Welding Fixture With Multi-Directional Pressing for Precise Gap Control
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Solution Overview
Problem
Existing laser welding technologies face challenges in controlling the gap between products accurately, leading to functional failures and size deviations due to inefficient positioning and pressing processes, which result in large cumulative tolerances and reduced welding quality.
Innovation Solution
A welding fixture with a top pressing plate and multi-directional side-pressing mechanism, featuring sliding blocks and a side-pressing canceling control assembly, allows for precise positioning and pressing of workpieces in multiple dimensions, ensuring stable gaps and efficient clamping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional positioning assembly method is used, then the assembly process is simple, but the cumulative tolerances are large and positioning precision is poor
Solution Approach 1:
The positioning system is segmented into multiple independent positioning dies (first positioning die, second positioning die, third positioning die, fourth positioning die) that each control specific degrees of freedom. This segmentation allows precise control of workpiece position without requiring a single complex positioning structure, thereby improving positioning precision while managing device complexity through modular design.
Solution Approach 2:
The side-pressing mechanism employs self-pressing sliding blocks with elastic components that automatically exert pressing force on the workpiece sides when the pressing plate moves. The elastic components store and release energy to provide continuous side pressing during the pressing process, enabling the system to self-regulate positioning and pressing forces without additional complex control mechanisms.
2Manufacturing precision
If conventional pressing method is used, then the pressing process is simple, but the gap control between workpieces is poor
Solution Approach 1:
The side-pressing mechanism performs preliminary side pressing of the workpiece before the top pressing plate applies vertical force. The sliding blocks are positioned to contact the workpiece sides in advance, and the elastic components are pre-loaded to provide initial lateral constraint. This preliminary action ensures that the workpiece is properly positioned and constrained before the main pressing operation, improving gap control precision.
Solution Approach 2:
The pressing system transitions from conventional single-dimension (vertical) pressing to multi-dimension pressing by adding lateral side pressing through the sliding blocks. The side-pressing mechanism applies forces in both horizontal dimensions while the top pressing plate applies vertical force, creating three-dimensional constraint that precisely controls the gap between workpieces from multiple directions simultaneously.
3Productivity
If manual positioning and pressing is used, then the equipment is simple, but the production efficiency is low
Solution Approach 1:
The side-pressing mechanism merges multiple pressing functions into a single integrated system. The first and second sliding blocks work together to press opposite sides of the workpiece, while the third and fourth sliding blocks press other opposite sides. All sliding blocks are driven by the same pressing plate movement, combining multiple pressing actions into one coordinated operation that improves productivity without requiring separate actuators for each side.
Solution Approach 2:
The sliding blocks serve multiple functions: they provide lateral positioning constraint, apply side pressing force during clamping, and can be reset for unloading operations. The elastic components provide both positioning and pressing functions. This multi-functionality allows the side-pressing mechanism to handle both clamping and unloading operations efficiently, improving productivity while managing device complexity through versatile component design.
4Reliability
If traditional welding fixture is used, then the fixture structure is simple, but the welding quality is inconsistent
Solution Approach 1:
The positioning system applies different positioning strategies to different locations of the workpiece through specialized positioning dies. Each positioning die is designed with specific geometric features that match the workpiece geometry at its location, providing localized precise constraint. This local quality approach ensures that each critical position of the workpiece is controlled with appropriate precision, leading to consistent welding quality across the entire assembly.
Solution Approach 2:
The system replaces conventional mechanical positioning with elastic field-based positioning using spring-loaded sliding blocks. The elastic components provide continuous adaptive force that compensates for minor variations in workpiece dimensions, replacing rigid mechanical contact with flexible elastic interaction. This substitution maintains position tolerance within acceptable ranges while ensuring consistent welding quality even with slight dimensional variations.
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 improves positional tolerances, enhances welding quality, and increases clamping and unloading efficiency by allowing simultaneous tight pressing and release of workpiece sides, reducing accumulated tolerances and improving dimensional accuracy.
Implementation Method 1
each of the side-pushing self-pressing sliding blocks is slidably connected to the base by a transverse elastic part in a side-pushing pressing direction, and the transverse elastic parts corresponding to the side-pushing self-pressing sliding blocks are configured to force the two side-pushing self-pressing sliding blocks in each of the pairs of the side-pushing self-pressing sliding blocks to move oppositely
Implementation Method 2
the cross-shaped lifting plate, elastically connected to the base by vertical elastic components arranged in a pressing direction
Implementation Method 3
each of wedge-shaped fitting structures is defined between each of the end segments and the corresponding pair of the side-pushing self-pressing sliding blocks, when the cross-shaped lifting plate descends, the two side-pushing self-pressing sliding blocks in each of the pairs of the side-pushing self-pressing sliding blocks move closely under action of the corresponding wedge-shaped fitting structure
Data Source
AI summary
A welding fixture and a locking method are provided. The welding fixture includes a base and workpiece positioning dies; a top pressing plate slidably connected to the base in a pressing lifting direction is configured to press top surfaces of workpieces placed on the workpiece positioning dies; welding avoidance grooves are disposed on the top pressing plate, and each of the welding avoidance grooves is located above a corresponding one of the workpiece positioning dies; and a side-pressing mechanism disposed on the base is configured to perform and cancel lateral pressing of the workpieces. The welding fixture has advantages: the side-pressing mechanism can achieve tight pressing of sides of multiple workpieces at the same time, and the side-pressing mechanism can also cancel the tight pressing of the sides of the multiple workpieces after welding at the same time, which can greatly improve clamping efficiency and efficiency of unloading the workpieces.