Resistance Welding Force Distribution for Multi-Point Weld Consistency
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Solution Overview
Problem
In multi-point resistance welding, achieving precise and identical electrode forces across multiple welding points is challenging, particularly for large components with varying thicknesses, leading to longer cycle times and the need for multiple stations.
Innovation Solution
A welding device with a coupling joint that divides the total electrode force into individual forces using linear guides and a distributor link, allowing for precise force distribution and compensation for tolerances and material thickness differences, enabling the use of a single power source and accommodating various electrode configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple welding stations are used for large components, then welding coverage is improved, but device complexity and space requirements increase
Solution Approach 1:
The welding device is divided into multiple electrode pairs (first pair and second pair) that can be independently activated. This segmentation allows a single device to perform multiple welding operations at different locations, effectively providing multi-station functionality while using only one physical device.
Solution Approach 2:
The welding device is designed with universal functionality to perform welding at multiple positions (first welding position and second welding position) using a single device. The electrode pairs can be selectively activated based on the component being welded, making the device adaptable to various welding scenarios without requiring multiple specialized stations.
2Reliability
If electrode force is increased for better weld quality, then welding reliability is improved, but control precision over individual electrode forces becomes more difficult
Solution Approach 1:
The electrode pairs are designed with independent actuation capability, allowing the electrode force to be dynamically adjusted for each pair. The first electrode pair and second electrode pair can receive different electrode forces independently, enabling precise control over force distribution while maintaining high weld quality at each position.
Solution Approach 2:
Each electrode pair is equipped with independent force control, allowing the electrode force to be locally optimized for specific welding positions. The first electrode pair can be assigned a different force than the second electrode pair, enabling precise local control tailored to the specific requirements of each welding location.
3Measurement precision
If multiple power sources are used for each electrode pair, then electrode force control is improved, but device size and complexity increase
Solution Approach 1:
A single power source is designed to serve multiple electrode pairs through a multi-functional force generation mechanism. The power source can distribute different electrode forces to the first electrode pair and second electrode pair independently, eliminating the need for separate power sources while maintaining precise control capability.
Solution Approach 2:
Multiple power source functions are merged into a single power source unit. The unified power source incorporates the capability to independently control and distribute force to multiple electrode pairs, combining what would traditionally require separate power sources into one integrated system, thereby reducing device complexity while maintaining control 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
This solution allows for precise and identical electrode forces across multiple welding points, reducing cycle times, increasing productivity, and ensuring high-quality welds with a compact design that requires less maintenance compared to traditional systems.
Implementation Method 1
a coupling joint (25) between the power source (19) and the electrode pairs (15, 17), by means of which a total electrode force (27) that can be generated by the power source (19) is introduced into the electrode pairs (15, 17) and the further electrode pairs (15, 17) and by means of which the total electrode force (27) and the further total electrode force (27) can be divided into the electrode force (21) and the further electrode force (21)
Implementation Method 2
The moving welding electrode (39) is mounted in a longitudinally displaceable manner by means of a linear guide (43) and the further moving welding electrode (41) is mounted in a longitudinally displaceable manner by means of a further linear guide (45)
Implementation Method 3
a pair of electrodes (15), by means of which an electrode force (21) and an electrical welding current can be introduced into the components; at least one further pair of electrodes (17), by means of which a further electrode force (21) and a further electrical welding current can be introduced into the components
Implementation Method 4
the distributor link can carry out tilting movements or pivoting movements around the distributor joint, whereby tolerances and/or different material thicknesses of joining partners can advantageously be compensated for
Data Source
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AI summary
A welding device (1) for joining components by means of resistance welding is proposed, comprising: - a pair of electrodes (15), by means of which an electrode force (21) and an electrical welding current IS1 can be introduced into the components, - at least one further pair of electrodes (17), by means of which an electrode force (23) and a further electrical welding current IS2 can be introduced into the components, - a power source (19), by means of which the electrode forces (21, 23) can be generated, - a coupling link (35), which is mechanically connected between the power source (19) and the pairs of electrodes (15, 17) and by means of which a total electrode force (27) that can be generated by the power source (19) can be divided into the electrode force (21) and the further electrode force (23).