Pivotable Spot Welding Electrodes for Non-Parallel Workpieces
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Solution Overview
Problem
Existing spot welding assemblies face challenges in achieving adequate contact and conductivity when work pieces are not parallel to the electrodes, leading to insufficient welds, especially in automated processes where manual adjustments are time-consuming and labor-intensive.
Innovation Solution
The introduction of pivotable base and gun electrodes allows for orientation adjustment to ensure flat contact with work pieces, even when they are not parallel, enhancing electrical and thermal conductivity during welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If static electrodes are used in automated spot welding assemblies, then automation is maintained, but adequate contact and conductivity cannot be ensured when work pieces are not parallel to the electrodes
Solution Approach 1:
The patent applies the dynamics principle by making the electrodes pivotable rather than static. The base electrode and gun electrode are both configured to pivot about respective axes, allowing them to dynamically adjust their orientation to maintain adequate contact with work pieces that may not be perfectly parallel to the original electrode plane. This dynamic adjustment capability resolves the contradiction by enabling automated systems to adapt to work piece variations without sacrificing contact reliability.
2Reliability
If manual adjustments are made to electrode orientation, then contact adequacy is improved, but time consumption and labor intensity increase
Solution Approach 1:
The patent applies the self-service principle by enabling the electrodes to automatically pivot and adjust their own orientation to maintain adequate contact with work pieces. The pivotable base electrode and gun electrode can self-adjust to work piece variations without requiring external manual intervention, thus maintaining contact adequacy while preserving welding speed and productivity.
3Adaptability or versatility
If electrodes are made pivotable to accommodate work piece variations, then adaptability is improved, but device complexity increases
Solution Approach 1:
The patent uses the dynamics principle to provide adaptability through pivotable electrodes. The base electrode pivots about a first axis and the gun electrode pivots about a second axis, allowing the system to accommodate work pieces with various orientations and dimensional variations. This dynamic capability enhances adaptability while keeping the mechanism relatively simple compared to more complex adjustment systems.
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 enables reliable and efficient welding in both automated and manual operations by ensuring sufficient contact and conductivity, regardless of work piece placement or dimensionality, thereby ensuring a successful weld.
Implementation Method 1
the base electrode is configured to pivot about a first axis and the gun electrode is configured to pivot about a second axis
Implementation Method 2
A current is then applied through the base and gun electrodes and the first and second work pieces in order to melt regions of at least one of the first work piece and/or the second work piece to form a weld therebetween
Implementation Method 3
A current is then applied through the base and gun electrodes and the first and second work pieces in order to melt regions of at least one of the first work piece and/or the second work piece
Data Source
Figure 1
Figure 2A~2C
Figure 3A~3B
AI summary
A spot welding assembly for welding a first work piece to a second work piece. The spot welding assembly includes a base. A base electrode is coupled with the base for supporting the first work piece. A welding gun is moveable toward and away from the base. A gun electrode is coupled with the welding gun for supporting the second work piece and for locating the second work piece against the first work piece upon movement of the welding gun toward the base to allow the first and second work pieces to be welded to one another. The base electrode is rotatable and pivotable relative to the base, and the gun electrode is rotatable and pivotable relative to the welding gun.