Shear Stud Feeder with Polymer Slide Rails
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Solution Overview
Problem
The manual process of welding shear studs onto steel beams in composite beam construction is time-consuming and labor-intensive, requiring constant manual loading of studs into a stud welding gun.
Innovation Solution
A shear stud feeder system with a support frame, magazine, and feed mechanism that automatically dispenses shear studs to a stud welding gun, featuring slide rails with polymer coatings and a gate assembly for efficient stud delivery, reducing the need for manual loading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual loading of shear studs is used, then the welding process can be performed, but the process is time-consuming and labor-intensive
Solution Approach 1:
The system divides the stud supply into discrete units held in a magazine, with a feed mechanism that releases studs one at a time. This segmentation allows automated delivery to the welding gun, eliminating manual loading and significantly increasing welding productivity while reducing time loss.
2Extent of automation
If automated feed mechanism is implemented, then loading efficiency improves, but device complexity increases
Solution Approach 1:
The feed mechanism is designed to be triggered automatically by the welding gun's operation. When the gun is pulled back after welding, it triggers the feed mechanism to release the next stud. This self-service approach provides automated stud delivery without requiring complex external control systems, balancing automation with simplicity.
3Ease of operation
If slide rails with polymer coating are used, then stud movement is facilitated, but manufacturing complexity increases
Solution Approach 1:
The slide rails are coated with polymer materials that change the surface properties to reduce friction. This parameter change in surface characteristics facilitates smooth stud movement along the rails during feeding, improving ease of operation while the coating process remains a standard manufacturing technique.
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
The system significantly reduces the time and effort required for welding shear studs, enhancing the efficiency and speed of the stud welding process by automating the delivery of studs to the welding gun.
Implementation Method 1
each slide rail includes a layer of polymer disposed thereon
Data Source
AI summary
A shear stud feeder for a stud welding gun may include a support frame having a first slide rail and a second slide rail longitudinally spaced apart from the first slide rail to form a slot therebetween. The shear stud feeder may also include a magazine removably engaged with the support frame. The magazine may be adapted to support a plurality of shear studs by the head of each shear stud in a manner in which the body of each shear stud hangs below a bottom of the magazine and wherein the magazine is adapted to dispense the plurality of shear studs to the slot. The shear stud feeder may include a feed mechanism disposed adjacent to either the first slide rail or the second slide rail and a gate assembly adjacent to a front end of each of the first slide rail and the second slide rail.