Welding Tong Position Control Using Normalized Displacement Signals
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Solution Overview
Problem
Conventional resistance welding systems face challenges in maintaining consistent weld quality due to variations in material thickness combinations and new materials, leading to reduced weldability and a narrower process window, with existing sensor placement methods being impractical and requiring extensive calibration for each mechanical configuration.
Innovation Solution
An apparatus and method that compensates for mechanical tong properties and electrode force by generating a normalized displacement signal, allowing for targeted monitoring and regulation of the welding process, enabling consistent weld quality across different tong configurations and material combinations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the sensor is placed between the two welding electrodes to achieve optimum detection of the displacement signal, then the measurement precision is improved, but the device complexity increases and the ease of operation deteriorates due to impractical sensor placement and extensive calibration requirements
Solution Approach 1:
The patent introduces an intermediary computational process that processes displacement signals from sensors placed in practical locations (not between electrodes). A controller calculates normalized displacement signals by compensating for mechanical tong properties, serving as a mediator between the sensor and the welding process control. This allows accurate displacement monitoring without requiring sensors in impractical positions.
Solution Approach 2:
The patent replaces the mechanical requirement of placing a sensor between electrodes with a computational solution. Instead of physically positioning the sensor in the optimal but impractical location, the system uses mathematical normalization of displacement signals from readily accessible sensor positions, substituting mechanical sensor placement with computational processing.
2Measurement precision
If the sensor system is attached to the movable tong arm to enable displacement detection, then the measurement capability is improved, but the device complexity increases and the ease of manufacture deteriorates due to dependence on mechanical tong configuration
Solution Approach 1:
The patent creates a universal solution that works across different mechanical tong configurations. The controller normalizes displacement signals by compensating for mechanical properties, making the system multi-functional and adaptable to various tong designs without requiring separate calibration for each configuration. This universal approach eliminates the need for extensive calibration procedures.
Solution Approach 2:
The patent changes the parameter being monitored from raw displacement to normalized displacement. By transforming the displacement signal through mathematical normalization that accounts for mechanical tong properties, the system achieves consistency across different mechanical configurations without requiring physical reconfiguration or extensive calibration for each setup.
3Manufacturing precision
If the force applied to the welding tong is increased to maintain weld quality with new material combinations, then the manufacturing precision is improved, but the device durability deteriorates due to potential tool damage
Solution Approach 1:
The patent implements feedback control by continuously monitoring the normalized displacement signal during the welding process. The controller uses this feedback to regulate the welding parameters in real-time, ensuring consistent weld quality without requiring excessive force. The feedback loop allows dynamic adjustment that prevents tool damage while maintaining precision.
Solution Approach 2:
The patent introduces dynamic regulation of the welding process through normalized displacement monitoring. Instead of applying static high force, the system dynamically adjusts welding parameters based on real-time displacement feedback, allowing optimal force application that maintains weld quality while preventing tool damage through adaptive control.
Data Source
AI summary
A control apparatus for a welding tool includes a determination module for determining a normalized displacement signal, in which a deflection of a tong-shaped tool, due to an effect of a mechanical force generated on the tool during a work process using the tong-shaped tool, is compensated for. The control apparatus further includes a force regulation module for regulating a progression of the force which the tong-shaped tool applies to at least one component during the work process on at least one component. The force regulation module is configured to regulate the progression of the force during the work process based on the normalized displacement signal.