Voice Coil Material Positioning for Consistent Welding Force
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Solution Overview
Problem
Existing material positioners in the welding industry face challenges in providing quality welds with high productivity due to varying spring rates, manual reconfiguration for different materials, and inefficiencies in pneumatic/hydraulic systems, leading to increased costs and reduced productivity.
Innovation Solution
A material positioner utilizing a first and second fixture with adjustable positioning mechanisms, including a voice coil actuator (VCA) controlled by a control unit, ensures consistent force application based on material characteristics, enabling efficient welding of various materials without manual reconfiguration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If spring force is used to position the material, then the material can be positioned in the weld area, but the spring rate changes during useful life causing less quality welds
Solution Approach 1:
The patent replaces the mechanical spring-based positioning system with a voice coil actuator (VCA) that uses electromagnetic force to position materials. This substitution eliminates the problem of varying spring rates during the component's useful life, as the VCA provides consistent positioning force through electrical control rather than mechanical elasticity.
Solution Approach 2:
The patent changes the control parameter from mechanical spring compression to electrical signal control. The VCA's positioning force can be precisely adjusted by varying the electrical signal parameters, allowing consistent positioning performance throughout the device's operational life without degradation.
2Adaptability or versatility
If manual reconfiguration is used for different materials, then the welder can accommodate various materials, but production time increases impacting productivity
Solution Approach 1:
The patent implements a control unit that automatically determines the appropriate positioning force for different materials based on their characteristics. The system self-adjusts by selecting the correct VCA signal parameters without requiring manual intervention, thereby maintaining versatility while eliminating the time-consuming manual reconfiguration process.
Solution Approach 2:
The control unit is pre-programmed with material characteristics and corresponding positioning parameters. When a material is identified, the system automatically retrieves and applies the pre-determined optimal settings, eliminating the need for manual adjustment and maintaining high productivity across different material types.
3Adaptability or versatility
If pneumatic or hydraulic cylinders are used to provide force, then the welder can operate over a wider range of materials, but the system becomes inefficient when not all material needs are required at maximum pressure
Solution Approach 1:
The patent replaces pneumatic/hydraulic pressure systems with an electrically-controlled VCA that can precisely modulate positioning force through electrical signal adjustment. This allows the system to provide exactly the right amount of force needed for each specific material, eliminating the energy waste associated with oversized pneumatic/hydraulic systems operating at maximum pressure for all materials.
Solution Approach 2:
Instead of using maximum pressure capacity for all welding operations, the VCA applies only the necessary positioning force required for each specific material size and type. This partial action approach eliminates the energy waste of using excessive force for small-diameter materials while maintaining the capability to handle large-diameter materials when needed.
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 enhances weld quality and productivity by maintaining a constant force throughout the welding process, accommodating a wide range of materials and simplifying setup, thus reducing costs and operational complexity.
Implementation Method 1
A material positioner utilizing a first and second fixture with adjustable positioning mechanisms, including a voice coil actuator (VCA) controlled by a control unit
Implementation Method 2
a heat generator adapted to weld the first and second materials to each other
Data Source
AI summary
A material positioner can utilize characteristics of the material being welded to locate the material to be welded. In some embodiments, the material positioner has a voice coil actuator (VCA) for material positioning. In some embodiments, the VCA is sent a signal based on the characteristics of the material being welded and/or the type of weld being completed. In at least some embodiments, a single welder can be used over a wide range of materials. In some embodiments, end-uses that require components to be in generally mating engagement for further processing can benefit from a material positioner.