Wedge Electrode Tip Removal Structure for Load Distribution
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing removal devices for welding electrode tips often damage or deform due to high loads applied during the removal process, particularly because the insertion pieces receive concentrated bending and shearing forces, leading to increased manufacturing costs when attempting to strengthen them.
Innovation Solution
A removal device utilizing two wedge-shaped insertion pieces that overlap to increase thickness from the front end to the back, distributing the load across both sides of the insertion pieces, thereby reducing the risk of damage and deformation without requiring additional strengthening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single insertion piece is used to remove the electrode tip, then the device structure is simple, but the insertion piece receives concentrated bending and shearing forces leading to damage or deformation
Solution Approach 1:
The single insertion piece is divided into two separate insertion pieces (first and second insertion pieces) that are inserted into the space between the electrode tip and the large diameter portion. Each insertion piece contacts different semicircle areas, distributing the reactive force and reducing concentrated bending and shearing forces on each individual piece, thereby preventing damage or deformation.
2Reliability
If the insertion piece is strengthened by a thermal process, then the damage or deformation is prevented, but the manufacturing cost increases
Solution Approach 1:
Instead of strengthening the material through thermal processes, the solution segments the load-bearing function across two insertion pieces. This structural division distributes the reactive force, allowing the use of standard material specifications without additional heat treatment or strengthening processes, thereby maintaining low manufacturing costs while ensuring durability.
3Strength
If the contact length of the insertion piece is increased, then the bending moment and shearing force are reduced, but the device complexity increases
Solution Approach 1:
The total contact length requirement is achieved by segmenting the contact function across two insertion pieces. Each piece contacts a semicircle area of the electrode tip end surface, and together they provide sufficient contact length to reduce bending moment and shearing force without requiring each individual piece to be overly complex or elongated.
Solution Approach 2:
The solution transitions from a single-piece linear contact approach to a two-piece radial distribution approach. By arranging the two insertion pieces to contact different semicircle areas around the electrode tip, the contact is distributed in the radial dimension, effectively increasing the total contact length and reducing concentrated forces without increasing the complexity of each individual piece.
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 device effectively prevents damage and deformation of the insertion pieces by evenly distributing the load, allowing for the removal of welding electrode tips without increasing the strength of the components, thus maintaining efficiency and reducing costs.
Implementation Method 1
each of the first insertion piece and the second insertion piece having a wedge shape having a thickness that increases from a front end to a back portion in an insertion direction
Data Source
AI summary
A removal device of a welding electrode tip includes a first insertion piece and a second insertion piece that are inserted into a space formed between an end surface of a large diameter portion of a shank and an end surface of the welding electrode tip, each of the first insertion piece and the second insertion piece having a wedge shape having a thickness that increases from a front end to a back portion in an insertion direction, wherein the first insertion piece and the second insertion piece have a thickness by overlap of the first insertion piece and the second insertion piece, and the thickness changes from a thickness smaller than a length of the space to a thickness larger than the length of the space according to an overlap amount in the space.