Projection Nut Feed Rod Structure for Full-Stroke Foreign Object Detection
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Solution Overview
Problem
Existing projection nut feeding devices do not provide comprehensive safety measures at all points in the entire stroke range of the feed rod, particularly when the advance and retraction length is set by an advance and retraction type electric motor, risking injury from foreign objects like hands or tools.
Innovation Solution
A projection nut feeding device with a guide rod inserted into a hollow main rod, equipped with a compression coil spring, an advance and retraction type electric motor, and a detection system that includes an extension member and sensor, allowing for detection of foreign objects at arbitrary positions along the feed rod's stroke.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the advance and retraction length of the feed rod is set to be long, then the feed rod can reach distant welding positions, but the detection distance between the detection object member and sensor becomes insufficient, compromising safety detection capability
Solution Approach 1:
The feed rod is segmented into a main rod and a guide rod that can move independently within it. The guide rod is further divided into a detection portion with the detection object member and an extension portion. This segmentation allows the detection portion to maintain a fixed detection distance from the sensor while the extension portion provides the necessary long reach for distant welding positions.
Solution Approach 2:
The guide rod is nested within the hollow main rod, allowing the guide rod to slide in and out of the main rod. This nested structure enables the detection object member on the guide rod to maintain a consistent detection distance from the sensor mounted on the main rod, while the overall feed rod assembly can achieve long advance and retraction lengths.
2Ease of manufacture
If the feed rod structure is simplified, then manufacturing cost is reduced, but safety detection capability for foreign objects throughout the entire stroke range is compromised
Solution Approach 1:
The feed rod is divided into functional segments: the main rod providing structural support and housing, the guide rod providing detection capability, and the extension portion providing reach. This segmentation allows each component to be manufactured separately and assembled, maintaining ease of manufacture while achieving comprehensive safety detection throughout the entire stroke range.
Solution Approach 2:
The guide rod serves multiple functions: it acts as a structural component of the feed rod, provides the detection surface for foreign object detection, and its movement within the main rod enables the detection system to monitor the entire stroke range. This multi-functionality reduces the need for additional separate components, maintaining manufacturing simplicity.
3Device complexity
If the sensor is fixed at a specific position, then the device structure is simplified, but the detection system cannot adapt to arbitrary advance stop positions set by the electric motor
Solution Approach 1:
The guide rod is nested within the hollow main rod and can slide freely along its length. The detection object member is attached to the guide rod, while the sensor is mounted on the main rod at a fixed position. As the guide rod moves in and out of the main rod during feed rod advancement and retraction, the detection object member passes by the fixed sensor, enabling detection at any position in the stroke range without requiring the sensor to move or be repositioned.
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
Ensures reliable detection and prevention of injuries by prohibiting electrode advancement when foreign objects are caught, enabling flexible and accurate setting of feed rod lengths, even for long strokes, without impairing detection performance.
Implementation Method 1
a compression coil spring that applies elastic force, in an extrusion direction, to the guide rod is disposed in the main rod
Data Source
AI summary
A feed rod 7 configured with a hollow main rod 20 and a guide rod 21 put in the main rod 20. An advance and retraction type electric motor 33 is provided which outputs in the same direction as the feed rod 7 and can set an advance stop position of the feed rod 7 at an arbitrary position. An extension member 42 extending in the direction opposite to an advance direction of the main rod 20 is formed, and a detection object member 48 to be detected by a sensor 51 is attached to the extension member 42. The fixing structure of the sensor 51 is configured such that the sensor 51 can be fixed at an arbitrary position on a long stationary member 53 or 62 disposed along the advance and retraction operation direction of the feed rod 7.