Segmented Blankholder Plates for Variable-Thickness Panel Welding
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Solution Overview
Problem
Existing blankholders for welding apparatuses struggle to effectively clamp panels with variable thickness edges, leading to complex arrangements and unsatisfactory welding processes when trying to maintain coplanar upper surfaces.
Innovation Solution
A blankholder with an upper gripping element and a lower gripping element, where the lower gripping element features movable plates that can adjust to varying panel thicknesses, allowing for automatic adaptation and alignment of panels with different thicknesses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed reference blankholder is used for welding panels, then the blankholder structure is simple, but it cannot adapt to panels with variable thickness edges
Solution Approach 1:
The lower gripping element is divided into multiple movable plates that can independently adjust their positions. Each plate can move vertically to adapt to different thicknesses at different locations along the panel edge, allowing the blankholder to handle variable thickness profiles without requiring a completely complex reconfigurable structure.
Solution Approach 2:
The lower gripping element transitions from a fixed structure to a dynamic one where the plates can move vertically. This dynamic capability allows the blankholder to automatically adapt to varying panel thicknesses while maintaining a relatively simple overall structure, as the movement mechanism is localized to individual plates rather than the entire blankholder.
2Adaptability or versatility
If temporary support structures are added to handle variable thickness, then adaptability improves, but device complexity and manufacturing cost increase
Solution Approach 1:
The movable plates are designed to automatically adjust their positions based on the panel thickness they encounter. The plates move vertically under the influence of the panel's geometry and the clamping force, eliminating the need for external temporary support structures. This self-adjusting mechanism simplifies manufacturing while maintaining adaptability.
3Adaptability or versatility
If the upper gripping element is made movable to adapt to thickness variations, then adaptability improves, but the welding arrangement becomes complex as welding must be done from bottom up
Solution Approach 1:
Instead of making the upper gripping element movable (which would complicate the welding arrangement), the invention inverts the approach by making the lower gripping element movable. This allows the upper gripping element to remain fixed, maintaining the conventional top-down welding arrangement while still achieving adaptability to variable thickness through the movable lower plates.
4Reliability
If the blankholder handles only the greatest thickness, then the structure remains simple, but panels with less thickness cannot be effectively clamped
Solution Approach 1:
The lower gripping element is segmented into multiple independent movable plates that can each adjust to the local thickness. This segmentation allows the blankholder to effectively clamp panels with thicknesses less than the maximum by having individual plates move to the appropriate height, ensuring reliable clamping across a range of thicknesses without compromising structural simplicity.
Data Source
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AI summary
A blankholder (12) for a welding apparatus comprises an upper gripping element (14) and a lower gripping element (16) having longitudinal development along one direction (X). The upper gripping element (14) is movable between a closed position, wherein a panel (18, 20) is clamped between said upper gripping element (14) and said lower gripping element (16), and an open position, wherein the panel (18, 20) may slide between said upper gripping element (14) and said lower gripping element (16). The lower gripping element (16) comprises a lower operating surface (22) facing the upper gripping element (14). The lower gripping element (16) comprises a plurality of movable plates (24) arranged along the direction (X). The movable plates (24) are adapted to be moved by handling means (25) in a direction substantially perpendicular to the lower operating surface (22), between a first position, wherein they do not protrude or protrude by a minimum height relative to the operating surface (24), and a second position, wherein they protrude with respect to the operating surface (24) by a predetermined maximum height. The movable plates (24) are provided with a gripping surface (26).