Electric Welding Ram Control for Consistent Spot Weld Force
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Solution Overview
Problem
Existing single-spot welding devices face challenges in accurately applying force during resistance welding, particularly in automatic wire mesh welding, due to difficulties in adjusting force magnitude and synchronization of power application elements, leading to inconsistent and inefficient weld quality.
Innovation Solution
The implementation of an electric drive system for the welding plunger, utilizing a linear motor, servo motor, or servomotor with position feedback, and a mechanical damping element, allows for precise control and adjustment of welding force, enabling simultaneous high-speed production of consistent weld spots.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If hydraulic or pneumatic force application systems are used, then force can be applied to the welding spot, but the force magnitude is difficult to adjust and synchronization between multiple power application elements is difficult to achieve
Solution Approach 1:
The patent replaces hydraulic or pneumatic force application systems with an electric drive system consisting of a motor and gear mechanism. This substitution enables precise electronic control of welding force magnitude through motor torque control and gear ratio selection, eliminating the difficulty of adjusting force in traditional hydraulic/pneumatic systems while maintaining the ability to apply sufficient welding force.
Solution Approach 2:
The patent incorporates position feedback means that cyclically move the welding plunger to initial and nominal positions, enabling precise control and synchronization of multiple power application elements. The feedback mechanism allows the control system to monitor and adjust the position and force application timing, achieving accurate synchronization across multiple welding elements without the limitations of hydraulic/pneumatic timing control.
2Productivity
If time-controlled motion of force application elements is used in automated welding systems, then high cycle operation is achieved, but the position of the force element and exact application point on the material are not precisely known
Solution Approach 1:
The patent implements position feedback means that continuously monitor the position of the welding plunger during cyclic motion. This feedback system enables the control unit to precisely determine the actual position of the force element at any moment during the welding cycle, allowing for accurate control of the application point on the material while maintaining high cycle operation speeds.
Solution Approach 2:
The replacement of traditional time-controlled mechanical motion with an electrically controlled system featuring feedback enables simultaneous achievement of high speed and high precision. The motor-driven system with position feedback provides both rapid cyclic operation and accurate positioning information, eliminating the trade-off present in time-controlled mechanical systems.
3Manufacturing precision
If the welding plunger is moved to the welding spot using an electric drive, then precise control of welding force and position is achieved, but the complexity of the device increases
Solution Approach 1:
The patent replaces complex hydraulic or pneumatic control systems with a more compact and controllable electric drive system. The motor and gear mechanism provide precise force and position control through electronic control, reducing the overall system complexity compared to traditional hydraulic/pneumatic systems while achieving superior weld spot quality consistency through programmable control.
Solution Approach 2:
The electric drive system serves multiple functions: it provides the driving force for plunger motion, enables precise position control through feedback, allows programmable welding cycle timing, and facilitates synchronization of multiple power application elements. This multi-functionality consolidates what would otherwise require separate systems, reducing overall device complexity while maintaining high 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 solution enables rapid, high-quality, and consistent weld production with reduced maintenance needs, overcoming the limitations of hydraulic and pneumatic systems by providing precise force application and synchronization, resulting in increased efficiency and improved weld quality.
Implementation Method 1
the electric drive is a linear motor
Implementation Method 2
a mechanical damping element is provided between the electric drive and the current-carrying part of the single-spot welding device
Data Source
AI summary
A single-spot welding device having a welding ram, the welding ram having a welding electrode, wherein the welding ram is movable cyclically out of a starting position to a welding material, and an electric drive is provided, by means of which the welding ram can be moved to the welding material and by means of which the force can be applied to the welding material. The method for carrying out welding comprises the following steps: moving a welding ram of a single-spot welding device out of a starting position by means of an electric drive, pressing the welding ram during the welding by means of an electric drive, and moving the welding ram back into the starting position.