Multi-Slot Hot Press Welding Head for Simultaneous Wire Alignment
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Solution Overview
Problem
Existing hot press welding heads can only weld a single wire, resulting in low efficiency and requiring manual alignment, which is time-consuming and laborious.
Innovation Solution
A hot press welding head with a main body featuring multiple positioning slots arranged in a row along its longitudinal direction, allowing for simultaneous positioning of multiple wires, combined with a moving device to automate the alignment process, such as a multi-degree of freedom robot or robotic arm.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a traditional hot press welding head is used to weld a single wire, then the welding process is simple, but the welding efficiency is low
Solution Approach 1:
The welding head is segmented into multiple independent positioning slots, each capable of holding and positioning a wire separately. This allows multiple wires to be welded simultaneously while maintaining the simplicity of individual slot design, thus improving productivity without excessive complexity
Solution Approach 2:
The welding head is designed with multi-functionality to handle multiple wires simultaneously through multiple positioning slots. This universal design enables the same welding head structure to process different numbers of wires (1-6 wires) by adjusting the positioning slots, improving productivity while keeping the base structure relatively simple
2Ease of operation
If manual alignment of the welding head and wire is performed, then the alignment can be adjusted, but the process is time-consuming and laborious
Solution Approach 1:
The positioning slots are designed to enable self-positioning of wires through their geometric features (V-shaped or U-shaped cross-sections). The wires automatically align themselves within the slots during insertion, eliminating the need for manual alignment operations and reducing both time and labor requirements
Solution Approach 2:
The positioning slots are pre-configured with specific geometries (V-shaped or U-shaped cross-sections) that automatically guide and position the wires before welding begins. This preliminary positioning action eliminates the need for subsequent manual alignment adjustments, saving time and simplifying operation
3Productivity
If multiple positioning slots are added to weld multiple wires simultaneously, then welding efficiency increases, but the positioning precision may be compromised
Solution Approach 1:
Each positioning slot is designed with specific local geometric features (V-shaped or U-shaped cross-sections) optimized for precise wire positioning. This local quality ensures that each individual slot maintains high positioning precision for its specific wire, even when multiple slots are present in the same welding head, thus maintaining manufacturing precision while improving productivity
Data Source
AI summary
A hot press welding head includes a main body having a front side surface and a rear side surface opposite to each other in its transverse direction, and a curved bottom surface between bottom edges of the front side surface and the rear side surface. The bottom edge of the front side surface is lower than the bottom edge of the rear side surface in a height direction of the main body. Multiple positioning slots are formed on the curved bottom surface. The multiple positioning slots are arranged in a row along a longitudinal direction of the main body for simultaneously positioning multiple welded wires. The positioning slot extends along the transverse direction of the main body between the front side surface and the rear side surface.