturing precision is maintained, but the ease of operation for maintenance deteriorates
Solution Approach 1:
The apparatus is segmented into modular components with standardized connection interfaces. The camera module assembly can be detached and replaced as a unit, making maintenance operations simple while the precision is maintained through carefully designed mating features and alignment mechanisms at the connection points.
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
Enables convenient and accurate inspection of welding tips by allowing easy replacement of camera modules and preventing contamination, ensuring reliable contamination level analysis and extending the apparatus's operational lifespan.
Implementation Method 1
a first light transmission portion through which a light reflected from the welding tip to be inspected is transmitted
Implementation Method 2
a second light transmission portion through which the light reflected from the welding tip is transmitted that has been emitted from the light source for a camera lighting
Data Source
AI summary
Description according to the present disclosure relates to an apparatus for inspecting a welding tip of a spot welding gun, and more particularly, to an apparatus for inspecting a welding tip of a spot welding gun, the apparatus enabling a user to replace a camera module swiftly and conveniently.