TIG Coil Welding Start for Uneven Terminal Heights
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Solution Overview
Problem
Existing terminal member welding methods, such as those described in Patent Literature 1, face challenges in achieving accurate and even welding when the distances from the tip surfaces of the workpieces to the electrode tip are different, leading to uneven melting and bead formation.
Innovation Solution
A welding method that detects the workpiece with a shorter distance to the electrode tip, abuts the electrode tip on its surface, and then generates an arc by separating the electrode tip from this workpiece while maintaining energization, allowing for uniform melting and welding of both workpieces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electrode tip is inserted in the gap of the welded joint to perform TIG welding, then welding can be performed between terminal members, but highly accurate positioning is needed and abrasion of the electrode tip proceeds
Solution Approach 1:
The electrode tip is made to abut on the tip surface of one workpiece before welding starts. This preliminary contact ensures proper positioning and eliminates the need for highly accurate gap insertion, while also preventing electrode tip abrasion that occurs with repeated insertion and pull-out movements
2Adaptability or versatility
If the heights of the first and second terminal members are different, then welding can be performed on uneven surfaces, but contact areas of the terminal members and electrode are uneven and melting is not evenly performed
Solution Approach 1:
One workpiece acts as an intermediary by providing a stable tip surface for the electrode to abut on. This intermediary approach ensures uniform contact area and even melting, allowing welding between terminal members of different heights without compromising welding quality
Solution Approach 2:
The electrode tip concentration is localized on the tip surface of one workpiece that has been selected as the abutment target. This localized contact ensures uniform energy distribution and even melting at the welding point, regardless of the height difference between the two workpieces
3Adaptability or versatility
If the distances from respective tip surfaces to the electrode tip are different, then welding can be performed on workpieces at different positions, but contact areas are uneven and welding cannot be performed sometimes
Solution Approach 1:
The system performs preliminary detection to identify which workpiece has the shorter distance to the electrode tip. Based on this detection, the electrode tip is made to abut on the detected workpiece's tip surface, ensuring optimal contact area and reliable welding initiation even when workpieces are at different distances
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 method ensures reliable and uniform welding even when the distances from the tip surfaces of the workpieces to the electrode tip are different, preventing melting defects and ensuring a uniformly formed weld bead.
Implementation Method 1
generating an arc by separating the tip of the energized electrode from the tip surface of the one detected in the first step, after the second step, and arc welding the first workpiece and the second workpiece
Data Source
AI summary
A TIG welding device (10) includes a welding robot (11), robot control device (12), welding torch (13), welding control device (14), gas feeder (15), and a height detection device (16). The welding torch (13) is set at a reference position, and the height detection device (16) detects the respective heights of two tip parts (4e). The robot control device (12) drives the welding robot (11) such that a torch electrode (13c) of the welding torch (13) abuts on central part of the higher tip part (4e). When the torch electrode (13c) is moved toward the reference position while power is supplied to the torch electrode (13c), and inert gas flows in the periphery of the torch electrode (13c), arc (AC) is generated in a gap between the tip parts (4e) and the torch electrode (13c). The overall two tip parts (4e) are melted and welded by this arc (AC).