Monolithic Welding Gun Power Module With Integrated Transformer Cooling
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Solution Overview
Problem
Conventional power source modules for welding guns are complex, prone to errors, and inefficient due to multiple components and energy-intensive pneumatic/hydraulic drives, with poor heat dissipation and increased installation space requirements.
Innovation Solution
A monolithic power source module with a single, integral base body featuring an immovable fastening means for the first joining tool, a linearly movable actuator for the second tool, and a transformer unit integrated within the base body for efficient heat dissipation and reduced component complexity, along with integrated cooling channels for effective thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple separate components and support plates are used in conventional power source modules, then components can be arranged flexibly, but the device complexity and number of components increase significantly
Solution Approach 1:
The patent merges multiple separate support plates and components into a single monolithic base body. The base body integrates fixed fastening elements, movable fastening elements, and receiving spaces for the transformer unit, eliminating the need for multiple separate support structures and reducing overall device complexity while maintaining functional flexibility.
Solution Approach 2:
The monolithic base body serves multiple functions simultaneously: it provides structural support, contains integrated fastening elements for both fixed and movable tools, creates receiving spaces for the transformer unit, and offers mounting surfaces for various components. This multi-functionality reduces the need for separate specialized components.
2Ease of operation
If pneumatic or hydraulic drive systems are used for the actuator, then linear movement is achieved, but energy consumption increases
Solution Approach 1:
The patent replaces pneumatic or hydraulic drive systems with an electric motor-driven actuator. The actuator includes an electric motor that directly drives the linear movement of the movable fastening element, eliminating the need for compressed air or hydraulic fluid systems and significantly reducing energy consumption while maintaining operational effectiveness.
3Ease of operation
If components are arranged exposed on support elements, then accessibility is improved, but heat dissipation becomes inefficient and additional protective housings are required
Solution Approach 1:
The patent nests the transformer unit and other components within receiving spaces formed in the monolithic base body. The base body acts as a protective housing that encloses these components, providing thermal management through integrated cooling channels while maintaining accessibility through strategically placed openings and access points.
Solution Approach 2:
The base body incorporates localized cooling channels and thermal management features specifically at the locations where the transformer unit and other heat-generating components are housed. This targeted approach improves heat dissipation efficiency without compromising the overall accessibility of components that require frequent access.
4Adaptability or versatility
If conventional multi-component power source modules are used, then functional requirements are met, but assembly and conversion become complex and time-consuming
Solution Approach 1:
The patent combines multiple components that would traditionally require separate assembly into a single monolithic base body. The integrated structure includes pre-formed receiving spaces, fastening elements, and mounting surfaces, eliminating the need for complex assembly operations and reducing the potential for assembly errors.
Solution Approach 2:
The base body is manufactured as a complete, integrated structure with all necessary features (receiving spaces, fastening elements, cooling channels) already incorporated during the monolithic manufacturing process. This preliminary integration of functions simplifies subsequent assembly steps and enables easier conversion between different welding gun configurations.
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 solution simplifies handling and assembly, reduces the risk of errors, enhances heat dissipation, and minimizes energy consumption by integrating components and cooling channels within the base body, resulting in a more efficient and user-friendly welding gun design.
Implementation Method 1
a transformer unit (14) for supplying electrical power to the joining tool (5, 50) is arranged in the first or a further receiving space (8, 9)
Implementation Method 2
The base body can be configured, particularly advantageously, to provide separate receiving compartments for different components... heat conduction can occur via the base body itself, so that heat generated, for example, by the transformer unit, can be dissipated more quickly from the receiving space
Data Source
Figure 1
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Figure 4~5
AI summary
The present invention relates to a power source module (1) for joining processes with electrically generated heat support, in particular for welding guns (58), comprising a monolithic, one-piece base body (2) which forms a first fixed fastening element for connecting a first joining tool and at least one first receiving space (8). In the first receiving space (8) an actuator with a linearly movable second fastening element (10) for connecting to a second joining tool is arranged, and in the first or a further receiving space a transformer unit (14) for supplying electrical power to the joining tool is arranged.Furthermore, the invention relates to a welding gun (58) in particular for electric spot welding, comprising such a power source module (1) and a first joining tool designed as a stationary electrode arm (6), and a second joining tool designed as a movable electrode arm, wherein the stationary electrode arm is connected to the first fastening means and the movable electrode arm is connected to the second linearly movable fastening means, wherein the electrode arms have electrodes (62) electrically connected to the transformer.