Resistance Pressure Welding Sphere to Metal Sheet
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Solution Overview
Problem
Existing methods for connecting spherical or ball-like geometries to metal sheets lack precision and reliability, hindering industrialization due to inadequate positioning accuracy and connection strength.
Innovation Solution
Resistance pressure welding is employed, utilizing a first electrode with a suction device to position and weld the ball to the metal sheet, with a high welding current generated for a short duration to achieve precise and strong connections, minimizing welding spatter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated welding methods are used to connect spheres to metal sheets, then productivity increases, but positioning accuracy deteriorates
Solution Approach 1:
The suction device captures and pre-positions the sphere on the first electrode before welding occurs. This preliminary positioning action ensures the sphere is correctly located relative to the metal sheet before the welding process begins, enabling both automated high-speed production and precise positioning accuracy.
2Strength
If welding current is applied for longer duration, then connection strength improves, but welding spatter increases
Solution Approach 1:
The welding process uses periodic action by discharging a capacitor to generate a high welding current for a very short, controlled duration (less than one second, particularly less than 60 ms or less than 10 ms). This time-limited periodic current application achieves strong connections while minimizing welding spatter.
3Strength
If high welding current is generated, then connection strength improves, but energy consumption increases
Solution Approach 1:
The capacitor discharge mechanism generates a very high welding current but only for a brief periodic interval (less than one second, particularly less than 60 ms or less than 10 ms). This allows strong connections to be formed with relatively low total energy consumption, as the high current is applied only when needed for the actual welding moment.
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
This method ensures high positioning accuracy and strong connections with short cycle times, maintaining a clean and high-quality welded joint, suitable for automated processes and applications like vehicle body panels.
Implementation Method 1
a suction device associated with the first electrode... into which the ball is sucked by means of a suction device
Implementation Method 2
the welding current is generated by discharging a capacitor, which has the advantage that a very high welding current can be generated for a short time
Implementation Method 3
the sphere is welded to the metal sheet by generating a welding current flowing through the metal sheet and the sphere between the two electrodes
Implementation Method 4
The basic idea of the invention is to connect the ball to the metal sheet by resistance pressure welding
Data Source
AI summary
The invention relates to a method for automatically welding a sphere (9) onto a metal sheet (12) comprising the following steps: providing a sphere (9); providing a first electrode (1); taking hold of the sphere by means of a first electrode (1); providing a metal sheet (12); providing a second electrode (15); pressing the metal sheet and the sphere (9) together, the sphere (9) being pressed against the metal sheet (12) by means of the first electrode (1) and the metal sheet (12) being pressed against the sphere (9) by means of the second electrode (15); welding the sphere (9) and the metal sheet (12) together by generating a welding current between the two electrodes (1, 15).