Pressure Welding Device with Floating Component Mount
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Solution Overview
Problem
Existing pressure welding devices require manual and complex modifications to adapt to different component dimensions, leading to increased setup and downtimes, reduced automation, and compromised ergonomics.
Innovation Solution
A pressure welding device with an adjustable coupling device between the component mount and upsetting head, featuring a pulling-type upsetting drive with parallel cylinders, allowing for automatic adaptation to varying component lengths and improved force distribution, which enhances precision and reduces deformations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual modification is used to adapt to different component dimensions, then the device can be adjusted to different component lengths, but the setup time and complexity increase
Solution Approach 1:
The patent implements a dynamically adjustable component mount that can be rapidly repositioned along the machine axis to accommodate different component lengths. The mounting position is made variable through a drive mechanism that allows quick adjustment without manual modification, directly resolving the contradiction between adaptability and setup time.
Solution Approach 2:
The component mount is designed as a universal mounting device that can handle multiple component dimensions and types. By creating a multi-functional mounting system with adjustable positioning capabilities, the device achieves versatility across different component specifications while maintaining rapid setup through automated adjustment mechanisms.
2Adaptability or versatility
If manual modification is used to adapt to different component dimensions, then the device can accommodate varying component lengths, but the degree of automation decreases
Solution Approach 1:
The component mount incorporates self-adjusting capabilities through automated drive mechanisms that can reposition the mounting location based on programmed parameters. This self-service functionality eliminates the need for manual intervention in adaptation processes, thereby maintaining high automation levels while achieving versatile component accommodation.
Solution Approach 2:
The system employs dynamic, programmable control of the component mount position that automatically adapts to different component dimensions. This automated dynamic adjustment replaces manual modification processes, preserving the degree of automation while achieving the required adaptability to various component specifications.
3Adaptability or versatility
If manual modification is used to adapt to different component dimensions, then the device can be adjusted, but device complexity increases
Solution Approach 1:
The patent designs a universal component mount with integrated adjustment mechanisms that can handle multiple component types and sizes through a single standardized interface. This multi-functional design eliminates the need for multiple specialized fixtures or complex manual modifications, thereby reducing overall device complexity while maintaining high adaptability.
Solution Approach 2:
The system replaces static, manually-modified configurations with a dynamic, programmably-controlled mounting system. This dynamic approach consolidates multiple adjustment functions into a single automated mechanism, reducing the complexity of manual modification procedures while achieving the same adaptability to different component dimensions.
4Force
If traditional upsetting drive with pressure forces is used, then the upsetting function is achieved, but undesired deformations and kinking occur
Solution Approach 1:
The patent inverts the traditional approach by using a pulling-type upsetting drive instead of a pushing mechanism. This inversion of the force application direction eliminates the kinking and undesired deformations that occur with conventional pressure-based upsetting, while still achieving the necessary upsetting force through tensile loading of the material.
5Force
If cylinders are arranged at high position, then the force flow is optimized, but ergonomics and accessibility are worsened
Solution Approach 1:
The patent resolves the spatial conflict by arranging cylinders at different vertical levels (different dimensions) rather than at a single high position. This multi-level arrangement maintains the optimized force flow path while bringing at least one cylinder to a lower, more accessible position that improves ergonomics and operator accessibility to the working area.
Data Source
AI summary
A pressure welding device (1) includes a plastification device (7), an upsetting device (8) and a mounting (11) for the components (2,3) to be welded together and a machine frame (12). The pressure welding device further includes a machine head (13) and an upsetting head (27) which can be moved relative one another along a machine axis (6). The mounting (11) includes a component seat (36), which is mounted on the machine frame (12) so as to be able to float between the machine head (13) and the upsetting head (27), and a preferably automatic adjusting device (17) for adaptation to different component dimensions, in particular component lengths.