Spot Welding Chip Collection With Impeller Suction and Low Noise
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Solution Overview
Problem
Existing chip collection systems for spot welding generate noise due to the use of compressors, which is undesirable for improving the work environment, and they require a solution that maintains performance without relying on compressor-supplied compressed air.
Innovation Solution
A chip collection system utilizing an electric motor-driven centrifugal impeller to generate suction force for collecting chips, eliminating the need for a compressor and incorporating noise-reducing features such as air filters with porous members and a design that minimizes noise generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a compressor is used to supply compressed air for chip collection, then chip collection performance is improved, but noise level increases
Solution Approach 1:
The patent replaces the compressor-based pneumatic system with an electric motor-driven impeller system. The impeller directly generates suction force by rotating and creating pressure differential, eliminating the need for compressed air generation and thus removing the noise source while maintaining chip collection capability
Solution Approach 2:
The patent extracts and removes the compressor component from the chip collection system. By eliminating the compressor entirely and using only the impeller for chip suction, the system removes the primary noise-generating element while preserving the essential chip collection function
2Ease of operation
If compressed air from a factory compressor is used, then chip collection is achieved, but the work environment deteriorates due to noise
Solution Approach 1:
The system replaces the factory compressor infrastructure dependency with a self-contained electric motor and impeller assembly. This substitution enables chip collection while eliminating the noise pollution that degrades the work environment
3Object-affected harmful factors
If an electric motor-driven impeller is used instead of a compressor, then noise is reduced, but chip collection performance may be compromised
Solution Approach 1:
The patent optimizes the impeller parameters including blade geometry, rotation speed, and housing design to maximize suction force generation. By carefully adjusting these parameters, the electric motor-driven impeller achieves sufficient chip collection performance while maintaining low noise operation
Solution Approach 2:
The impeller design replicates the effective suction-generating functionality of compressor systems but through a different mechanical approach. The impeller copies the pressure differential creation mechanism without using the noisy compressor architecture
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 effectively reduces noise while maintaining chip collection performance, improving the work environment by eliminating compressor noise and enhancing operational efficiency through efficient chip collection and disposal.
Implementation Method 1
an impeller rotatable by the electric motor to generate a suction force
Implementation Method 2
an air filter which is a vertically elongated bottomed cylinder... having a porous member in the inner space
Data Source
AI summary
A chip collection system includes a tip dresser that cuts a distal end of an electrode tip for spot welding, and a suction unit that sucks and collects chips (M1) produced when the distal end of the electrode tip is cut with the tip dresser. The suction unit includes an electric motor (6) being rotatable, a centrifugal impeller (5) rotatable by the electric motor (6) to generate a suction force, and a chip collection case (9) into which the chips (M1) are collectable. The suction unit collects chips (M1) moving with air sucked in response to rotation of the centrifugal impeller (5) into the chip collection case (9).