Spot Welding Apparatus with Dual Actuators for Stacked Plates
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Solution Overview
Problem
Existing spot welding apparatuses face challenges in achieving high weld quality and workability when welding stacked plates of different rigidities due to uneven pressing forces and varying contact resistances, leading to inconsistent current densities and reduced weld strength.
Innovation Solution
A spot welding apparatus with a pressing force actuator and a control pressing force actuator that allows for controlled pressing forces on the workpiece, reducing the apparatus's size and increasing the operating space, thereby stabilizing contact resistances and improving weld quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional spot welding apparatus is used to weld stacked plates of different rigidities, then the welding process can be performed, but the pressing forces become uneven and contact resistances vary, leading to inconsistent current densities and reduced weld strength
Solution Approach 1:
The patent applies parameter changes by independently controlling the pressing force parameters of the movable electrode and fixed electrode through separate actuators. This allows adjustment of contact pressure parameters to compensate for rigidity differences in stacked plates, ensuring uniform contact resistance and current density distribution, thereby improving weld strength and consistency.
2Manufacturing precision
If the pressing force of the movable electrode is reduced to improve current density distribution, then weld quality improves, but the apparatus requires complex control mechanisms that increase device complexity
Solution Approach 1:
The patent segments the pressing force control into two independent parts: a movable electrode actuator controlling the movable electrode's pressing force, and a fixed electrode actuator controlling the fixed electrode's pressing force. This segmentation allows independent adjustment of each electrode's contact pressure, simplifying the control strategy while achieving uniform current density distribution across plates of different rigidities.
3Ease of operation
If the apparatus size is reduced to improve workability and operating space, then ease of operation improves, but the arrangement of actuators and components becomes more constrained
Solution Approach 1:
The patent optimizes the spatial arrangement of actuators and components by utilizing the width direction dimension. The movable electrode actuator is arranged on one side of the support bracket while the fixed electrode actuator is arranged on the other side, extending in the width direction. This dimensional arrangement reduces interference between components, improves operating space, and enhances workability without compromising functional performance.
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 apparatus achieves improved weld quality and workability by ensuring consistent pressing forces and current densities across the workpiece, enhancing the weld strength and reducing the size and complexity of the welding equipment.
Implementation Method 1
a welding transformer serving as a power source that applies a current between the first welding electrode and the second welding electrode
Implementation Method 2
a pressing force actuator that causes a second welding electrode facing the first welding electrode to move between a pressing force applying position, where the second welding electrode holds a workpiece together with the first welding electrode such that the first welding electrode and the second welding electrode apply pressing forces to the workpiece
Data Source
AI summary
There is provided a spot welding apparatus. The spot welding apparatus includes a pressing force actuator that causes a movable electrode to move to a pressing force applying position where the movable electrode applies a pressing force to a workpiece together with a fixed electrode, a control pressing force applying actuator that causes a receiving unit to move to a control pressing force applying position where the receiving unit is located adjacent to the fixed electrode and comes into contact with the workpiece so as to apply a control pressing force, and a welding transformer. The control pressing force applying actuator and the welding transformer are linearly aligned at a rear side of the pressing force actuator that is arranged at a front side of a support bracket.