Resistance Welding Electrode Positioning for Automated Joining Elements
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing resistance welding methods for manufacturing compound structures are prone to malfunction and cannot realize a variable, automated process efficiently, especially when feeding and orienting joining elements.
Innovation Solution
A device and method that utilize a positioning device with a retention force oriented perpendicular to the joining direction to accurately position joining elements for resistance welding, allowing for automated and precise alignment of joining elements, enabling resistance welding in any direction and accommodating various geometries without the need for specially formed electrodes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If joining elements are fed automatically through guidance channels perpendicular to the joint stamp, then automation is improved, but the device complexity increases and malfunction proneness increases
Solution Approach 1:
Instead of feeding joining elements through a guidance channel perpendicular to the joint stamp (conventional approach), the invention feeds them parallel to the joint stamp's longitudinal extension. This inversion of the feeding direction simplifies the device structure and reduces malfunction proneness while maintaining automation.
Solution Approach 2:
The joint stamp serves multiple functions: it acts as both the feeding guide (guidance channel) and the welding electrode. This multi-functionality eliminates the need for separate perpendicular guidance channels, reducing device complexity while maintaining automated feeding capability.
2Ease of operation
If joining elements are oriented by gravity on a guidance device, then ease of operation is improved, but reliability decreases due to malfunction proneness
Solution Approach 1:
The invention replaces the gravity-based mechanical orientation system with an automated positioning system where the joint stamp itself serves as the guidance channel. This substitution eliminates the complex guidance device that was prone to malfunction while maintaining ease of operation through automated control.
3Manufacturing precision
If resistance welding is performed with specially formed electrodes for specific geometries, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
The joint stamp is designed as a universal component that serves as both the feeding guide and welding electrode. Its longitudinal extension can accommodate various joining element geometries without requiring specially formed electrodes, thus maintaining manufacturing precision while reducing device complexity and cost.
Solution Approach 2:
The invention enables dynamic adaptation to different geometries through the parallel feeding arrangement and the design of the joint stamp as a universal guide, allowing the same electrode structure to handle various joining element shapes without requiring specialized electrode forms.
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 provides a simple, cost-effective, and reliable method for manufacturing compound structures by ensuring precise positioning and retention of joining elements, preventing malfunctions and allowing for flexible automation in resistance welding processes, independent of gravity or part orientation.
Implementation Method 1
the joining element, which consists of an electrically conductible material, is heated by resistance heating, and is thereby welded with a structural element which is also electrically conductible upon forming a welding spot
Implementation Method 2
The retention device is configured to exert a retention force, which is particularly oriented perpendicular to the joining direction, onto the joining element
Implementation Method 3
establishing an electrically conductible connection of the joining element with the structural element by resistance welding
Data Source
AI summary
Device (10) for manufacturing a component compound by resistance welding, comprises a welding electrode (12) for transmitting an electric current to a joining element (17) and for exerting a joining force onto the joining element (17) along a joining direction (22) in order to establish a connection of the joining element (17) with a structural element by resistance welding; as well as a positioning device (20) for positioning at least one joining element (17) on the axis of the joining direction (22) in order to contact and particularly apply a force to the joining element (17) by means of the welding electrode (12). The positioning device (20) comprises a retention device (30) for exerting a retention force onto the joining element (17), wherein the retention device (30) is movably arranged.