Welding Gun Orientation Detection Using Solenoid Inductance
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Solution Overview
Problem
In manual stud welding, ensuring the perpendicular orientation of the welding gun relative to the workpiece surface is crucial for a high-quality weld joint, but existing methods lack simplicity and require additional sensors to detect deviations in the support tube orientation.
Innovation Solution
The method determines the inductance of the solenoid coil at the start of the welding process, using the change in inductance based on the coil core's insertion depth to assess the correct orientation of the welding gun, allowing automatic control to terminate or continue the welding process based on predefined setpoint values, without additional sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If additional sensors are used to detect deviations in support tube orientation, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The solenoid coil serves dual functions: it generates the magnetic field for lifting the welding stud and simultaneously acts as the sensing element for detecting support tube orientation through inductance changes. This self-service approach eliminates the need for separate orientation sensors, resolving the contradiction between measurement precision and device complexity
Solution Approach 2:
The solenoid coil is designed to perform multiple functions: electromagnetic actuation for stud lifting and orientation sensing through inductance measurement. By making the existing component multi-functional, the patent achieves accurate orientation detection without adding separate sensing devices, thus resolving the technical contradiction
2Ease of operation
If the support tube is obliquely oriented, then ease of operation is improved, but manufacturing precision deteriorates
Solution Approach 1:
The system measures the actual support tube orientation through inductance changes and provides feedback to the operator via display or signal. This feedback mechanism allows the operator to adjust the support tube orientation to achieve the correct perpendicular alignment, ensuring high weld joint quality while maintaining operational flexibility
Solution Approach 2:
The orientation measurement and indication are performed before the welding process begins, allowing the operator to correct any oblique positioning in advance. This preliminary detection and correction ensures that the welding operation starts with proper alignment, guaranteeing manufacturing 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 approach ensures that the welding gun is properly oriented before initiating the welding process, preventing suboptimal welds by automatically determining the correct insertion depth of the coil core into the solenoid coil, thus maintaining the quality of the weld joint.
Implementation Method 1
the solenoid includes an electric coil, which in the electrically energized state exerts a magnetic force on its coil core
Implementation Method 2
the inductance of the coil of the solenoid changes as a function of how far the coil core, coupled to the welding stud, is inserted into the coil
Implementation Method 3
The arc generates a weld pool on the workpiece, into which the welding stud is subsequently lowered again, and at that location is welded to the workpiece
Data Source
AI summary
A device and a method for position measurement for welding guns, wherein based on the inductance of the coil, which changes depending on the insertion depth of the welding stud into a solenoid coil, it is inferred how far the welding stud is inserted into the solenoid in order to allow conclusions to be drawn concerning a proper arrangement of the welding stud relative to the workpiece.