Single-Sided Spot Welding Head for Complex Joint Access
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Solution Overview
Problem
Existing single-sided welding heads have a limited range of operable joints due to fixed or axially movable electrodes, making it impractical to weld complex geometries like those found in motor vehicles without significant modifications to the metal sheets or equipment, which is costly and inefficient.
Innovation Solution
A single-sided welding head with movable electrodes that allow angular, linear, and orthogonal motion, enabling the electrodes to be positioned adaptively to align with a wide range of joint geometries by varying their angle, offset, and distance, facilitated by a combination of actuators and cradles connected to an industrial robot for precise manipulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the welding head uses fixed or axially movable electrodes, then the structure is simple, but the range of operable joints is limited
Solution Approach 1:
The patent applies dynamics by transforming fixed or axially movable electrodes into dynamically adjustable electrodes that can perform angular motion and transverse movement. The first electrode is mounted on a cradle allowing angular motion about an axis, while the second electrode can move transversely relative to the first electrode, enabling the welding head to adapt to various joint geometries.
Solution Approach 2:
The patent introduces additional dimensions of movement beyond simple axial motion. The first electrode gains angular motion capability (rotational dimension), and the second electrode gains transverse movement capability (lateral dimension), transforming a one-degree-of-freedom system into a multi-degree-of-freedom system that can access complex joint geometries.
2Adaptability or versatility
If the welding head uses movable electrodes with multiple degrees of freedom, then the range of operable joints is expanded, but the device complexity increases
Solution Approach 1:
The patent segments the electrode positioning function into two independent subsystems: the first electrode with angular motion capability mounted on a cradle, and the second electrode with transverse movement capability. This segmentation allows each electrode to be controlled independently, simplifying the control architecture while achieving complex positioning capabilities.
Solution Approach 2:
The welding head achieves multi-functionality by enabling the electrodes to perform multiple types of movements (angular motion, transverse movement, axial movement) that allow a single welding head design to handle various joint geometries including T-joints, lap joints, and joints with humps or projections, replacing the need for multiple specialized welding heads.
3Manufacturing precision
If the electrode geometry is adapted to specific joint types, then welding precision is improved, but the equipment cannot operate on other joint types
Solution Approach 1:
Instead of using fixed electrode geometries optimized for specific joint types, the patent implements dynamic electrode positioning systems that can adjust the orientation and position of electrodes in real-time. The first electrode can rotate angularly about an axis, and the second electrode can move transversely, allowing precise positioning accuracy across multiple joint types without requiring physical reconfiguration of the electrode geometry.
Data Source
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AI summary
Described herein is a single-sided welding head (1) comprising a first welding electrode (2) and a second welding electrode (4), the first and second welding electrodes (2, 4) being carried by a body (6) of said welding head (1), wherein: - the first welding electrode (2) is movable relative to the body (6) of said welding head (1) at least along a first co-ordinate of motion (θ2); - the second welding electrode (4) is movable relative to the body (6) of said welding head (1) at least along a second co-ordinate of motion (X4); - said first co-ordinate of motion (θ2) is a co-ordinate of angular motion that develops about a first axis of rotation (X2); and - said second co-ordinate of motion (X4) is a co-ordinate of linear motion that develops along a first axis of translation (X4).