Roller Electrode Orientation Checking Using Distance Sensors
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Solution Overview
Problem
Accurately checking the orientation of roller electrodes relative to a stacked body during seam welding is challenging due to reliance on human vision, which leads to inaccuracies, especially with varying shapes of stacked bodies.
Innovation Solution
An electrode orientation checking apparatus and method that includes a machine stand with a positioning guide and distance sensors to detect the orientation of roller electrodes relative to the stacked body, allowing for precise calculation of the line segment direction without relying on human vision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If human vision is used to check the orientation of roller electrodes, then the checking process is simple and does not require complex equipment, but the measurement precision is insufficient and cannot accurately check orientation during welding
Solution Approach 1:
The patent replaces the mechanical human vision system with an optical measurement system consisting of a laser displacement sensor and positioning guide. The laser sensor optically measures the position of the roller electrode surface relative to the stacked body, eliminating the need for human visual inspection and providing precise quantitative data for orientation checking during welding operations.
Solution Approach 2:
The patent introduces a positioning guide as an intermediary component that establishes a reference relationship between the laser displacement sensor and the stacked body. The positioning guide includes a positioning surface that contacts the stacked body and defines the measurement baseline, serving as a mediator that enables accurate orientation measurement without requiring direct complex positioning between the sensor and workpiece.
2Measurement precision
If the orientation checking apparatus is designed with high measurement precision components, then the orientation can be accurately checked, but the ease of operation becomes difficult due to complex setup and positioning requirements
Solution Approach 1:
The positioning guide is designed to self-position on the stacked body through its positioning surface that contacts the workpiece. This self-service mechanism automatically establishes the correct measurement reference without requiring complex manual alignment or adjustment by the operator, thereby maintaining ease of operation while ensuring measurement precision.
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 high-accuracy checking of roller electrode orientation during welding, improving the formation of nuggets and reducing sputtering by reproducing the outer circumferential surface of the roller electrode on the line segment connecting rotational centers, thus ensuring proper alignment.
Implementation Method 1
a set of distance sensors provided on the machine stand, respectively fixed farther forward than the positioning surface and farther backward than the positioning surface in a progression direction of the roller electrodes relative to the stacked body, and each configured to detect a distance, along an extension direction of the line segment, to the stacked body sandwiched by the positioning surface and the other roller electrode
Data Source
AI summary
An electrode orientation checking apparatus includes a machine stand attached to a seam welding apparatus from which one roller electrode of a set has been removed, a positioning guide and a set of distance sensors that are provided on the machine stand, and a calculating section. A positioning surface of the positioning guide is fixed at a position corresponding to a portion of an outer circumferential surface of the one roller electrode before being removed, the portion lying on a line segment connecting rotational centers of the roller electrodes. The distance sensors are respectively fixed forward and backward of the positioning surface in a progression direction of the roller electrodes. The calculating section calculates data for acquiring a direction of the line segment relative to the stacked body.