Single-Sided Spot Welding Using Plasma Hole and MAG Fill
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Solution Overview
Problem
Existing spot welding methods require at least two electrodes and precise alignment, making them inefficient and unreliable, especially when accessing only one side of the metallic sheets and dealing with geometrical and electrical non-uniformities.
Innovation Solution
A spot welding apparatus and method utilizing a combination of plasma and MAG technologies, allowing for welding with a single electrode by creating a hole with plasma and filling it with MAG welding, while applying controlled pressure and optimizing timing sequences to improve weld quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional spot welding uses at least two electrodes to concentrate welding current, then welding current concentration is achieved, but alignment accuracy and device complexity increase
Solution Approach 1:
The patent extracts the current concentration function from the electrode contact method and implements it through a single electrode with a concentrated current path. The welding current is concentrated through the single electrode's geometry and electrical properties rather than requiring multiple electrodes to converge at a point, thereby eliminating alignment complexity while maintaining current concentration effectiveness
Solution Approach 2:
The single electrode performs multiple functions: it applies mechanical pressure to clamp the sheets together, concentrates welding current through its electrical design, and creates the welding arc. This multi-functionality replaces the traditional two-electrode system where each electrode had separate functions for clamping and current delivery
2Force
If traditional spot welding uses two electrodes to clamp sheets together, then welding pressure is applied, but accessibility requirements increase
Solution Approach 1:
Instead of applying pressure from both sides of the workpiece as in traditional spot welding, the patent inverts the approach by applying pressure from only one side through the single electrode. The electrode penetrates through the top sheet and applies clamping force to the stacked sheets from the accessible side only, eliminating the need for bottom-side access
3Power
If welding current is concentrated into a small spot, then welding energy density increases, but sensitivity to non-uniformities increases
Solution Approach 1:
The patent changes the electrical parameters by using a single electrode configuration that modifies current distribution characteristics. The single electrode creates a more uniform current density profile compared to two-electrode systems, reducing sensitivity to local non-uniformities while maintaining sufficient energy concentration for effective welding through optimized electrode geometry and material properties
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 solution enables efficient and reliable spot welding with improved resistance to non-uniformities, allowing for welding from one side and reducing the complexity and alignment requirements of traditional methods.
Implementation Method 1
a plasma source for creating holes through at least one of the welded metals
Implementation Method 2
Spot welding is a process in which contacting metal surface points are joined by the heat obtained from resistance to electric current
Data Source
AI summary
The invention pertains to a welding apparatus, particularly to a spot sa welding apparatus which utilizes a single welding electrode/torch to weld vertically adjacent metallic sheets or plates together. The apparatus comprises a MAG welding apparatus with a welding torch and shielding inert or semi-inert gases gas source configured to protect the welded working place, an apparatus for creating holes in at least one of the welded metallic sheets and at least one frame part for assembling the MAG welding apparatus and apparatus for creating holes.