Multi-Head Resistance Welding Tool for Parallel Element Setting
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Solution Overview
Problem
The existing methods for setting resistance welding elements in flat workpieces, particularly in the automotive sector, are inefficient due to serial setting processes that require individual approach and swiveling of setting heads, leading to disadvantages such as increased production time and logistics effort.
Innovation Solution
A press-connected tool with multiple setting heads in both tool parts allows for simultaneous punching or pressing of resistance welding elements into a flat workpiece from both sides without pre-holes, using a closing movement to fix the workpiece and apply precise forces, enabling parallel setting of numerous elements within a single stroke.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If serial setting process with robot-guided setting head is used, then individual setting points can be approached, but production time increases and logistics effort increases
Solution Approach 1:
Multiple setting heads are merged into a single tool, allowing simultaneous setting of multiple resistance welding elements. The tool combines several setting heads arranged in different positions and orientations, enabling parallel processing that eliminates the serial approach and significantly reduces production time while maintaining the capability to reach individual setting points.
Solution Approach 2:
The invention transitions from a single-point serial setting approach to a multi-point parallel setting by adding spatial dimensions. Multiple setting heads are arranged in three-dimensional space with different positions and orientations, allowing simultaneous access to multiple setting points on the workpiece without requiring tool movement between points.
2Adaptability or versatility
If setting head must swivel around workpiece to access both sides, then both sides can be set, but device complexity increases
Solution Approach 1:
The tool is segmented into multiple independent setting heads, each capable of being actuated separately. This segmentation allows each setting head to be positioned and oriented optimally for its specific setting point, eliminating the need for a single setting head to swivel and reposition itself for accessing different sides of the workpiece.
Solution Approach 2:
The tool incorporates dynamic actuation mechanisms that allow setting heads to be activated in different sequences and with different forces. This dynamic control enables selective setting of resistance welding elements on different sides of the workpiece without requiring physical swiveling of the entire setting head assembly.
Data Source
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AI summary
The invention relates to a tool (1) for setting a plurality of resistance welding elements into at least one planar workpiece (4), comprising a first tool part (2) and a second tool part (3), between which substantially the entire area of the workpiece (4) can be arranged and between which the workpiece can be fixed in a defined position by means of a closing motion (D) of the first and/or of the second tool part (2, 3); and comprising a plurality of setting heads (25, 35) arranged both in the first tool part (2) and in the second tool part (3), by means of which a plurality of resistance welding elements can be punched or pressed into the fixed workpiece (4) from both workpiece sides without pre-holes in the course of the closing motion (D). The invention further relates to preferred uses of such a tool (1).