Vibro-Spot Welding Electrode Segmentation for Plastic Flow
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Solution Overview
Problem
Existing vibro-spot welding methods face limitations in achieving widespread plastic flow and strong welding strength due to simple cross-sectional shapes of vibration electrodes, leading to potential surface defects and mechanical weaknesses in welded metal plates.
Innovation Solution
A device and method employing a pair of vibration electrodes with a complex cross-sectional design, including a vibration cylinder housing with divided piston chambers and individually controlled pistons, allowing for various vibration patterns and controlled current and stroke to induce extensive plastic flow and solid-phase welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a simple cross-sectional shape of vibration electrode is used, then the device complexity is reduced, but the plastic flow of welding portions is limited and welding strength is insufficient
Solution Approach 1:
The vibration electrode is divided into multiple segments with different cross-sectional shapes (e.g., circular, rectangular, triangular sections) along its length, allowing each segment to generate different vibration patterns and plastic flow characteristics, thereby improving welding strength without requiring a completely complex electrode design
Solution Approach 2:
The invention transitions from considering only the cross-sectional shape to incorporating the longitudinal dimension by varying the cross-sectional shape along the length of the electrode, creating a three-dimensional structural solution that enhances welding performance
2Productivity
If high current is applied for spot welding, then welding speed is improved, but electric arc occurs and surface defects are generated
Solution Approach 1:
The vibration electrode applies periodic vibratory motion during the welding process, creating cyclic plastic flow that enhances welding speed while the intermittent nature of vibration prevents continuous electric arc formation and reduces surface defects
Solution Approach 2:
Mechanical vibration is introduced to the welding process through the vibration electrode, which generates plastic flow and enhances welding speed while avoiding the harmful effects of electric arc associated with conventional high-current spot welding
3Strength
If friction stir welding is used for light metal plates, then electric arc does not occur and mechanical strength is excellent, but welding indentation or hole remains at the welding surface
Solution Approach 1:
The vibration electrode acts as an intermediary between the heating electrode and the metal plates, transferring mechanical vibration energy to generate plastic flow and achieve welding, thereby avoiding direct contact and indentation issues of friction stir welding while maintaining excellent mechanical strength
4Device complexity
If vibration electrodes are disposed on both surfaces with simple cross-sectional shape, then device complexity is reduced, but widespread plastic flow and strong welding strength cannot be achieved
Solution Approach 1:
Different segments of the vibration electrode are designed with different cross-sectional shapes tailored to specific welding requirements, creating localized quality variations that generate diverse plastic flow patterns and ensure reliable welding across different metal plate configurations
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 enables strong welding strength by promoting widespread plastic flow and solid-phase welding, reducing surface defects and mechanical weaknesses, while accommodating different metal types and thicknesses through controlled current and vibration patterns.
Implementation Method 1
heat due to electrical resistance and pressure are applied to welding portions of the overlapped metal plates
Implementation Method 2
generates plastic flow at the welding portions by moving the welding portions reciprocally
Implementation Method 3
applying linear and repetitive load to the welding portions using a heating electrode and vibration electrodes
Implementation Method 4
solid phase welding means welding method in which a probe of a rotating tool is inserted into the overlapped metal plate
Implementation Method 5
the metal plates around the tool are softened by frictional heat between the rotating probe and the metal plates
Data Source
AI summary
A device of vibro-spot welding includes: a vibration cylinder housing having first and second chambers; an annular rod integrally connected with a first piston disposed in the first chamber and having one end penetrating a side of the vibration cylinder housing; a circular rod penetrating the annular rod integrally connected to a second piston disposed in the second chamber and having one end penetrating the side of the vibration cylinder housing; a leading-in housing wrapping an exterior surface of the vibration cylinder housing and receiving current; an electrode supporter threaded with one end of the leading-in housing; a heating electrode threaded with one end of the electrode supporter; a first vibration electrode threaded with the one end of the annular rod and penetrating the electrode supporter and the heating electrode; and a second vibration electrode threaded with the one end of the circular rod and penetrating the first vibration electrode.