Stud Welding Head With Spring Coupling for Dual Ignition Modes
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Solution Overview
Problem
Existing stud welding technologies are inflexible and prone to wear, as they are specialized for specific welding processes, and current solutions for reducing wear are costly and not suitable for compact welding systems like welding guns.
Innovation Solution
A welding head with a movably mounted stud holder and a spring element, coupled with an electric drive via a controllable coupling unit, allowing for flexible movement sequences and dynamics, enabling both drawn arc and tip ignition welding processes with the same head, while minimizing wear on the electric drive.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a reciprocating piston is connected directly to the electric motor to transmit force, then the bolt can be moved along the axis, but the electric motor is damaged due to transmitted forces
Solution Approach 1:
The system is divided into two distinct operational modes: spring-loaded operation for the plunging movement and electric motor operation for the lifting movement. This segmentation allows each component to perform its designated function without subjecting the electric motor to damaging forces during the plunging phase.
Solution Approach 2:
The system dynamically switches between spring-loaded operation and electric motor operation based on the required movement phase. The spring element is engaged during plunging to protect the motor, while the motor is engaged during lifting. This dynamic operation allows the system to adapt its force transmission mechanism to the specific operational requirements.
2Reliability
If complex composite systems are used to reduce wear, then wear is reduced, but costs increase and compactness is compromised
Solution Approach 1:
The spring element serves a dual function: it provides the plunging force and simultaneously acts as a protective element that absorbs forces during decoupling. This self-service approach eliminates the need for additional complex protective mechanisms while maintaining wear resistance and reliability.
Solution Approach 2:
The harmful forces acting on the electric motor are extracted and redirected through the spring element and buffer element. Instead of using complex composite systems to manage these forces, the invention extracts the force transmission path during plunging and redirects it through passive mechanical elements that do not involve the electric motor.
3Reliability
If the welding head is specialized for a specific welding process, then it provides optimized performance for that process, but it becomes inflexible and cannot implement other welding processes
Solution Approach 1:
The system employs dynamic operation modes that can be switched based on the required welding process. By dynamically engaging or disengaging the electric motor and spring element, the system can adapt its movement characteristics to match the requirements of different welding processes such as drawn arc or tip ignition welding.
Solution Approach 2:
The welding head is designed with multi-functionality to accommodate different welding processes. The combination of spring-loaded plunging capability and electric motor-driven lifting capability allows the same welding head to perform both drawn arc welding and tip ignition welding, eliminating the need for process-specific specialized heads.
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 solution provides high functional reliability, robustness, and quality of the welded joint, with the ability to adapt movement sequences and dynamics, reducing wear and maintaining the integrity of the electric drive, thus being suitable for compact welding systems.
Implementation Method 1
a spring element which presses the stud holder along the axis in the direction of the workpiece
Implementation Method 2
an arc is always ignited, which heats the component and the workpiece in a designated area so that a melt or a melt lens is formed in this area
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3~4
AI summary
The invention relates to a welding head and a welding device, as well as a method for welding a stud (1) to a workpiece (2) according to the principle of lift ignition, and a method for welding a stud (1) to a workpiece (2) according to the principle of tip ignition. The welding head is designed to perform both welding methods, i.e., both according to the principle of lift ignition and according to the principle of tip ignition.