One-Side Spot Welding Device for Closed Cross Sections
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Solution Overview
Problem
Vehicle body panels with closed cross sections pose a challenge for bidirectional spot welding due to restricted access, leading to difficulties in applying sufficient pressing force and deforming panels during one-side spot welding.
Innovation Solution
A one-side spot welding device featuring a cylindrical base with a push rod and sliding welding head, capable of radial movement, and a cylindrical welding tip with pneumatic pressure control, allowing for precise application of pressing force and electric current to form electrical resistance and heat for welding, while the shape of the welding heads and tips can be adjusted to change the nugget shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If one-side spot welding is used to weld panels with closed cross sections, then welding accessibility is improved, but panel deformation increases due to insufficient pressing force distribution
Solution Approach 1:
The welding head is divided into multiple unit welding heads (typically 3) arranged circumferentially around the push rod. Each unit welding head can be independently spaced apart radially to contact the panel, distributing the pressing force across multiple contact points. This segmentation allows one-side spot welding to access closed cross-section panels while reducing deformation through force distribution.
Solution Approach 2:
The unit welding heads are arranged in a circumferential direction around the push rod, creating a three-dimensional configuration. When spaced apart, they form a radial arrangement that enables contact with panels from multiple angular positions, effectively adding a circumferential dimension to the pressing force application and improving both accessibility and force distribution.
2Stability of the object's composition
If multiple unit welding heads are spaced apart radially, then pressing force distribution is improved, but device complexity increases due to additional moving parts
Solution Approach 1:
Multiple unit welding heads are integrated onto a single welding head structure that rotates or expands radially around a central push rod. The cam mechanism combines the radial spacing function with the welding head structure itself, eliminating the need for separate actuating mechanisms for each unit head. This merging reduces overall device complexity while maintaining multiple contact points.
Solution Approach 2:
The cam mechanism automatically converts the axial motion of the push rod into radial spacing of the unit welding heads through its geometric profile. The unit welding heads with cam surfaces interact with the cam driving surface to self-generate the radial spacing motion, eliminating the need for external actuators or complex control systems for each head.
3Force
If cam mechanism is used to space unit welding heads radially, then pressing force application is improved, but manufacturing complexity increases due to cam surface precision requirements
Solution Approach 1:
A pneumatic cylinder is used to drive the push rod axially, providing controlled and adjustable pressing force. The pneumatic system allows for easy adjustment of force magnitude through pressure control, and the cylindrical design integrates smoothly with the radial expansion mechanism. The cam surfaces are designed with standard geometric profiles that can be manufactured using conventional machining processes.
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
This solution enhances workability and quality of welding for panels with closed cross sections, improving marketability and allowing the use of existing spot welding guns to reduce costs.
Implementation Method 1
forming electrical resistance by applying electric current
Implementation Method 2
using welding heat produced by the electrical resistance
Implementation Method 3
The push rod and the welding tip may be capable of moving in an upward and a downward direction by operation of a cylinder disposed at a lower side thereof
Data Source
AI summary
A one-side spot welding device includes a base which is formed in a cylindrical shape, a welding head and a welding tip. The base has a push rod operable in an upward and a downward direction with respect to the base and has a slide groove in an upper inner circumferential surface thereof. The welding head is installed at an upper side of the base so as to be slidable in a radial direction and equally divided in a circumferential direction so as to include a plurality of unit welding heads in close contact with one another. The unit welding heads are capable of being spaced apart from one another in the radial direction by the push rod. The welding tip is formed in a cylindrical shape so as to be configured at an outer circumference of the base, operates in an upward and a downward direction and is capable of applying welding electric current to the welding head.