Pressure Welding Angular Adjustment Mechanism
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Solution Overview
Problem
Existing pressure welding devices face challenges in achieving precise angular alignment of components, leading to unreliable and time-consuming preparation, potential position changes due to settlement, and insufficient clamping security, especially when welding components at angles other than a common line of alignment.
Innovation Solution
A pressure welding device with a mechanical angle adjustment system that includes adjustable axes intersecting at the welding point, allowing for reproducible and accurate solid angle settings, enabling components to be aligned at various spatial angles, and compensating for component shortenings during the welding process, thereby ensuring high-quality welds and optimized clamping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If components are welded at an angle using conventional clamping devices, then welding capability is achieved, but preparation time increases and positioning reliability decreases
Solution Approach 1:
The clamping device incorporates an articulated mechanism that allows dynamic adjustment of the component holder to various angular positions. This enables the device to adapt to different welding angles without requiring separate fixed fixtures for each angle, thereby reducing preparation time while maintaining welding capability.
Solution Approach 2:
The invention changes the angular parameter of the component holder through the articulated mechanism. By allowing continuous or discrete adjustment of the angle parameter, the device can accommodate different welding configurations without manual repositioning or additional preparation steps.
2Adaptability or versatility
If components are welded at an angle using conventional clamping devices, then welding capability is achieved, but clamping security is insufficient
Solution Approach 1:
The articulated mechanism provides dynamic clamping adjustment that maintains optimal clamping force and security across various angular positions. The mechanism ensures that the component remains securely held regardless of the angle, preventing position changes during welding.
Solution Approach 2:
The clamping device performs preliminary positioning and securing of the component at the desired angle before welding begins. This preliminary action ensures that the component is firmly fixed in the correct angular position, preventing any settlement or movement during the welding process.
3Measurement precision
If mechanical angle adjustment with intersecting axes is implemented, then positioning precision and reproducibility improve, but device complexity increases
Solution Approach 1:
The angle adjustment mechanism is segmented into multiple independent adjustment axes that intersect at the welding point. Each axis can be adjusted independently, allowing precise control of angular positioning through a series of simpler, modular adjustments rather than a single complex mechanism.
Solution Approach 2:
The intersecting adjustment axes act as intermediaries between the component holder and the base structure. These axes provide a mechanical means to achieve precise angular positioning while isolating the complexity of the adjustment mechanism from the welding process itself.
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 mechanical angle adjustment system enhances the reproducibility and reliability of component alignment, reduces preparation time, and ensures precise angular positioning, resulting in improved welding quality, operational safety, and cost-effectiveness by minimizing construction costs and maintaining dimensional accuracy.
Implementation Method 1
two components are rubbed together under pressure and in a rotary motion, with the component material being plasticized and melted at the connection point
Implementation Method 2
an arc is ignited between the spaced components and driven in rotation by electromagnetic forces by means of a driving device, e.g. a coil arrangement
Implementation Method 3
the components are then additionally pressed together and welded together with increased force
Data Source
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AI summary
The press welding device comprises a plasticizing device (2), a compressing device (3) and/or a tensioning device (7) for components (5) to be welded, where the compressing device comprises an angular adjuster (14) for mutually angled spatial adjustment of the component to be welded around an angle-of-attack alpha , beta , gamma . The plasticizing device and the compressing device are spatially separated and arranged at opposite sides of the component. The angular adjuster comprises an adjusting shaft and an actuating device, which comprises an actuating element and a manual or motoric actuating drive. The press welding device comprises a plasticizing device (2), a compressing device (3) and/or a tensioning device (7) for components (5) to be welded, where the compressing device comprises an angular adjuster (14) for mutually angled spatial adjustment of the component to be welded around an angle-of-attack alpha , beta , gamma . The plasticizing device and the compressing device are spatially separated and arranged at opposite sides of the component. The angular adjuster comprises an adjusting shaft and an actuating device, which comprises an actuating element, a manual or motoric actuating drive to be actuated, and an arrangement for reproducible positioning. The plasticizing device is formed as friction device or as arc-driving device. The compressing device comprises a component holder for a base component, where the component holder is arranged between the plasticizing device and the compressing device. The angular adjuster is arranged on the component holder, which comprises a sled and a mounting plate with a tension carrier and a retension unit for the base component. The angular adjuster comprises the actuating device for lateral pivotable adjustment of the base component around an upright adjusting axis and/or an actuating device for angle position of the base component around a diagonally lying adjusting axis. The angle adjuster comprises an actuating device for rotatably adjusting the tension arrangement or the base component around a longitudinally directed adjusting axis. Two or three joints are arranged between the sled and the mounting plate. The tension arrangement comprises tension elements with a joint for single or multi-layered movable bearing on the tension carrier. The angle adjuster comprises an actuating device arranged on the tension device of the add-on component.