Tong-Type Welding Apparatus for Beading Flange Distortion Control
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Solution Overview
Problem
Conventional welding methods for seamed or beaded flanges in sheet metal components often result in unwanted impressions and distortions on the exterior-facing side due to local pressure and relative movement during the welding process, which affects the geometrical tolerances and surface finish of visible vehicle components.
Innovation Solution
A method and apparatus that utilize a tong-type welding apparatus with a support system, including a thermally conductive insert and a movable abutment with complementary guide surfaces, to clamp the beading flange between the joining electrode and the support, ensuring accurate positioning and distributing pressure evenly to prevent distortions, while also providing tong compensation for electrode wear and positioning inaccuracies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If conventional welding methods are used with the abutment clamping the component locally, then welding force is applied effectively, but unwanted impressions and distortions are produced on the exterior-facing side
Solution Approach 1:
The support is divided into multiple supports that can be positioned at different locations. Each support can be independently adjusted to provide distributed support across the component, preventing local pressure concentrations that cause surface distortions while maintaining effective welding force application.
Solution Approach 2:
The support system acts as a counterbalance to the clamping force applied by the welding apparatus. By positioning supports at strategic locations, the system counteracts the local pressure that would otherwise cause surface impressions, distributing the force evenly across the component without compromising welding effectiveness.
2Stability of the object's composition
If the abutment is urged against the flange during welding, then the parts are fixed relative to one another, but relative movement and distortions occur due to high temperatures
Solution Approach 1:
The support system incorporates adjustable and movable supports that can adapt to thermal expansion and movement during welding. The supports are positioned to maintain optimal contact with the component throughout the welding process, dynamically compensating for thermal effects and maintaining positioning stability without causing distortions.
Solution Approach 2:
The supports act as intermediary elements between the welding apparatus and the component. They provide a stable reference framework that mediates the interaction between the clamping force and the component, ensuring that parts remain fixed relative to one another while preventing direct transmission of distorting forces to the component surface.
3Power
If the joining electrode is placed directly on the flange, then welding current is applied effectively, but visible welding marks are produced on both sides of the flange
Solution Approach 1:
The harmful effect of visible welding marks is extracted and isolated to the interior-facing side of the component. By strategically positioning the joining electrode to contact only the interior side and configuring the support system to bear the welding current path, the welding marks are confined to the hidden surface while the exterior surface remains mark-free.
Solution Approach 2:
Different sides of the component are treated differently regarding welding mark acceptance. The interior-facing side is designed to accommodate welding marks as they are not visible, while the exterior-facing side is protected from direct electrode contact. The support system is configured to apply current and support the component in a way that concentrates welding effects on the interior side only.
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 approach enables spatter-free, high-quality welds with minimal surface finish requirements, suitable for visible vehicle components like doors and hoods, ensuring they are ready for painting without extensive machining.
Implementation Method 1
Electric current is then applied to the beading flange using the joining electrode and the counter-electrode
Implementation Method 2
a thermally conductive insert is provided (opposite the joining electrode) in the support to dissipate the high temperatures which arise during welding
Data Source
AI summary
A method and an apparatus for joining first and second sheet metal parts includes a support where the first and second parts are positioned with an edge of the second part surrounded by a beading flange of the first part. A joining electrode is positioned adjacent to the beading flange and a counter-electrode is positioned adjacent to the second part. An abutment of a tong-type welding apparatus in placed in contact with the support, and the joining electrode and the abutment are urged toward one another to press or clamp the beading flange between the joining electrode and the support. An electric current is applied to the beading flange using the joining electrode and the counter-electrode to weld the parts together.