Stud Welding Gun With Integrated Gas Supply and Auto Current Control
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Solution Overview
Problem
The existing methods for attaching bolts to substrates are complex, requiring high amperage electrical currents and manual adjustment of parameters, which can lead to inconsistent bonding quality due to user experience and skill variations.
Innovation Solution
A welding device with a welding gun that integrates a gas tank, gas line, and control systems for automated gas flow and electrical current management, allowing for controlled welding processes and improved bonding consistency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the gas container is transported separately from the welding device, then the gas supply is available, but the device complexity and ease of operation are reduced due to manual handling requirements
Solution Approach 1:
The patent combines the gas container with the welding device by providing a receptacle on the welding device housing that receives and supports the gas container. This integration eliminates the need for separate manual handling of the gas container, simplifies the overall system operation, and reduces the complexity associated with managing separate components.
Solution Approach 2:
The welding device is designed to automatically manage the gas container through the integrated receptacle system, eliminating the need for user intervention in gas container handling and positioning. The device serves itself by incorporating the gas supply management directly into its structure.
2Manufacturing precision
If manual parameter adjustment is used for welding current and duration, then the device is simpler, but the manufacturing precision and reliability are reduced due to user skill variations
Solution Approach 1:
The patent incorporates a control unit that automatically controls the welding current and duration based on pre-set parameters. This automated control system eliminates variations caused by manual adjustment, ensuring consistent bonding quality. The control unit manages the welding process parameters without requiring user skill or judgment, thereby improving manufacturing precision.
3Power
If high electric current is supplied via external cables, then the welding energy is sufficient, but the ease of operation and portability are reduced
Solution Approach 1:
The patent integrates the gas container and its support structure directly into the welding device housing. This merging of components creates a self-contained unit that maintains full welding functionality while improving ease of operation by eliminating separate gas container handling and reducing the overall system complexity.
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 device simplifies and improves the bolt attachment process by automating gas flow and electrical current control, ensuring consistent bonding quality and reducing user dependency on experience.
Implementation Method 1
an electric current is applied. As soon as the electric current flows between the bolt and the substrate, the bolt is lifted from the substrate by the formation of an electric arc. Due to the energy released, the material of the bolt and the substrate partially liquefies.
Implementation Method 2
a gas flow control device for regulating the gas flow through the gas line
Data Source
Figure 1
Figure 2
AI summary
Disclosed is an apparatus for welding a weld stud to a substrate, comprising a welding gun which includes a casing and a stud holder for the weld stud, further comprising a gas container and a gas line for conducting gas from the gas container to the stud holder, the gas container being supported by the welding gun.