Resistance Welding Time Control Using Electrode Position and Torque
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Solution Overview
Problem
In resistance welding, determining the optimal welding time is typically manual and time-consuming, requiring manual intervention and offline testing, especially for varying workpiece materials and thickness combinations, which can be inefficient and labor-intensive.
Innovation Solution
Monitoring the time courses of the actual position value and torque of the electrode drive during the welding process to identify characteristic features that indicate the quality of the weld, allowing for dynamic adjustment of the welding time online without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual determination of welding time is used, then welding quality can be ensured, but time consumption and labor intensity increase significantly
Solution Approach 1:
The system continuously monitors the actual position value and torque during welding, compares these values against pre-stored reference profiles, and automatically adjusts the welding time based on the degree of matching. This closed-loop feedback mechanism replaces manual determination while ensuring welding quality through real-time process control and adaptation.
2Manufacturing precision
If manual intervention and offline testing are used for each workpiece, then optimal welding parameters can be determined, but productivity decreases due to labor-intensive processes
Solution Approach 1:
The welding system performs self-adjustment by automatically comparing real-time process data (position and torque) with reference profiles stored in memory. The control unit autonomously determines the optimal welding time without requiring manual intervention or offline testing for each workpiece, enabling the system to serve itself and maintain high productivity while ensuring manufacturing precision.
3Ease of manufacture
If fixed welding time is used for all workpieces, then process simplicity is maintained, but welding quality varies with different materials and thickness combinations
Solution Approach 1:
The system transitions from a static, fixed welding time approach to a dynamic adjustment mechanism. Based on real-time monitoring of position and torque profiles, the welding time is continuously adapted to match the specific characteristics of each workpiece. This dynamic approach maintains process simplicity from the operator's perspective while internally adjusting parameters to ensure consistent welding quality across different materials and thickness combinations.
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
Enables automatic determination of the optimal welding time during the process, reducing time and effort, and ensuring a high-quality weld connection regardless of workpiece materials or disturbance variables, improving efficiency in applications like body shell construction.
Implementation Method 1
The actual welding process then follows, during which the welding electrodes are energized with a welding current for a predetermined welding time or current duration. This causes resistance heating of the two workpieces to be welded between the welding electrodes, heating them to the required welding temperature.
Data Source
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AI summary
The invention relates to a method for resistance welding of workpieces (121, 122), wherein welding electrodes (111, 112) are pressed against a welding point (125) of the workpieces (121, 122) by means of an electrode drive (130) and are energized with a welding current, wherein a first time course (310, 410, 510) of a position value associated with a welding electrode position is determined (204) and wherein a second time course (320, 420, 520) of a torque of the electrode drive (130) is determined (204), wherein the first time course and the second time course are each examined for characteristic features and wherein a duration of energization of the welding electrodes (111, 112) is determined as a function of the occurrence of the characteristic features.