Pressure Welding Device Direct Drive Spindle Actuation
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Solution Overview
Problem
Existing pressure welding devices face limitations in performance capacity, quality, automation, and ergonomics, with complex and costly setups, and require frequent maintenance due to belt drives and susceptibility to wear.
Innovation Solution
A pressure welding device with an actuating drive arranged axially spaced from the spindle end, featuring a direct drive spindle configuration, reduced inertia, and an upsetting drive with parallel cylinders for improved force transmission and ergonomic design, allowing for compact, cost-effective, and adaptable configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the actuating drive is arranged at the rear end of the spindle, then the component mount can be actuated, but the device complexity increases and the component mount becomes more complex and heavier
Solution Approach 1:
The actuating device is separated from the spindle drive motor, with the actuating drive arranged axially spaced from the spindle end. This segmentation allows the component mount to be actuated independently while simplifying its structure and reducing its weight, as it no longer needs to integrate the actuating mechanism within the spindle assembly.
2Ease of manufacture
If a belt drive is used for the spindle, then the setup is simpler, but wear susceptibility increases and maintenance frequency increases
Solution Approach 1:
The belt drive is replaced with a direct drive configuration where the spindle drive motor is arranged flush with the drive train and machine axis. This eliminates the intermediate belt drive mechanism, removing the source of wear and maintenance requirements while maintaining simple setup. The direct drive transmits torque directly without mechanical intermediaries that are susceptible to wear.
3Volume of moving object
If the actuating device is integrated with the spindle drive, then the configuration is compact, but the inertia increases and the drive train becomes longer
Solution Approach 1:
The actuating device is segmented from the spindle drive motor and arranged axially spaced therefrom. This separation reduces the inertia of the rotating mass by excluding the actuating device components from the rotating assembly, while the axial spacing maintains a compact overall configuration. The measuring device for actuating stroke is also arranged in this spaced configuration to enable accurate control without adding to rotating inertia.
4Adaptability or versatility
If intermediate gear with belt drive is used, then the drive train is more flexible in configuration, but transverse forces are introduced and wear increases
Solution Approach 1:
The intermediate gear with belt drive is replaced by a direct drive arrangement where the spindle drive motor is flush with the drive train and machine axis. This substitution eliminates the generation of transverse forces that would otherwise be introduced by belt drives and intermediate gears, while still allowing configuration flexibility through the axial spacing of the actuating device and the option for stationary or floating spindle drive arrangements.
Data Source
AI summary
A pressure welding method and a pressure welding device (1) includes a plasticizing unit (7), a compression unit (8), a machine head (13) that includes a spindle (54) and a component holder (34). The pressure welding device (1) further includes a spindle drive (56) and an actuation mechanism (41) that includes an actuation drive (65) for the component holder (34). The actuation drive (65) is placed between the spindle drive (56) and the spindle (54) within a drive train (57).