Multi-Point Projection Welding for Distortion-Free Car-Body Assembly
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Solution Overview
Problem
Current vehicle body assembly processes require multiple separate apparatuses for loading and welding components, leading to inefficiencies, distortion issues, and the need for numerous jigs that are cumbersome to reconfigure for different vehicle types, especially when dealing with complex shapes like closed sections.
Innovation Solution
A multi-point projection welding method and system that integrates picking, aligning, gripping, pressurizing, and welding functions into a single apparatus, using protrusions on components to concentrate welding pressure and current, allowing for simultaneous welding of multiple points without distorting the vehicle body and eliminating the need for multiple jigs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate multi-step apparatuses are used for loading and welding components, then the welding process can be performed, but the equipment complexity increases and the assembly process becomes cumbersome
Solution Approach 1:
The patent combines the loading apparatus and welding apparatus into a single integrated apparatus. The loading unit positions the component panel on the vehicle body panel, and the welding unit immediately performs projection welding at the same location without requiring transfer to separate equipment. This integration eliminates the need for multiple separate apparatuses while maintaining reliable welding processes.
Solution Approach 2:
The integrated apparatus performs multiple functions: it loads/positions component panels, aligns them using alignment marks, and performs projection welding all through one system. The apparatus is designed to handle both positioning and welding operations, making it a multi-functional device that replaces several specialized apparatuses.
2Manufacturing precision
If pre-set assembly jigs are prepared for every component, then component positioning is accurate, but the adaptability to different vehicle types decreases due to the need to reconfigure equipment
Solution Approach 1:
The apparatus uses a robotic arm with dynamic positioning capabilities that can adapt to different vehicle types through programmable motion paths. Instead of fixed mechanical jigs, the system uses software-controlled robot movements to position components accurately on various vehicle models, allowing quick reconfiguration by updating control programs rather than physical reassembly.
Solution Approach 2:
The patent replaces traditional mechanical assembly jigs with a robotic arm system controlled by computer software. The robotic arm uses vision systems and programmable coordinates to achieve precise positioning without requiring physical jigs for each component or vehicle type. This substitution of mechanical systems with automated control systems enables easy adaptation to different vehicle models.
3Strength
If concentrated welding pressure is applied at one corresponding point of two panels, then welding is achieved, but the vehicle body becomes distorted
Solution Approach 1:
The welding process is divided into multiple projection points distributed across the welding area. Instead of applying concentrated pressure at a single point, the system uses multiple protrusions on the component panel that contact different locations on the vehicle body panel simultaneously. This distributes the welding pressure across multiple segments, preventing localized distortion while achieving strong joints at each projection point.
4Shape
If multiple clamping jigs are used to prevent distortion, then the vehicle body shape is maintained, but the concentration welding is hindered
Solution Approach 1:
The component panel itself provides the clamping function through its protrusions. The protrusions are designed to contact the vehicle body panel and maintain proper positioning and pressure during welding without requiring external clamping jigs. The component's own geometry serves the dual purpose of positioning and applying welding pressure, eliminating the need for separate clamping devices that would interfere with concentration welding.
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 approach simplifies the assembly process, reduces equipment and process complexity, prevents distortion, and enables efficient welding of complex vehicle structures by concentrating welding pressure and current on protrusions, allowing for flexible adaptation to different vehicle types without the need for extensive reconfiguration.
Implementation Method 1
supplying current to the vehicle body pressurizing tip and the component pressurizing tip such that the protrusion of the component panel contacts the vehicle body panel while the vehicle body pressurizing tip and the component pressurizing tip apply pressure to the vehicle body panel and the component panel, respectively
Data Source
AI summary
A component loading-welding system for welding a component panel to a vehicle body panel includes a rotation portion body having first and second opposing sides. The first opposing side is coupled to a robot arm. A picking device is installed in the rotation portion body and is configured to hold and release the component panel. A vehicle body pressurizing tip is installed in the rotation portion body. A pressurizing portion body is rotatably installed at the second opposing side of the rotation portion body. A pin clamp is installed in the pressurizing portion body and is configured to clamp the component panel. A component pressurizing tip is installed in the pressurizing portion body and is configured to apply pressure to the component panel. A multi point projection welding method is also disclosed.