Electric Spot Welding Head Magnetic Field Cancellation
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Solution Overview
Problem
Existing spot welding heads generate strong magnetic fields close to the operator's body due to high electric currents, posing a safety risk during manual operation.
Innovation Solution
The loop-shaped sheath of the welding head is repositioned to be parallel and centered between the electrode supporting elements, with the current flowing in an opposite direction to that through the electrodes, effectively canceling or reducing the magnetic field, and a protective aluminum shield is added to further minimize exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the loop portion sheath is positioned at the rear of the welding head, then the structure is simple and easy to manufacture, but the magnetic field generated is close to the operator's body causing safety risks
Solution Approach 1:
The loop portion of the tubular sheath is repositioned from the rear of the welding head to the front region, specifically between the electrode supporting elements. This spatial reconfiguration changes the dimensional arrangement of the conductor loop, moving the magnetic field generation zone away from the operator's body while maintaining electrical functionality.
Solution Approach 2:
The invention utilizes the magnetic field generated by current flow through the looped conductor to cancel or reduce the magnetic field generated by current flow through the electrodes. By strategically positioning the loop portion and orienting it parallel to the electrode supporting elements, the magnetic fields substantially cancel each other out, converting a harmful effect into a beneficial reduction of overall magnetic field exposure.
2Power
If high electric current flows through the conductor in the loop portion, then welding power is sufficient, but magnetic field generation increases posing safety risks
Solution Approach 1:
The high electric current necessary for welding, which generates harmful magnetic fields, is routed through the looped conductor positioned between the electrode supporting elements. The magnetic field generated by this current flow substantially cancels the magnetic field generated by current flow through the electrodes, thereby maintaining sufficient welding power while reducing overall magnetic field exposure to acceptable levels.
Solution Approach 2:
The looped conductor is pre-configured and positioned to generate a magnetic field that opposes and cancels the magnetic field generated by the electrode current flow. This preliminary anti-action is built into the welding head structure, ensuring that the harmful magnetic field effects are reduced before they can affect the operator.
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 configuration significantly reduces the overall magnetic field, keeping it away from the operator's body and enhancing safety by minimizing residual magnetic field exposure.
Implementation Method 1
the magnetic field generated by electromagnetic induction caused by electric current flowing through the electric conductor placed into the loop-shaped sheath
Implementation Method 2
the welding head according to the present invention is provided with a protection shield on its rear side, for example made of aluminium, in order to protect more efficiently the operator thereby further dramatically decreasing the residual magnetic field generated by the current through the welding head
Data Source
AI summary
A spot welding head includes an electrical conductor guided into a tubular sheath whose ends are rigidly connected to rear ends of supporting bodies of several electrodes. The sheath defines a substantially stiff loop portion configured and arranged so as to be substantially parallel and to face an annular path defined by the electrodes and the supporting bodies, in such a way that two magnetic fields, one generated by electromagnetic induction caused by electric current flowing through the electric conductor placed into the loop-shaped sheath, and the other generated by electromagnetic induction caused by electric current flowing through the electrodes and the supporting bodies thereof, substantially cancel each other out or generate an overall magnetic field which is located forward of the rear end of the welding head or forward of the operator's body.