Resistance Welder Electrode Misalignment Detection by Simultaneous Clamping
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Solution Overview
Problem
Existing electrode-misalignment detection devices in resistance welders are unable to effectively detect misalignment of both upper and lower electrodes, leading to welding defects and reduced conduction efficiency.
Innovation Solution
An electrode-misalignment detection device that includes clamping members, a signal generator, a non-closed-state detector, and a misalignment determiner, which simultaneously approach the outer peripheries of both electrodes to detect misalignment by determining if the clamping members are in a predetermined closed state, and optionally uses electrode distance sensors to detect misalignment through non-contact distance measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a conductive detection plate with a tolerance hole is used to detect electrode misalignment, then misalignment detection capability is improved, but the device complexity increases and only single-electrode misalignment can be detected
Solution Approach 1:
The detection function is segmented into two independent detection paths: one for upper electrode misalignment and one for lower electrode misalignment. Each path uses a simple clamping member with a stopper, eliminating the need for a complex detection plate while enabling simultaneous detection of both electrodes.
Solution Approach 2:
The detection plate is extracted and replaced with simpler clamping members. The stopper elements are extracted from the complex plate structure and used as independent detection indicators on separate clamping members, simplifying the overall device structure.
2Measurement precision
If the robot is taught to fit electrodes into the tolerance hole sequentially, then misalignment detection is achieved, but the detection process becomes time-consuming and reduces productivity
Solution Approach 1:
The clamping members are preliminarily positioned at the determination position before electrode welding. The stoppers are pre-configured to indicate misalignment, allowing simultaneous detection of both electrodes without sequential teaching or repeated positioning operations.
Solution Approach 2:
The clamping members with stoppers automatically indicate misalignment through their own mechanical configuration. The stoppers serve as self-indicating elements that visually show when electrodes are misaligned, eliminating the need for complex teaching procedures or repeated detection cycles.
3Adaptability or versatility
If the detection plate is disposed within the movable range of the robot, then detection flexibility is improved, but the detection precision for both electrodes simultaneously is reduced
Solution Approach 1:
The single detection plate is segmented into multiple independent clamping members positioned at different locations. Each clamping member independently detects one electrode, enabling simultaneous detection of both upper and lower electrodes with high precision while maintaining flexibility in positioning.
Solution Approach 2:
The detection approach transitions from a single-plane detection plate to a multi-dimensional arrangement of clamping members with stoppers. The stoppers extend in the radial direction of electrodes, creating a new dimensional indicator system that enables simultaneous detection without compromising precision.
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 accurately detects misalignment of either electrode, ensuring proper alignment for improved resistance welding quality and preventing defects by providing notifications for operator correction.
Implementation Method 1
a clamping member movable toward the outer peripheries of the both of the opposing electrodes to clamp the opposing electrodes from opposite radially outer sides
Implementation Method 2
a signal generator configured to output a movement state signal according to a movement state of the clamping member toward the outer peripheries of the opposing electrodes
Implementation Method 3
resistance welding is mainly achieved by melting joint members using Joule's heat produced in accordance with contact resistance between the joint members
Implementation Method 4
Joule's heat produced in accordance with contact resistance between the joint members
Data Source
AI summary
An electrode-misalignment detection device in a resistance welder that joins members together by holding them between opposing electrodes and applying pressure and electricity thereto includes an electrode misalignment detector that simultaneously approaches outer peripheries of both electrodes to detect misalignment thereof. The electrode misalignment detector includes a clamping member, a signal generator, a non-closed-state detector, and a misalignment determiner. The clamping member is movable toward the electrodes to clamp them from opposite radially outer sides and is settable in a predetermined closed state when the electrodes are located at appropriate positions. The signal generator outputs a movement state signal according to a movement state of the clamping member. The non-closed-state detector detects that the clamping member is in a state other than the predetermined closed state based on the movement state signal. The misalignment determiner determines electrode misalignment if the clamping member is not in the predetermined closed state.