Rotary Two-Way Welding Gun for Variable Flange Spot Welding
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Solution Overview
Problem
Existing spot welding guns are limited by fixed welding tips that cannot accommodate vehicle body panels with varying flange shapes, requiring multiple guns and increasing costs and inefficiencies in welding operations.
Innovation Solution
A two-way welding gun with a welding tip adjuster that allows selection between a first and second welding tip, depending on the flange shape, using a rotary mechanism to align the appropriate tip with a fixed tip for efficient spot welding across different panel shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a welding tip with a defined shape is used to match the flange shape, then spot welding can be easily performed on flanges with matching shapes, but spot welding cannot be performed on flanges with different shapes
Solution Approach 1:
The welding gun is designed with multiple welding tips (first welding tip and second welding tip) that can be selectively used depending on the flange shape. This allows a single welding gun to perform multiple functions - welding both first-type flanges (using the first welding tip) and second-type flanges (using the second welding tip), thereby achieving universality and eliminating the need for multiple specialized welding guns
Solution Approach 2:
The welding tip is designed to be changeable rather than fixed. The welding tip can be dynamically switched between different types (first welding tip and second welding tip) based on the welding task requirements. This dynamic adaptability allows the system to respond to different flange shapes, resolving the contradiction between having a fixed tip design and needing to accommodate various flange geometries
2Adaptability or versatility
If multiple spot welding guns with different welding tip shapes are used to handle various flange shapes, then all flange shapes can be welded, but additional facilities and costs are needed and welding space arrangement efficiency decreases
Solution Approach 1:
Multiple welding tip functions are merged into a single welding gun body. Instead of having separate welding guns for different flange types, the invention combines the functionality of multiple tips (first welding tip for first-type flanges, second welding tip for second-type flanges) into one integrated system. This merging reduces the number of devices needed, optimizes welding space arrangement, and improves overall productivity while maintaining the capability to weld various flange shapes
3Adaptability or versatility
If multiple spot welding guns with different welding tip shapes are used to handle various flange shapes, then all flange shapes can be welded, but additional costs are incurred
Solution Approach 1:
The welding gun is designed with multiple welding tips (first welding tip and second welding tip) that can be selectively used depending on the flange shape. This allows a single welding gun to perform multiple functions - welding both first-type flanges (using the first welding tip) and second-type flanges (using the second welding tip), thereby achieving universality and eliminating the need for multiple specialized welding guns, which reduces manufacturing costs
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 efficient spot welding of vehicle body panels with various shapes using a single gun, improving productivity and reducing the need for multiple guns and associated facilities, thereby minimizing costs and optimizing welding space arrangement.
Implementation Method 1
a pressure cylinder (16) mounted on the lower portion of the base frame (210), and a welding tip adjuster (100) mounted to a piston rod (18) of the pressure cylinder to be movable forwards and rearwards
Data Source
AI summary
A two-way welding gun includes a first welding tip or a second welding tip selected to be used depending on the shape of the flange of a vehicle body panel, which is an object for the spot welding, so that flanges of first vehicle body panels each including a shape matching the first welding tip are easily spot welded to each other using the first welding tip, and flanges of second vehicle body panels each including a shape different from the first welding tip but matching the second welding tip are easily spot welded to each other using the second welding tip.