Resistance Spot Welding Electrode Motion for Uneven Steel Plates
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Solution Overview
Problem
Resistance spot welding of layered steel plates with different thicknesses often results in inadequate nugget merging into thinner plates, leading to welding failures and high costs due to the need for electrodes with high thermal conductivity, while increasing electric current generates spatters.
Innovation Solution
A method and apparatus for resistance spot welding using two electrodes, where the second electrode moves parallel to the surface of the thinner steel plate, thrusting into it to push the nugget formed before deviation, thereby increasing the merged nugget amount without limiting electrode materials and reducing spatter generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If electric current is increased to improve nugget merging into thinner steel plates, then weld strength is improved, but spatter generation increases
Solution Approach 1:
The second electrode is moved in the thickness direction of the workpiece during welding. This dynamic adjustment allows the electrode position to be optimized in real-time, improving nugget merging into thinner plates without requiring excessive current increase, thereby reducing spatter generation while maintaining weld strength
Solution Approach 2:
The invention changes the position parameter of the second electrode in the thickness direction of the workpiece. By adjusting the electrode position rather than only increasing current, the nugget can merge better into thinner plates without causing excessive spatter, resolving the contradiction between weld strength and spatter control
2Strength
If two kinds of electrodes made of different materials are used to adjust nugget position, then weld strength is improved, but electrode cost increases
Solution Approach 1:
The invention makes the electrode position adjustable in the thickness direction, allowing a single electrode configuration to adapt to different plate thickness combinations. This eliminates the need for multiple specialized electrodes made of different materials, reducing cost while maintaining the ability to optimize nugget position for various welding scenarios
Solution Approach 2:
By making the second electrode movable in the thickness direction, the system achieves dynamic adaptability to different workpiece configurations. This replaces the static solution of using different electrode materials with a dynamic positional adjustment mechanism, reducing electrode cost while maintaining weld quality
3Manufacturing precision
If the second electrode moves relative to the first electrode in the thickness direction of the workpiece, then nugget merging into thinner plates is improved, but device complexity increases
Solution Approach 1:
The second electrode is made movable in the thickness direction of the workpiece, allowing dynamic adjustment of electrode position during welding. This enables precise control of nugget formation and merging into thinner plates, achieving high manufacturing precision through controlled movement rather than complex multi-electrode configurations
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 enhances weld strength of steel plates with different thicknesses without the need for expensive electrodes and minimizes spatter production, ensuring stable and productive welding.
Implementation Method 1
resistance spot welding
Data Source
AI summary
A method of resistance spot welding that enables an improvement of a weld strength of steel plates having different plate thicknesses while inhibiting generation of spatters is provided. One aspect of the present disclosure is the method of resistance spot welding, the method including welding a workpiece made of layered steel plates with a resistance spot welding apparatus. The resistance spot welding apparatus includes a first electrode configured to contact a first steel plate among the steel plates, and a second electrode configured to contact, among the steel plates, a second steel plate that is thinner than the first steel plate, and the second electrode being arranged such that the workpiece is interposed between the first electrode and the second electrode. The welding includes welding while moving the second electrode relative to the first electrode in a direction parallel with a plate surface of the second steel plate.