Resistance Welder Attachment With Pivoting Electrodes for Flexible Access
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Solution Overview
Problem
Existing spot welding technologies lack flexibility in tooling, with C-type guns providing high rigidity but limited workspace and X-type configurations offering less rigidity and flexibility, making them unsuitable for various metal thicknesses and shapes.
Innovation Solution
A multi-purpose attachment device that allows electrodes to pivot and slide, enabling a wider opening like an X-type configuration while maintaining collinear alignment for C-type welds, with a fluid cooling system for temperature control, ensuring consistent force and accurate measurements during welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If C-type gun configuration is used, then rigidity is improved, but workspace and flexibility are worsened
Solution Approach 1:
The patent applies dynamics by making the electrode support structure movable rather than fixed. The first electrode support can pivot relative to the second electrode support, allowing the system to transition between a rigid C-type configuration (when closed) and a flexible X-type configuration (when open), thus resolving the contradiction between rigidity and workspace flexibility
Solution Approach 2:
The patent achieves universality by designing a single welding device that can operate in multiple configurations. The electrode assembly can function both as a C-type gun for rigid, forceful welding and as an X-type configuration for accessing hard-to-reach areas, eliminating the need for separate specialized tools
2Adaptability or versatility
If X-type configuration is used, then workspace and flexibility are improved, but rigidity is worsened
Solution Approach 1:
The patent uses dynamics to allow the electrode support structure to transition between configurations. When the first electrode support pivots to an open position, the device achieves the wide workspace of an X-type configuration while maintaining structural integrity through the controlled pivot mechanism, thus gaining flexibility without permanently sacrificing rigidity
3Strength
If electrode force is increased for thick materials, then welding strength is improved, but tooling flexibility is worsened
Solution Approach 1:
The patent applies dynamics by enabling the electrode assembly to pivot and adjust its configuration. This allows the system to maintain high welding forces when needed for thick materials while being able to reposition for different welding locations and angles, thus preserving both welding strength and tooling flexibility
Solution Approach 2:
The patent achieves universality by designing a single device that can handle both thick materials requiring high force and thin materials requiring flexibility. The adjustable configuration allows the same tool to adapt to different material thicknesses and welding positions, eliminating the need for multiple specialized tools
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 device provides the flexibility of both X and C-type welders, allowing for welding on elongated sheet metal surfaces with precise force transmission and effective cooling, enhancing the versatility and accuracy of spot welding processes.
Implementation Method 1
Fluid cooling provides a means to cool the electrodes during operation
Implementation Method 2
electric current is communicated to one of the electrodes which travels through the metal layers at the compression point and onto the second electrode. This electric current is communicated at significant amperage for a period of time whereupon resistance from the metal material positioned between the electrodes generates heat sufficient to melt and weld the metal layers
Data Source
AI summary
A resistance welding device is configured for use in combination with a resistance welder having a translating welding electrode. A first arm of the welding device is in a translating rotational engagement with a second arm thereof. The first arm of the device is engageable to a translating electrode from the resistance welder. Translation of the welding electrode of the resistance welder moves first and second electrodes to contact metal therebetween and spot weld the metal.