Welding Force Sensing Plate for Precise Resistance Welding
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Solution Overview
Problem
Conventional electric resistance welding machines fail to accurately control and measure the welding force due to indirect force measurement methods that are influenced by sliding friction, weight, and electromagnetic forces, leading to oscillations and deviations, especially when repeatability is critical.
Innovation Solution
A welding apparatus with a measurement device comprising a plate with deformation sensors placed directly at the weld point, which measures the welding force independently of electrode position and is insensitive to electromagnetic disturbances, using strain gauges to accurately determine the force applied during welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If indirect force measurement using gauges and pressure regulator valves is used, then the measurement system is simple to implement, but the measurement precision deteriorates due to sliding friction, weight, and electromagnetic forces affecting the readings
Solution Approach 1:
The patent replaces indirect mechanical pressure measurement with direct force measurement using deformation sensors (strain gauges) that measure actual force at the electrode-part interface. This substitution eliminates the mechanical transmission path that introduces friction and weight errors, providing accurate force measurement while maintaining system simplicity.
Solution Approach 2:
The patent introduces deformation sensors as intermediary elements between the electrode and the measurement system. These sensors directly detect force at the critical interface without being affected by electromagnetic forces or mechanical friction, serving as a mediator that provides accurate force data while isolating the measurement system from harmful influences.
2Object-affected harmful factors
If sensors are positioned at a considerable distance from the weld point to avoid electromagnetic interference, then the sensors are protected from electromagnetic disturbances, but the measurement precision deteriorates because friction and weight of the movable stem components affect the force reading
Solution Approach 1:
The patent introduces deformation sensors as intermediary elements between the electrode and the measurement system. These sensors directly detect force at the critical interface without being affected by electromagnetic forces or mechanical friction, serving as a mediator that provides accurate force data while isolating the measurement system from harmful influences.
Solution Approach 2:
The patent replaces indirect mechanical pressure measurement with direct force measurement using deformation sensors (strain gauges) that measure actual force at the electrode-part interface. This substitution eliminates the mechanical transmission path that introduces friction and weight errors, providing accurate force measurement while maintaining system simplicity.
3Object-affected harmful factors
If force measurement is performed without current flow at the electrodes, then the measurement device is not subjected to electromagnetic forces, but the measurement precision deteriorates because the force value does not correspond to actual welding conditions
Solution Approach 1:
The patent introduces deformation sensors as intermediary elements between the electrode and the measurement system. These sensors directly detect force at the critical interface without being affected by electromagnetic forces or mechanical friction, serving as a mediator that provides accurate force data while isolating the measurement system from harmful influences.
Solution Approach 2:
The patent replaces indirect mechanical pressure measurement with direct force measurement using deformation sensors (strain gauges) that measure actual force at the electrode-part interface. This substitution eliminates the mechanical transmission path that introduces friction and weight errors, providing accurate force measurement while maintaining system simplicity.
4Adaptability or versatility
If the electrode position varies relative to the cylinder axis (off-axis welding), then the apparatus is more versatile, but the measurement precision deteriorates because forces opposing the pusher cylinder action are not accounted for
Solution Approach 1:
The patent replaces indirect mechanical pressure measurement with direct force measurement using deformation sensors (strain gauges) that measure actual force at the electrode-part interface. This substitution eliminates the mechanical transmission path that introduces friction and weight errors, providing accurate force measurement while maintaining system simplicity.
Solution Approach 2:
The patent introduces deformation sensors as intermediary elements between the electrode and the measurement system. These sensors directly detect force at the critical interface without being affected by electromagnetic forces or mechanical friction, serving as a mediator that provides accurate force data while isolating the measurement system from harmful influences.
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 apparatus ensures precise and reliable measurement and adjustment of welding force, reducing process uncertainties and maintaining accuracy even under varying conditions, thus enhancing the repeatability and reliability of the welding process.
Implementation Method 1
A welding apparatus with a measurement device comprising a plate with deformation sensors placed directly at the weld point, which measures the welding force independently of electrode position and is insensitive to electromagnetic disturbances, using strain gauges to accurately determine the force applied during welding.
Implementation Method 2
this technique entails pressing at least one electrode against the parts to be welded and then having an electric current pass through the electrode and the parts; owing to the Joule effect, the current causes the localized heating of the point of contact between the parts and the electrode, up until the liquefaction of the material involved and the consequent welding.
Data Source
AI summary
A welding apparatus includes a movement assembly for at least one electrode configured to which can be passed through by current for the execution of welding treatments. The assembly includes at least one cylinder and at least one stem which rigidly supports the electrode; the stem is at least partially accommodated in the cylinder and is coaxially movable with an alternating straight motion along the longitudinal axis of the cylinder, in order to press the electrode against the parts to be welded with a corresponding welding force.A device for measuring the welding force is also provided, which has a plate, which is stably interposed between the stem and the electrode with the respective faces arranged at right angles to the longitudinal axis, and a plurality of deformation sensors accommodated in through slots provided in the plate and distributed along an imaginary circumference which is centered along the longitudinal axis.