Resistance Welding Device with Movable Electrode Head
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Solution Overview
Problem
Resistance welding devices struggle to securely attach small components, such as nuts, to metal sheets when the sheets are not horizontally oriented, and they require complex orientation and supply systems for efficient welding operations.
Innovation Solution
A resistance welding device with a clamp-like tool featuring a hollow head and movable electrodes, where one arm is integral to the clamp and the other can move, allowing for adjustable positioning and automatic component supply, using actuators and control systems to ensure stable welding in any orientation without needing active electrode movement systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the welding device uses a clamp with movable arms and electrodes for welding small components on metal sheets, then the welding operation can be performed on horizontally orientated sheets, but the device cannot handle workpieces with spatial orientations different from horizontal
Solution Approach 1:
The clamp is designed with movable arms that can dynamically adjust their positions and orientations. The first arm is integral to the clamp while the second arm is assembled with the capacity of being moved with respect to the clamp by means of a first actuator, enabling the device to adapt to different spatial orientations of workpieces
Solution Approach 2:
The welding device is designed to perform multiple functions: it can weld small components in various spatial orientations, supply components automatically via the hollow head mechanism, and maintain stable operation without requiring separate orientation adjustment systems
2Productivity
If the electrode tip is positioned close to the head inlet for efficient welding, then the component can be securely welded, but the component cannot be properly supplied and positioned before welding
Solution Approach 1:
The electrode is designed to move dynamically between two positions: a standby position where the tip is inside the hollow head allowing component supply and positioning, and a working position where the tip protrudes through the inlet for welding. This dynamic positioning resolves the contradiction between component supply accessibility and welding efficiency
Solution Approach 2:
The hollow head structure allows preliminary component supply and positioning to occur before the electrode moves to its working position. The component is placed on the workpiece between the electrode tip and the head inlet during the standby phase, ensuring proper positioning before welding begins
3Reliability
If the electrode is housed inside the hollow head for protection, then the electrode is protected during component supply, but the electrode cannot contact the component for welding
Solution Approach 1:
The electrode is designed with movable capability relative to the hollow head, allowing it to transition between a protected position inside the head and an active position protruding through the inlet. This dynamic movement enables the electrode to be protected during component supply while maintaining welding capability when needed
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
Enables secure welding of small components in any spatial orientation with simplified construction and efficient automatic component supply, allowing for consecutive operations without manual intervention, while maintaining consistent electrode pressure during welding.
Implementation Method 1
the second arm is assembled with the capacity of being moved with respect to the clamp by means of a first actuator
Implementation Method 2
the clamp being able to be moved with respect to the frame supporting it by means of a second actuator
Implementation Method 3
resistance welding device... passing a welding current through the electrodes
Implementation Method 4
said head being subjected to the effect of elastic means which tend to arrange it in a standby position
Data Source
AI summary
A resistance welding device, comprising a frame for supporting a tool configured like a clamp with two arms arranged facing one another and having respective welding electrodes, of which a first arm is integral to the clamp and the second arm is assembled with the capacity of being moved with respect to the clamp by means of a first actuator, such that respective movements along a straight trajectory can be imparted to the arms of the clamp for moving their electrodes closer to or away from one another. One of the arms has a hollow head housing the corresponding electrode in a guided manner the tip of which is suitable for receiving the support of a component to be welded on the workpiece, the head and the electrode being able to adopt at least one standby position (A) in which the electrode is inside the mentioned head; and a working position (B), in which the tip of the electrode is arranged in or exceeds the inlet of the head, accordingly placing the component to be welded outside the head.