Servo-Driven Cam Flash Butt Welding Machine
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Solution Overview
Problem
Flash butt welding machines with cam disks require frequent changes of cam disks for different welding processes, leading to inefficiencies and the inability to achieve high-speed upset impacts necessary for quality welds, while machines with servo motors lack flexibility in annealing and have complex, expensive nut disengagement mechanisms.
Innovation Solution
A flash butt welding machine utilizing a servo motor-driven cam body with programmable control, allowing for variable movement and upset impact programming through a curve with distinct sections, enabling flexible programming and free movement of holding means during annealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a cam disk is used to drive the holding means, then high-speed upset impact can be achieved, but frequent replacement of cam disks is required for different welding processes
Solution Approach 1:
The patent applies dynamics by replacing the static cam disk with a dynamic cam body that can be repositioned along the spindle axis. The cam body's position is adjusted via a drive mechanism (motor-driven lead screw or rack and pinion) to change the engagement point with the scanner, thereby varying the motion program without replacing the entire cam component. This enables the system to adapt to different welding processes while maintaining high-speed upset impact capability.
2Adaptability or versatility
If a servo motor drives the spindle directly, then programmable control is achieved, but high-speed upset impact cannot be achieved
Solution Approach 1:
The patent introduces a cam body as an intermediary between the servo motor-driven spindle and the scanner/holding means. The cam body translates the controlled rotation of the spindle into the desired non-linear motion of the scanner, including high-speed upset impact. This intermediary mechanism enables the servo motor to achieve both programmable control and high-speed impact by decoupling the motor's rotation from the scanner's complex motion path.
3Reliability
If the holding means is clamped during annealing, then positioning is maintained, but distortions occur due to restricted free movement
Solution Approach 1:
The patent applies dynamics by enabling the holding means to transition between clamped and unclamped states. During annealing, the holding means is decoupled from the drive mechanism, allowing it to move freely and accommodate thermal expansion and stress relief without causing distortions. The dynamic reconfiguration of the drive system enables this free movement while maintaining positioning stability when clamping is required for welding operations.
Data Source
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AI summary
The flash welding machine comprises a drive, a cam gear coupled with the drive, a first holding unit (1) for holding a first joining partner, a second holding unit (2) for holding a second joint partner, a control- and/or regulating unit, and a spring and/or a linear drive. The first holding unit is connected with a scanner (7) of the cam gear. The drive comprises a servo motor (9). The cam gear comprises a curved body such as a cam plate (8). The curve of the curved body comprises a section or a first portion with an infinite or almost infinite slope. The flash welding machine comprises a drive, a cam gear coupled with the drive, a first holding unit (1) for holding a first joining partner, a second holding unit (2) for holding a second joint partner, a control- and/or regulating unit, and a spring and/or a linear drive. The first holding unit is connected with a scanner (7) of the cam gear. The drive comprises a servo motor (9). The cam gear comprises a curved body such as a cam plate (8). The curve of the curved body comprises a section or a first portion with an infinite or almost infinite slope, and a constant negative slope in a third portion. The curve comprises a constant positive slope in a second portion. The first, second and third portions or the section is/are arranged one after the other. The control- and/or regulating unit is programmable. The program is selected from the control- and/or regulating unit and a desired movement of the curved body when the curved body is accelerated and/or decelerated during a program execution. The spring is a coiled torsion spring. The linear drive is a pneumatic drive or a hydraulic drive. The control- and/or regulating unit controls and/or regulates the rotation of the servomotor and coupling of the curved body with the servomotor. The spring and/or a linear drive is/are coupled with the first holding unit.