Welding Rod End Inspection Using Contact Pressure Measurement
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Solution Overview
Problem
Conventional welding rod inspection apparatuses have complex structures and can only determine the eccentric state of welding rods, making it difficult to detect bending or deformation at the end surfaces, which can lead to defects in battery modules or packs.
Innovation Solution
A welding rod inspection apparatus with a simple structure, featuring a pair of measurement units spaced apart by a predetermined distance, each equipped with a pressure sensor to measure contact pressures, allowing for the detection of eccentricity, bending, and end surface deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional eddy current type distance sensors and laser position meters are used to detect welding rod eccentricity, then the eccentric state can be measured, but the device structure becomes complicated and bending or end surface deformation cannot be detected
Solution Approach 1:
The patent replaces complex electromagnetic and optical measurement systems (eddy current sensors, laser position meters) with a simple mechanical measurement system using contact-type measurers that directly touch the welding rod. This mechanical approach simplifies the device structure while maintaining measurement capability for eccentricity, bending, and end surface deformation through pressure sensor readings.
Solution Approach 2:
The patent creates a universal measurement system where the same simple mechanical measurer structure can detect multiple types of welding rod defects (eccentricity, bending, end surface deformation) through a single integrated apparatus, rather than requiring separate specialized sensors for each defect type.
2Measurement precision
If conventional detection apparatus is used, then eccentric state can be determined, but bending phenomenon and end surface deformation are difficult to determine
Solution Approach 1:
The patent creates a universal measurement system where the same simple mechanical measurer structure can detect multiple types of welding rod defects (eccentricity, bending, end surface deformation) through a single integrated apparatus, rather than requiring separate specialized sensors for each defect type.
Solution Approach 2:
The patent uses pressure sensor readings as a versatile parameter that changes according to the type and degree of deformation. By analyzing variations in pressure values at different measurer positions, the system can distinguish between eccentricity, bending, and end surface deformation, enabling one measurement system to detect multiple defect types.
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 apparatus effectively reduces the defect rate in welding by accurately assessing the normalcy of welding rods, including eccentricity, bending, and end surface deformation, thereby maintaining consistent welding quality.
Implementation Method 1
an eddy current type distance sensor configured to measure the position of a core of a welding rod using electromagnetic induction
Data Source
AI summary
Discussed is a welding rod inspection apparatus for measuring whether a welding rod is deformed and an inspection method using the same, and more particularly a welding rod inspection apparatus including a plurality of measures configured to be brought into contact with a predetermined position of a lower end of the welding rod and a support die configured to support the plurality of measurers. The plurality of measurers can be located so as to be spaced apart from each other by a predetermined distance, and each of the plurality of measurers or the support die can be provided with a pressure sensor configured to measure a pressure applied to the plurality of measurers. An inspection method using the plurality of measurers is also discussed.