Segmented Welding Bar Assembly for Variable Weld Widths
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing material welders are limited by fixed weld beam widths, requiring replacement or additional equipment for varying weld widths, which increases costs and operator time.
Innovation Solution
A material welder with a top and bottom bar assembly, each equipped with heating elements of adjustable width, an actuator device for precise alignment, and a controller for selective heating and cooling, allowing for variable weld widths without the need for equipment changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a weld beam or bar of predetermined width is used, then the welding process is simple and reliable, but the weld width is fixed and cannot be adjusted for different situations
Solution Approach 1:
The weld beam is divided into multiple independent heating elements (first heating element and second heating element) that can be selectively activated. This segmentation allows the weld width to be adjusted by controlling which heating elements are active, eliminating the need to replace entire bars for different weld widths.
Solution Approach 2:
The heating elements are made adjustable and selective in their operation. The system dynamically configures the active heating elements based on the required weld width, transforming a static fixed-width bar system into a dynamic adjustable-width system without physical bar replacement.
2Adaptability or versatility
If multiple bars or beams of different widths are maintained, then various weld widths can be achieved, but the cost and operator time for replacing bars increase significantly
Solution Approach 1:
A single weld beam structure serves multiple functions by incorporating multiple heating elements that can be selectively activated. This universal design allows the same physical bar to produce different weld widths (narrow weld using first heating element, wide weld using both heating elements) without requiring multiple specialized bars.
Solution Approach 2:
The system automatically reconfigures the active heating elements based on the required weld width through electronic control, eliminating the manual intervention required for bar replacement. The welder adapts to different weld width requirements through selective activation of heating elements rather than physical bar changes.
3Ease of operation
If a single weld beam is used for all welding tasks, then equipment simplicity is maintained, but the weld width cannot be adjusted to meet different welding requirements
Solution Approach 1:
The system changes the operational parameters (which heating elements are active) rather than physical parameters (bar width) to achieve weld width adjustment. By controlling the electrical parameters and selective activation of heating elements, the system provides weld width variability while maintaining the simplicity of a single physical bar structure.
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 flexible welding of materials with adjustable weld widths, reducing operational costs and time by allowing a single welder to accommodate different welding requirements.
Implementation Method 1
a first and second heating element substantially in the same plane... adapted to selectively heat the first heating elements and/or second heating elements
Implementation Method 2
at least one hole and/or channel adapted such that fluid or air is circulated through the holes and/or channels and through a cooling device to cool the heating elements
Data Source
AI summary
A material welder for welding at least two portions of a weldable material together, including:a top bar assembly and a bottom bar assembly, a portion of the top bar assembly directly above a portion of the bottom bar assembly, the top bar assembly including a first and second heating element substantially in the same plane and the bottom bar assembly including a first and second heating element substantially in the same plane,at least one heating device adapted to selectively heat the first heating elements and/or second heating elements,an actuator device adapted to move the top bar assembly towards the bottom bar assembly and/or the bottom bar assembly towards the top bar assembly, such that the first heating element of the top bar assembly aligns with the first heating element of the bottom bar assembly and the second heating element of the top bar assembly aligns with the second heating element of the bottom bar assembly;a contact surface of the top bar assembly and a contact surface of the bottom bar assembly adapted to contact the material during a welding process.