Resistance Welding Force Measurement With Mechanical Coupling
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Solution Overview
Problem
Existing devices for measuring welding force and detecting electrical welding voltage in resistance welding devices require human operator intervention, leading to inaccuracies due to vibrations and bending moments, and are time-consuming and costly due to the need for repeated measurements.
Innovation Solution
A device that mechanically couples to the resistance welding device, eliminating the need for human operator intervention, using piezoelectric sensors and an evaluation unit for accurate and efficient measurement of welding force and voltage detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a human operator holds the device for measuring welding force and detecting electrical welding voltage, then the device can be operated manually, but vibrations and bending moments are introduced into the device which distort the measurement accuracy
Solution Approach 1:
The device is designed to be held by a coupling member that mechanically couples it to the electrode arm, enabling the device to measure welding force and detect electrical welding voltage autonomously without human operator intervention. This self-service mechanism eliminates the introduction of vibrations and bending moments caused by manual holding, thereby resolving the contradiction between ease of operation and measurement precision.
2Measurement precision
If multiple repetitions of welding force measurement and electrical welding voltage detection are carried out to reduce distortion impact, then measurement accuracy improves, but the process becomes time-consuming and expensive
Solution Approach 1:
By enabling the device to autonomously measure welding force and detect electrical welding voltage through mechanical coupling to the electrode arm, the system obtains stable measurements without requiring multiple repetitions. This eliminates the time loss associated with repeated measurements while maintaining high measurement accuracy, as the autonomous operation prevents introduction of vibrations and bending moments that would necessitate repetitions.
3Extent of automation
If the device is mechanically coupled to the resistance welding device for autonomous operation, then human operator presence is eliminated and measurement accuracy improves, but device complexity increases
Solution Approach 1:
The device achieves autonomous operation through a coupling member that mechanically couples it to the electrode arm, eliminating the need for human operator presence. While this introduces some complexity through the coupling mechanism, it enables self-service measurement and detection capabilities that improve overall system automation and measurement accuracy by eliminating human-induced vibrations and bending moments.
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 autonomous, accurate, and cost-effective measurement of welding force and electrical welding voltage, reducing measurement errors and operational time.
Implementation Method 1
The device comprises a piezoelectric sensor element that generates electrical polarization charges under the action of the welding force. The number of the electrical polarization charges is proportional to the magnitude of the welding force.
Data Source
AI summary
A device for measuring a welding force and for detecting a welding voltage during a welding process of a resistance welding device, which resistance welding device includes a welding gun with two electrode arms, includes two contact sockets for placing the device at the electrode arms. A sensor element is included for measuring the welding force exerted by the electrode arms during a welding process. A component is included and configured and disposed for detecting the welding voltage during the welding process. A coupling element is configured and disposed so that when the device is placed at the electrode arms, the coupling element mechanically couples the device to the resistance welding device.