Multi-Point Projection Welding for Car-Body Assembly Distortion Control
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Solution Overview
Problem
Current vehicle body assembly processes require multiple separate apparatuses for loading and welding components, leading to inefficiencies, distortion of the vehicle body during spot welding, and the need for numerous pre-set assembly jigs for different vehicle types, making the process cumbersome and prone to interference.
Innovation Solution
A multi-point projection welding method and system that integrates a picking apparatus, aligning apparatus, gripping apparatus, pressurizing apparatus, and projection welding apparatus to load and weld components using protrusions on the panels, allowing simultaneous welding of multiple points with adjustable pressure and current, reducing the need for multiple jigs and minimizing distortion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate multi-step apparatuses are used for loading and welding components, then each process can be performed with dedicated equipment, but the device complexity increases and the production line becomes cumbersome
Solution Approach 1:
The patent combines the loading apparatus and welding apparatus into a single integrated apparatus. The loading unit positions components on the vehicle body, and the welding unit performs welding at the same position, eliminating the need for separate multi-step apparatuses while maintaining dedicated functionality for each process
Solution Approach 2:
The integrated apparatus performs multiple functions: the loading unit handles component positioning and alignment, the welding unit performs spot welding, and the system can adapt to different vehicle types through programmable control, reducing the need for multiple specialized apparatuses
2Manufacturing precision
If pre-set assembly jigs are prepared for every component and vehicle type, then component positioning accuracy is improved, but the ease of operation deteriorates due to the need to change jigs according to vehicle type
Solution Approach 1:
The patent replaces mechanical pre-set assembly jigs with a loading unit that uses sensors and programmable control systems to detect and position components. The control unit stores position information for different vehicle types and automatically adjusts positioning parameters, eliminating the need for physical jig changes
Solution Approach 2:
The system changes operational parameters (positioning coordinates, welding parameters) based on detected vehicle type rather than changing physical jigs. The control unit receives vehicle type information and adjusts positioning parameters accordingly, maintaining precision while improving ease of operation
3Strength
If one corresponding point of two panels is pressurized during spot welding, then welding is performed at that point, but the vehicle body becomes distorted
Solution Approach 1:
The patent segments the welding process into multiple welding points distributed across the component rather than concentrating pressure at one point. The welding unit performs spot welding at multiple locations, distributing the thermal and mechanical stress to prevent localized distortion while maintaining overall welding strength
Solution Approach 2:
The system applies welding pressure and heat at multiple points rather than excessive pressure at a single point. By distributing the welding action across multiple locations, the total force and heat input are managed to prevent distortion while achieving sufficient welding strength at each point
4Stability of the object's composition
If multiple clamping jigs are used to secure components, then component positioning is maintained, but concentration welding is hindered
Solution Approach 1:
The patent combines the clamping function into the loading unit that is integrated with the welding unit. The loading unit positions and secures components using a coordinated system that maintains stability while allowing the welding unit to access welding points without interference from separate clamping devices
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 system simplifies the assembly process by integrating multiple functions into one apparatus, reducing the number of equipment and steps, preventing vehicle body distortion, and enabling flexible adaptation to different vehicle types and complex structures, while maintaining high welding strength and efficiency.
Implementation Method 1
supplying current to the vehicle body pressurizing tip and the component pressurizing tip such that the protrusion of the component panel contacts the vehicle body panel while the vehicle body pressurizing tip and the component pressurizing tip apply pressure to the vehicle body panel and the component panel, respectively
Implementation Method 2
applying pressure to the vehicle body panel using a vehicle body pressurizing tip and applying pressure to the component panel using a component pressurizing tip
Data Source
AI summary
A component loading-welding system for welding a component panel to a vehicle body panel includes a rotation portion body having first and second opposing sides. The first opposing side is coupled to a robot arm. A picking device is installed in the rotation portion body and is configured to hold and release the component panel. A vehicle body pressurizing tip is installed in the rotation portion body. A pressurizing portion body is rotatably installed at the second opposing side of the rotation portion body. A pin clamp is installed in the pressurizing portion body and is configured to clamp the component panel. A component pressurizing tip is installed in the pressurizing portion body and is configured to apply pressure to the component panel. A multi point projection welding method is also disclosed.