Same-Side Resistance Welding Head with Elastic Pressure Control
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Solution Overview
Problem
Conventional electric resistance welding heads with electrodes on the same side face challenges in achieving consistent welding quality, particularly when accessing hard-to-reach areas on components with varying shapes and dimensions, and ensuring reliable pressure control and electric contact.
Innovation Solution
The welding head incorporates an elastic device between the ground electrode and the support structure, a load detection system, and electronic control units to manage the movement and force of the electrodes, along with an adjustable distance between the electrodes, and a deformable contact element for improved surface adaptation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional welding guns are used, then the structure is simple, but the electrode cannot reach hard-to-access areas and may push on the vehicle body surface
Solution Approach 1:
The patent inverts the conventional welding gun configuration by placing both electrodes on the same side of the support structure instead of having them on opposite sides. This allows the welding head to access hard-to-reach areas while maintaining a compact structure that avoids pushing on the vehicle body surface.
Solution Approach 2:
The patent employs movable electrodes that can be actuated independently along their respective main axes. The welding electrode can be extended or retracted via an electrically operated actuator, allowing dynamic adjustment to reach different welding positions without requiring a complex articulated structure.
2Manufacturing precision
If pressure control is simplified, then the device is easier to operate, but welding quality consistency deteriorates
Solution Approach 1:
The patent incorporates a detecting device that monitors the load on the elastic device during welding operations. This feedback mechanism allows the control system to adjust the electrode positioning and pressure application in real-time, ensuring consistent welding quality while maintaining a relatively simple overall structure.
Solution Approach 2:
The patent uses an elastic device (such as a spring) between the ground electrode and the support structure to provide controlled pressure. The elastic device automatically adjusts its compression based on the welding conditions, providing consistent pressure without requiring complex active control mechanisms.
3Volume of moving object
If the welding head is made more compact, then it can access low-area components better, but cable and tube interference with unrelated bodies increases
Solution Approach 1:
By placing both electrodes on the same side of the support structure, the patent creates a compact welding head configuration that reduces the overall volume and improves access to low-area components. This inverted configuration also naturally routes cables and tubes along the same side, reducing interference with unrelated bodies.
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 ensures high-quality welding with reliable pressure control, easy adaptation to different applications, and protection of cables and tubes from interference, while maintaining consistent electric contact across various operative conditions.
Implementation Method 1
an elastic device which is operatively interposed between said ground electrode and said support structure
Implementation Method 2
supplying electrical current to said electrodes by means of said electric transformer for executing a resistance electric welding on said component
Data Source
AI summary
An electronically-controlled electric resistance welding head and method having a support structure and the electrodes located on the same side. The welding head including a ground electrode having an elastic device and a detecting device for detecting a force load on the elastic device on contact with a component to be welded. A welding electrode is movable relative to the ground electrode and the support structure to contact the component to be welded. An electronic control unit is operable to selectively increase the force applied by each electrode when in contact with the component to be welded until respective threshold values are achieved. Current is generated by a transformer for passage to the electrodes.