Synchronized Welding Nozzle Alignment Using Optical Sensing
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Solution Overview
Problem
Current welding devices with opening-closing nozzles using a melted drop face challenges in precise control and synchronization, leading to defective welds and increased commissioning cycles, making installation and maintenance inconvenient.
Innovation Solution
A welding device with a bidirectional moving wheel and power shaft mechanism that allows for synchronized opening and closing of left and right nozzles, utilizing a sensing photoelectric element and welding nozzle sensing film for precise alignment and distance setting, enabling accurate and efficient welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional closed welding nozzles are used as benchmark, then welding nozzle alignment can be controlled, but the commissioning cycle increases and installation/maintenance becomes inconvenient
Solution Approach 1:
The patent replaces the traditional mechanical closed nozzle benchmark system with an optical detection system. The sensing photoelectric element and welding nozzle sensing film create an optical measurement system that automatically detects and establishes the benchmark position, eliminating the need for manual mechanical alignment and reducing commissioning time while maintaining precision.
Solution Approach 2:
The welding nozzle sensing film automatically establishes the benchmark position when the photoelectric element detects it. The system performs self-alignment and self-calibration through the optical detection mechanism, eliminating the need for external manual adjustment and making installation and maintenance more convenient.
2Measurement precision
If welding nozzles are completely closed as benchmark, then alignment reference can be established, but welding may deviate and hit the product causing defective welding
Solution Approach 1:
The patent replaces the mechanical closed nozzle benchmark with an optical sensing system. The sensing photoelectric element detects the welding nozzle sensing film to establish an optical alignment reference, which is more precise and reliable than mechanical closure, preventing welding deviation and defects.
Solution Approach 2:
The optical detection system provides real-time feedback on welding nozzle alignment through the photoelectric element. This feedback mechanism ensures accurate positioning and allows for immediate correction of any deviation, improving welding quality and reliability compared to the open-loop mechanical benchmark system.
3Ease of manufacture
If manual alignment method is used, then installation process is simple, but welding nozzle synchronization and opening-closing action cannot be precisely controlled
Solution Approach 1:
The patent replaces manual mechanical alignment with an optical detection and control system. The sensing photoelectric element automatically detects the welding nozzle sensing film, and the control system precisely controls the synchronization and opening-closing action of the nozzles, achieving high precision without complicating the installation process.
Solution Approach 2:
The optical detection system performs automatic alignment and synchronization without requiring complex manual adjustment procedures. The system self-calibrates by detecting the sensing film and automatically establishes the benchmark position, maintaining installation simplicity while achieving precise nozzle control.
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 solution ensures stable, accurate, and synchronized opening and closing of welding nozzles, reducing defects and simplifying installation and maintenance, while maintaining precise control over the welding process.
Implementation Method 1
installing a sensing photoelectric element on the connection line H, so that a sensing center of the sensing photoelectric element coincides with the connection line H
Implementation Method 2
the bidirectional moving wheel which is driven by the power shaft drives the two welding nozzle connecting shafts to move towards or away from each other
Implementation Method 3
the power shaft is rotatably connected to the baseboard; the bidirectional moving wheel is fixed on the power shaft
Data Source
AI summary
The embodiment of the present disclosure provides a welding device, a welding method, and an installation and debugging method thereof. The welding device includes a baseboard, comprising: a left welding nozzle and a right welding nozzle, a power shaft, a bidirectional moving wheel, and two welding nozzle connecting shafts, wherein the welding nozzle connecting shafts are connected to the left welding nozzle and the right welding nozzle respectively, and the bidirectional moving wheel which is driven by the power shaft drives the two welding nozzle connecting shafts to move towards or away from each other.