Welding Force Measurement Device with Clutch Coupling
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Solution Overview
Problem
Current devices for measuring welding force and recording electrical welding tension during resistance welding processes require human operator presence, leading to inaccuracies due to vibrations and bending moments, and are time-consuming and expensive to operate.
Innovation Solution
A device that mechanically couples with the resistance welding device, allowing autonomous operation without an operator, using a clutch mechanism to secure the measurement system on the electrode arms, featuring piezoelectric sensors and an optocoupler for precise voltage measurement, and an evaluation unit for data processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a human operator holds the device during welding force measurement, then the device can be operated without temporary fixation, but vibrations and bending moments are introduced that distort the measurement accuracy
Solution Approach 1:
The patent extracts the human operator from the measurement system by implementing autonomous operation through a clutch mechanism. The measurement device is temporarily fixed to the electrode arms via the clutch mechanism, eliminating the need for human holding and thereby removing the source of vibrations and bending moments that caused measurement distortion.
Solution Approach 2:
The device achieves self-service through autonomous operation. The clutch mechanism automatically secures the measurement device to the electrode arms without requiring manual intervention during the welding process, allowing the system to perform measurements independently while maintaining stability and accuracy.
2Measurement precision
If the welding force measurement and voltage recording are repeated several times to obtain statistical averages, then the influence of vibrations and bending moments is reduced, but the operational time and cost increase
Solution Approach 1:
The patent removes the need for repeated measurements by extracting the source of measurement distortion - the human operator. By implementing autonomous operation with temporary fixation via the clutch mechanism, the system achieves stable, single-pass measurements that eliminate vibrations and bending moments at their source, thereby reducing operational time and cost while maintaining high measurement precision.
3Extent of automation
If the device is temporarily fixed to the electrode arms via a clutch mechanism, then autonomous operation is enabled without human operator presence, but the device complexity increases
Solution Approach 1:
The clutch mechanism serves as an intermediary between the measurement device and the electrode arms. This intermediate component enables autonomous operation by providing automatic temporary fixation, allowing the device to secure itself to the electrode arms without complex automation systems or continuous human intervention, thereby achieving a balance between automation extent and device complexity.
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
Enables high-accuracy, quick, and cost-effective measurement of welding force and electrical welding tension, eliminating operator-induced errors and reducing operational time and costs.
Implementation Method 1
The device has a piezoelectric sensor element that generates electrical polarization charges under the influence of the welding force. The number of electrical polarization charges is proportional to the magnitude of the welding force.
Implementation Method 2
The device has a charge amplifier unit that amplifies the electrical polarization charges into electrical direct voltages.
Implementation Method 3
The device has a component that detects the electrical welding voltage present between the electrode arms.
Data Source
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AI summary
The invention relates to a device (1) for measuring a welding force and detecting a welding voltage during a welding process of a resistance welding device (2), the resistance welding device (2) comprising a welding clamp (20) with two electrode arms (20.1, 20.2); with two contact sockets (12, 13) for placing the device (1) on the electrode arms (20.1, 20.2); with at least one sensor element (15.1 - 15.3) for measuring the welding force exerted by the electrode arms (20.1, 20.2) during a welding process; and with at least one component (17.1 - 17.3) for detecting the welding voltage during the welding process; wherein the device (1) has a coupling means (14) which, in the state of the device (1) being placed on the electrode arms (20.1, 20.2), mechanically couples the device (1) to the resistance welding device (2).