Welding Machine Frame Decoupling for Alignment Precision
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Solution Overview
Problem
Existing welding machine frames deform under uplift forces applied to workpieces, leading to non-parallelism between the sonotrode and workpiece, which adversely affects the quality of the weld seam.
Innovation Solution
The frame design includes a support structure that decouples the linear drive from the column, allowing vertical displacement of the carriage and sonotrode, ensuring alignment and minimizing frame deformation through the use of C-shaped brackets and a deformation measuring device for precise force control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the linear drive is rigidly connected to the column, then the frame structure is simple and rigid, but the frame deforms under welding forces causing non-parallelism between sonotrode and workpiece
Solution Approach 1:
The frame is segmented into rigid support structures and a movable carriage that can displace independently. The linear drive is mounted on the movable carriage rather than being rigidly connected to the column, allowing the carriage to absorb deformation while maintaining drive alignment.
Solution Approach 2:
The carriage is designed to be displaceable along the guide rail in the vertical direction, transforming from a static rigid connection to a dynamic adjustable connection. This allows the carriage to move with the support carrying the linear drive, preventing forced stresses while maintaining welding force application.
2Strength
If the support carrying the linear drive is made very stiff, then deformation is minimized, but forced stresses occur in the linear drive and carriage
Solution Approach 1:
The carriage is designed to be displaceable along the guide rail in the vertical direction, allowing it to move with the support carrying the linear drive. This dynamic adjustment prevents forced stresses in the linear drive and carriage while maintaining adequate support stiffness for force application.
Solution Approach 2:
The movable carriage acts as an intermediary between the rigid support structure and the linear drive. It absorbs the deformation through vertical displacement along the guide rail, preventing the transmission of forced stresses to the linear drive while maintaining the structural integrity of the support.
3Manufacturing precision
If the carriage is fixed in position, then alignment is maintained, but the frame deformation causes non-parallelism between sonotrode and workpiece
Solution Approach 1:
The carriage is designed to be displaceable along the guide rail in the vertical direction, allowing it to move with the support carrying the linear drive. This dynamic adjustment maintains the alignment between the sonotrode and workpiece by compensating for support deformation, while the guide rail ensures the displacement is purely vertical.
Solution Approach 2:
A deformation measuring device detects the deformation of the support carrying the linear drive and provides this information to a control device. The control device uses this feedback to control the position of the carriage along the guide rail, ensuring that the sonotrode remains aligned with the workpiece despite frame deformation.
4Manufacturing precision
If a deformation measuring device and control system are added, then alignment precision is improved, but device complexity increases
Solution Approach 1:
A deformation measuring device detects the deformation of the support carrying the linear drive and provides this information to a control device. The control device uses this feedback to control the position of the carriage along the guide rail, ensuring that the sonotrode remains aligned with the workpiece despite frame deformation.
Solution Approach 2:
The deformation measuring device and control system replace complex mechanical adjustment mechanisms. Instead of requiring manual realignment or complex mechanical compensation structures, the system uses sensors and automated control to maintain alignment, simplifying the overall mechanical design while improving precision.
Data Source
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AI summary
The present invention relates to a stand for a welding machine having a base plate and a column which is flexurally rigidly connected thereto and which is attached to a guide rail. The rack furthermore has a linear drive for applying a force from a work member to a work piece which can positioned on the base plate, the linear drive being supported by a slide which is displaceably guided along the guide rail. A support is furthermore provided which supports the slide and which counteracts a force-induced displacement of the slide by the linear drive.