Resistance Seam Welding Current Control for Container Frames
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Solution Overview
Problem
Current methods for determining welding current strength in resistance seam welding of container frames are inefficient, requiring iterative test welds, material wastage, and operator experience, leading to suboptimal weld quality and production downtime.
Innovation Solution
A method and device that control the welding current intensity during production by measuring electrical energy and temperature, determining the limits for optimal current range, allowing for automatic quality control without mechanical or visual inspections, and adjusting the current as needed to maintain optimal weld quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If iterative test welds with visual inspection and mechanical strength testing are used to determine welding current strength, then weld quality can be assessed, but production downtime increases and material consumption increases
Solution Approach 1:
The patent replaces mechanical strength testing and visual inspection with electrical measurement systems. A measurement device records electrical energy introduction and temperature at welding points, substituting the mechanical testing process with electrical and thermal measurements that provide immediate feedback without requiring physical sample destruction or time-consuming visual inspection.
Solution Approach 2:
The patent implements a feedback system where measurement data from electrical energy and temperature recordings is used to determine quality limits. The system continuously monitors welding parameters and provides feedback to adjust welding current, eliminating the need for iterative test welds and enabling real-time quality control during production.
2Reliability
If iterative test welds with visual inspection and mechanical strength testing are used to determine welding current strength, then weld quality can be assessed, but material consumption increases
Solution Approach 1:
The patent replaces mechanical strength testing and visual inspection with electrical measurement systems. A measurement device records electrical energy introduction and temperature at welding points, substituting the mechanical testing process with electrical and thermal measurements that provide immediate feedback without requiring physical sample destruction or time-consuming visual inspection.
Solution Approach 2:
The patent implements a feedback system where measurement data from electrical energy and temperature recordings is used to determine quality limits. The system continuously monitors welding parameters and provides feedback to adjust welding current, eliminating the need for iterative test welds and enabling real-time quality control during production.
3Ease of manufacture
If welding current strength is determined by operator experience and iterative testing, then initial settings can be made, but the process is highly dependent on operator skill and time-consuming
Solution Approach 1:
The patent implements a feedback system where measurement data from electrical energy and temperature recordings is used to determine quality limits. The system continuously monitors welding parameters and provides feedback to adjust welding current, eliminating the need for iterative test welds and enabling real-time quality control during production.
Solution Approach 2:
The measurement and evaluation system operates autonomously during production, automatically determining welding quality and current limits without requiring operator intervention for each adjustment. The system self-regulates by continuously monitoring and evaluating welding parameters, reducing dependence on operator experience and skill.
4Reliability
If continuous monitoring of welding energy and temperature is implemented, then real-time quality control is achieved, but device complexity increases
Solution Approach 1:
The patent integrates multiple measurement functions into a single monitoring device that simultaneously records electrical energy introduction and temperature at welding points. This multi-functional approach consolidates what would otherwise require separate measurement systems, reducing overall device complexity while maintaining comprehensive real-time quality control capabilities.
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 enables faster, more reliable, and material-saving assessment of welding current intensity, reducing production downtime and improving weld quality by automatically adjusting the welding current to maintain optimal conditions, even with less experienced operators.
Implementation Method 1
during this welding the electrical energy is determined several times
Implementation Method 2
and/or the temperature along the weld seam is determined several times
Implementation Method 3
resistance seam welding of overlapping seams of successive container bodies
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The method for assessing the applied welding current strength during electrical resistance seam welding of overlap joints of successively following container bodies (6) of production series, comprises welding a first row of the container bodies with a predetermined constant welding current strength by a control of a resistance welding machine during the production, where the row of the container bodies is welded by controlling an individual container body from the production series with welding current strength falling or rising during the seam welding. The method for assessing the applied welding current strength during electrical resistance seam welding of overlap joints of successively following container bodies (6) of production series, comprises welding a first row of the container bodies with a predetermined constant welding current strength by a control of a resistance welding machine during the production, where the row of the container bodies is welded by controlling an individual container body from the production series with welding current strength falling or rising during the seam welding, and testing whether the adjusted constant welding current strength in a predetermined distance to the welding current strength for cold welding and the welding current strength for hot welding and whether the adjusted welding current strength in a range. The position of the adjusted constant welding current strength is periodically determined and recorded for quality security purposes. After welding the individual container body, a changed constant welding current strength is adjusted, lies between the welding current strength of the cold welding and the welding current strength of the hot welding and is selected in dependent of the welding current strengths, where a new constant welding current strength is applied for the row of the container bodies of the production series following to the individual container body. The welding current strength is linearly selected during welding the container body in a falling or rising manner or the welding current strength has two ranges with different rise of the lowering or rising during welding the container body. The electrical energy is determined, in which the welding seam of the welding current and the electric voltage drop for each welding lens or selected welding lens is determined over the welding electrodes. The container bodies have an overlapping width, which changes along the seam. The container bodies are welded with its seam during the welding with lowering or rising welding current strength. The welding current strength is selected greater during the larger overlapping width and smaller during smaller overlapping width. The electrical energy is determined periodically in the container body or two container bodies from the production series during the welding and/or the temperature of the welding is determined based on the electrical energy values and/or the determined temperature values if the welding current strength proceeds the welding of the individual container body to cold and the welding current strength proceeds the welding of the individual container body to hot, and is assessed or changed based on the determination of the flow of the falling or rising welding current strength within the limits. The position of the adjusted welding current strength is recorded for quality security purposes. The electrical voltage drop is determined over the welding electrodes and/or the temperature is measured along the welding seam with an infrared thermometer. An independent claim is included for a welding apparatus for the resistance seam welding of container bodies.