Rotary Intermediate Electrode Set for High-Current Resistance Welding
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Solution Overview
Problem
Resistance welding equipment faces inefficiencies due to high current applications and increased production line speeds, leading to electrode wear, heat accumulation, and frequent replacements, especially when working with metals like aluminum.
Innovation Solution
The equipment employs a rotary-type intermediate electrode set with multiple attachable and detachable units that reduce the frequency of electrode replacement by distributing the workload across multiple electrodes, includes a cooling device to prevent heat accumulation, and allows for easy centering and replacement of electrode portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large current is applied for resistance welding, then welding performance is improved, but heat accumulates in the electrode causing wear and deterioration
Solution Approach 1:
The patent divides the welding system into multiple intermediate electrodes (first, second, third intermediate electrodes) that can be independently replaced. This segmentation allows the welding current path to be distributed across multiple electrode components, reducing heat accumulation in any single electrode and enabling selective replacement of worn electrodes without replacing the entire electrode assembly.
2Reliability
If electrode replacement frequency is increased, then welding performance is maintained, but production efficiency deteriorates due to replacement time
Solution Approach 1:
The intermediate electrodes are designed as separable, independently replaceable components. When one intermediate electrode wears out, only that specific electrode needs to be replaced while the other intermediate electrodes remain in use. This segmentation dramatically reduces the frequency and time of electrode replacements, maintaining production efficiency while ensuring welding quality.
Solution Approach 2:
The patent implements a dynamic electrode replacement system where intermediate electrodes can be individually swapped during production. The welding apparatus is designed to accommodate rapid replacement of intermediate electrodes without requiring shutdown of the entire welding system, allowing maintenance to be performed dynamically during operation rather than requiring complete system stoppage.
3Productivity
If production line speed is increased, then production efficiency is improved, but electrode wear increases due to heat accumulation
Solution Approach 1:
By segmenting the electrode system into multiple independently replaceable intermediate electrodes, the patent enables high-speed production while managing electrode wear. The multiple electrodes can be rotated or replaced individually, allowing the system to maintain high production speeds without the entire electrode assembly needing frequent replacement, thus extending effective electrode service life.
4Productivity
If aluminum workpieces are welded, then production requirements are met, but electrode wear increases due to aluminum adhesion
Solution Approach 1:
The segmentation of intermediate electrodes into independently replaceable components allows for targeted replacement of electrodes contaminated with aluminum adhesion. Instead of replacing all electrodes when working with aluminum, only the affected intermediate electrodes need to be swapped, maintaining productivity while managing the harmful adhesion effect.
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 configuration significantly reduces electrode replacement frequency, improves production efficiency, and maintains consistent welding performance even under high current and increased production demands by ensuring surface contact and controlled heat management.
Implementation Method 1
the intermediate electrode is attachable and detachable, the time for replacement of the intermediate electrode can be also shortened
Implementation Method 2
a large current is applied for a short time, and a nugget (alloy layer) is formed by using heat generation due to resistance of the metal, thereby achieving melt-joining
Data Source
Figure 1
Figure 2
Figure 3A~3C
AI summary
An equipment main bod includes an intermediate electrode set disposed between upper and lower welding electrodes and provided at at least one of the upper and lower welding electrode sides. The intermediate electrode set includes a plurality of intermediate units, each intermediate unit having an intermediate electrode set jig and an intermediate electrode attachable to and detachable from the intermediate electrode set jig, and is configured as a rotary type in which the plurality of intermediate units are provided so as to be rotatable in a circumferential direction such that the plurality of intermediate units sequentially stop at a welding position that is aligned with the upper and lower welding electrodes in an up-down direction. The intermediate electrode set is configured to resistance-weld the workpiece, while pressing the workpiece by the pressing unit, via the intermediate electrode of the intermediate unit at the welding position.