Welding Gun Plate Thickness Testing with a Dual-Thickness Jig
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional welding apparatuses face challenges in accurately measuring plate thickness due to electrode wear, requiring multiple dummy workpieces and increased costs, and inefficiencies in determining normal plate thickness testing, which affects work efficiency and production line operations.
Innovation Solution
A welding apparatus with a servo gun and a plate-shaped jig having different thickness portions, allowing for normal plate thickness testing confirmation using a single jig, reducing the need for multiple dummy workpieces and minimizing working space, while improving determination accuracy by measuring both thinner and thicker plate thicknesses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple dummy workpieces are prepared for plate thickness testing, then testing accuracy is improved, but cost increases and working space expands
Solution Approach 1:
The patent combines multiple testing functions into a single integrated test jig that includes both a first test portion with thickness less than the lower limit and a second test portion with thickness greater than the upper limit. This allows both types of thickness abnormalities to be detected using one dummy workpiece instead of requiring separate dummy workpieces for each testing scenario.
Solution Approach 2:
The test jig is designed with multi-functionality to serve multiple testing purposes simultaneously. By incorporating test portions representing different thickness abnormalities (both thinner and thicker than specified limits), a single universal test jig can validate the plate thickness detection function for various defect types, eliminating the need for multiple specialized dummy workpieces.
2Measurement precision
If multiple dummy workpieces are prepared for plate thickness testing, then testing coverage is improved, but work efficiency deteriorates
Solution Approach 1:
The patent combines multiple testing functions into a single integrated test jig that includes both a first test portion with thickness less than the lower limit and a second test portion with thickness greater than the upper limit. This allows both types of thickness abnormalities to be detected using one dummy workpiece instead of requiring separate dummy workpieces for each testing scenario.
Solution Approach 2:
The test jig is prepared in advance with all necessary test portions (both thinner and thicker sections) integrated into a single component. This preliminary preparation eliminates the need for operators to select between multiple dummy workpieces during testing, streamlining the testing process and improving work efficiency.
3Ease of operation
If electrode wear is not considered, then measurement simplicity is maintained, but measurement precision deteriorates
Solution Approach 1:
The patent addresses electrode wear by changing the reference parameter from absolute movement distance to relative thickness difference detection. The detection section identifies thickness abnormalities by comparing measured thickness against predetermined upper and lower limits, which compensates for electrode wear effects. This allows the system to maintain measurement simplicity while improving precision by focusing on relative rather than absolute measurements.
Data Source
AI summary
A plate thickness test mechanism includes a detection section that detects an abnormality when a plate thickness is thinner than a desired plate thickness by a predetermined amount or more or thicker than the desired plate thickness by the predetermined amount or more, a determination section that determines whether or not the detection section functions normally, and a plate-shaped test jig that has a first plate portion having a plate thickness thinner than a predetermined specific plate thickness, and a second plate portion having a plate thickness thicker than the specific plate thickness. The determination section determines whether or not a plate thickness test is normally performed on the basis of a detection result of the detection section obtained when the detection section tests the plate thicknesses of the first and second plate portions by taking the desired plate thickness as the specific plate thickness.