Swing-Type Electrode Chip Replacement Device for Bent Shank Protection
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Solution Overview
Problem
Conventional electrode chip replacement methods for spot welding machines often damage the shank when it is bent, due to the application of concentrated loads and unstable insertion processes, leading to removal failures and increased production downtime.
Innovation Solution
A swing-type electrode chip replacement apparatus with a movable plate that slides and swings, equipped with a restricting mechanism, urging means, and restoring mechanism, allowing for secure attachment and detachment of electrode chips without damaging the shank, even when it is bent.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a fork-like lever is inserted into the tapered portion of the shank and tilted to remove the electrode chip using leverage, then the electrode chip can be removed automatically without stopping the production line, but a concentrated load is applied to the shank and corner of the electrode chip causing damage
Solution Approach 1:
The patent introduces a U-shaped insertion portion as an intermediary structure that receives the shank. This insertion portion distributes the removal force across multiple contact points along the shank's tapered surface, rather than concentrating force at a single corner. The intermediary structure acts as a buffer that prevents direct concentrated loading on both the shank and electrode chip corner during automatic removal
Solution Approach 2:
The removal force is segmented and distributed through the U-shaped insertion portion that contacts multiple points on the shank. Instead of a single lever applying concentrated force, the insertion portion segments the force application across its curved surface, reducing peak stresses on both the shank and electrode chip
2Ease of operation
If the shank is separated when the electrode chip is melted and coagulated with a welding object member, then the electrode chip can be removed, but the shank can be bent slightly
Solution Approach 1:
The U-shaped insertion portion is designed with a geometry that provides beforehand cushioning for the shank during separation. The curved surfaces and controlled clearance in the insertion portion cushion the shank against sudden bending forces that occur during electrode chip removal, especially when the chip is melted and coagulated with the workpiece
Solution Approach 2:
The insertion portion allows controlled dynamic movement of the shank during the removal process. The design accommodates slight bending through controlled clearance and flexible contact, allowing the shank to move dynamically without suffering catastrophic damage from rigid constraints during the separation process
3Productivity
If the shank strikes a jig or welding object member during separation, then the electrode chip can be removed, but the shank may be bent
Solution Approach 1:
The U-shaped insertion portion serves as an intermediary guide structure that controls the separation path of the shank. By providing a defined geometric path within the insertion portion, the shank is guided away from jigs and welding object members, preventing accidental strikes that would cause bending while maintaining automatic removal capability
4Ease of operation
If the shank is bent and inserted forcibly into the insertion portion, then the electrode chip can be removed, but the shank is damaged
Solution Approach 1:
The insertion portion is designed with dynamic clearance and flexible contact surfaces that adapt to slightly bent shanks. Rather than requiring precise alignment, the design allows the shank to naturally settle into the insertion portion through controlled movement, eliminating the need for forcible insertion that would damage the shank
Data Source
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AI summary
This invention provides a swing type electrode chip replacement apparatus which enables an electrode chip to be attached/detached without damaging a shank even if the shank is bent. The swing type electrode chip replacement apparatus comprises a fixed plate 20 located in the vicinity of a spot welding machine and a movable plate 21 slidable in the back-forth direction on the fixed plate 20, its front end being swingable in the right-left direction. An attaching unit 1 for attaching an electrode chip 95 to the tip of a shank 90 of a spot welding machine or a magazine of the electrode chip 60 for removing the electrode chip 95 is loaded on this movable plate 21, which is slidable in the back-forth direction and swingable in the right-left direction when the shank 90 comes into contact with the attaching unit 1 or the magazine of electrode chips 60.