Spot Welding Arm Elastic Displacement Calculation
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Solution Overview
Problem
Conventional spot welding systems face challenges in accurately calculating the elastic displacement of gun arms, which affects welding accuracy, due to variations in gun arm spring constants and the need for individual reference data for each gun arm.
Innovation Solution
A spot welding system that includes a base, fixed and movable arms, electrode tips, and a drive part with position detection and spring constant calculation components to determine the combined and individual spring constants of the arms, allowing for precise calculation of elastic displacement and position correction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional even application of reference data is used to estimate elastic displacement, then the system is simple to operate, but the manufacturing precision of welding accuracy deteriorates due to individual gun arm variations
Solution Approach 1:
The system changes the parameter of spring constant from a fixed reference value to a dynamically calculated value based on actual gun arm characteristics. By calculating the combined spring constant from the relationship between pressing force and elastic displacement, the system adapts to individual gun arm variations, thereby improving welding accuracy while maintaining operational simplicity through automated calculation.
Solution Approach 2:
The system implements feedback by using the detected elastic displacement and pressing force data to calculate and update the spring constant for each gun arm. This feedback mechanism allows the system to continuously improve welding accuracy by adjusting the spring constant based on actual performance, eliminating the need for manual reference data measurement while maintaining ease of operation.
2Manufacturing precision
If individual reference data is obtained for each gun arm to improve welding accuracy, then the manufacturing precision improves, but the device complexity and time required for measurement increase
Solution Approach 1:
The system enables self-service by automatically calculating the spring constant for each gun arm using the detected elastic displacement and pressing force data. This eliminates the need for manual measurement and setup of individual reference data, reducing device complexity and preparation time while maintaining high welding accuracy through automated, individualized spring constant calculation.
Solution Approach 2:
The system performs preliminary action by calculating the spring constant automatically during the welding process setup phase using detected data, rather than requiring manual measurement beforehand. This preliminary automated calculation prepares the individualized spring constant values needed for accurate welding, reducing both device complexity and measurement time while ensuring high welding accuracy.
3Manufacturing precision
If manual measurement of reference data is performed for each gun arm, then the manufacturing precision improves, but the productivity decreases due to additional preparation time
Solution Approach 1:
The system performs self-service by automatically calculating individual spring constants using detected elastic displacement and pressing force data during normal operation. This eliminates the need for manual measurement and preparation of reference data for each gun arm, thereby maintaining high welding accuracy while significantly improving productivity by removing time-consuming manual setup procedures.
Solution Approach 2:
The system ensures continuity of useful action by continuously detecting elastic displacement and pressing force data to calculate spring constants during the welding process, rather than requiring separate manual measurement steps. This continuous automated calculation maintains high welding accuracy while improving productivity by eliminating interruptions and preparation time associated with manual reference data measurement.
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 approach enables accurate calculation of elastic displacement for individual gun arms, improving welding accuracy and reducing the need for manual reference data measurement, while allowing for frequent measurement of spring constant changes due to aging degradation.
Implementation Method 1
when the workpiece to be welded is pressed between the movable electrode tip and the fixed electrode tip, a gun arm which supports the movable electrode tip and the fixed electrode tip is elastically displaced
Data Source
AI summary
A spot welding system includes a position detection part which detects the position of a movable arm, a first calculation part which calculates the combined spring constant of the movable arm and a fixed arm based on a position when the movable arm is driven by a predetermined drive force and the drive force, a second calculation part which calculates the spring constant of the movable arm based on a position when the movable arm is driven by a predetermined drive force and the drive force, a third calculation part which calculates the spring constant of the fixed arm based on the combined spring constant and the spring constant of the movable arm, and an elastic displacement calculation part which calculates an amount of elastic displacement of the fixed arm based on the spring constant of the fixed arm and a drive force when welding is performed.