Plate Stack Welding Support Rollers for Distortion Control
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Solution Overview
Problem
The existing welding devices for plate laminated bodies face issues with sag in the welding bead due to gravity and thermal distortion, leading to deflection and inclination of the plate laminated body, which restricts the number of laminations and results in poor welding.
Innovation Solution
A welding device with a chuck that grips the plate laminated body in a horizontal position and supports it from below, using a support roller to rotate the plates while applying an equal support reaction force to correct deflection and inclination, and a control system to adjust the support height based on the rotation angle and load, ensuring consistent support and preventing distortion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the welding torch is positioned horizontally to weld outer peripheral edges of laminated plates, then the welding device can accommodate non-circular plate shapes, but sag occurs in the welding bead due to gravity causing poor welding
Solution Approach 1:
The patent inverts the conventional welding approach by positioning the welding torch vertically instead of horizontally, and rotating the plates horizontally instead of moving the torch horizontally. This inversion eliminates gravity-induced sag in the welding bead while maintaining the ability to weld non-circular plates through rotational movement.
Solution Approach 2:
The patent introduces dynamic rotation of the laminated plates around a vertical axis, transforming the static horizontal welding process into a dynamic rotational process. This allows the welding torch to remain stationary in the vertical direction while the plates rotate, achieving both precise welding quality and versatility for non-circular shapes.
2Quantity of substance
If multiple plates are laminated in the vertical direction, then the plate structure can achieve greater height and capacity, but thermal distortion during welding causes inclination with respect to the lamination direction
Solution Approach 1:
The patent introduces support rollers that apply counteracting support forces to compensate for thermal distortion during welding. These support rollers act as a counterweight system, providing upward support to prevent inclination of the laminated plate structure while allowing multiple plates to be welded together vertically.
Solution Approach 2:
The support rollers serve as intermediary elements between the welding process and the laminated plate structure. They mediate the thermal distortion effects by providing continuous support during welding, enabling stable lamination of multiple plates without inclination.
3Manufacturing precision
If the welding torch is held at a constant angle relative to the plate surface, then welding quality is maintained for circular plates, but the device cannot effectively correct inclination during welding of laminated bodies
Solution Approach 1:
The patent inverts the conventional approach by keeping the welding torch angle constant in the vertical direction and achieving adaptability through rotation of the plates rather than adjustment of the torch angle. This maintains welding quality while enabling processing of various plate shapes and sizes.
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 configuration effectively suppresses deflection and inclination due to thermal distortion, allowing for more laminations and preventing sag, thereby improving the quality of the welding process.
Implementation Method 1
a welding torch
Implementation Method 2
the support roller is constituted by a support roller, the plate laminated body is rotated around an axis of the plate laminated body
Data Source
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AI summary
A welding device for a plate laminated body according to an embodiment includes a welding torch, a chuck for gripping a plurality of laminated plates with a lamination direction being in a horizontal position, and at least one support extending along the lamination direction for supporting the plate laminated body from below.