Stud Welding Gun With Auto Plunge Setting and Weld Feedback
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for fastening bolts to substrates are complex and dependent on user expertise, as they require manual adjustment of parameters like electrical current duration and power, and visual inspection for connection quality, which can be inconsistent.
Innovation Solution
A welding gun with a retaining spring and carrier spring mechanism that automates the bolt lifting and immersion process, using a control device to manage electrical current and gas supply for consistent bonding, and an input/output system for parameter setting and process feedback.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual adjustment of welding parameters is used, then user flexibility is maintained, but operation complexity and dependency on user expertise increase
Solution Approach 1:
The welding gun automatically determines welding parameters based on detected bolt characteristics and automatically adjusts settings without user intervention. The system performs self-measurement of bolt diameter and self-adjustment of welding current and duration, eliminating the need for manual parameter setting while maintaining adaptability to different bolt types.
2Measurement precision
If visual inspection for connection quality is used, then simple equipment is required, but measurement precision and reliability decrease
Solution Approach 1:
The system incorporates sensors that detect welding parameters in real-time and provide feedback to the control unit. The control unit monitors welding current, duration, and bolt characteristics, automatically adjusting parameters to ensure optimal welding quality. This closed-loop feedback system replaces subjective visual inspection with objective measurement while keeping the device relatively simple.
3Manufacturing precision
If automated parameter adjustment is implemented, then manufacturing precision improves, but device complexity increases
Solution Approach 1:
The system replaces manual mechanical adjustment with electronic sensing and control. A detection unit measures bolt characteristics (diameter, material properties) and the control unit electronically adjusts welding parameters based on this data. This substitution of mechanical adjustment with electronic control achieves high precision while keeping the overall device complexity manageable through integration.
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
Simplifies the fastening process by automating key steps, ensuring consistent connection quality and reducing user dependency on experience, while providing real-time feedback on process parameters and outcomes.
Implementation Method 1
a lifting magnet (155) and a carrier (156), wherein the lifting magnet (155) is fixed to the carrier (156) and the holding device (144) is movable relative to the carrier (156) in the welding direction (110) and movable by the lifting magnet (155)
Implementation Method 2
an electric current flows between the bolt and the substrate, the bolt is lifted from the substrate by forming an electric arc. Due to the energy released, parts of the bolt and substrate material partially liquefy
Implementation Method 3
To prevent oxidation of the liquefied material, it is known to purge the contact point between the bolt and the substrate with an inert gas
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The invention relates to a welding gun (40) for welding a welding stud (20, 120) in a welding direction to a substrate (30), comprising a holding device (144) for holding the welding stud during a welding process, wherein the welding stud has a contact surface (125), which is provided in order to contact the substrate before and/or during the welding process, furthermore comprising a stud lifting device (150) for conveying the holding device into a plunge start position in the welding direction, furthermore comprising a stud plunging device (160) for conveying the holding device from the plunge start position in the welding direction, furthermore comprising a support element (170) having a support surface (175) for supporting the welding gun on the substrate, and furthermore comprising a device for automatically adjusting the plunge start position relative to the support surface in the welding direction.