Welding Tongs Position Control With Bending-Compensated Displacement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional resistance welding systems face challenges in maintaining consistent quality of weld spots, especially with new material thickness combinations, due to limitations in force regulation and path signal detection, which affects the process window and weldability.
Innovation Solution
A device and method for position control of pliers-shaped tools that compensates for mechanical bending and force variations by generating a standardized path signal, allowing for targeted force regulation and improved monitoring of the welding process, enabling consistent quality across different material combinations and tool configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sensor is attached to the movable clamping arm to detect position signal, then position control is achieved, but the displacement signal depends on mechanical configuration and bending, requiring complex recording for each configuration
Solution Approach 1:
A magnetic field sensor detects the position of a magnetic marker on the stationary clamping arm, providing an intermediary measurement method that is independent of the movable arm's mechanical configuration and bending, thus resolving the contradiction between position detection accuracy and system complexity
Solution Approach 2:
The mechanical configuration-dependent displacement measurement is replaced by a magnetic field-based position detection system, eliminating the need for complex mechanical recording while achieving accurate position control
2Manufacturing precision
If force regulation is used to control welding process, then welding quality is maintained, but the process window narrows with new material thickness combinations
Solution Approach 1:
The control system dynamically adjusts both force and position parameters based on real-time feedback from sensors, allowing adaptation to different material thickness combinations while maintaining welding quality consistency, thus expanding the process window
Solution Approach 2:
The system changes control parameters from force-only regulation to combined force and position regulation, enabling adaptation to various material combinations and expanding the viable process window while maintaining manufacturing precision
3Measurement precision
If sensor position is optimized for displacement detection, then detection accuracy is improved, but the weld cannot be created due to sensor interference
Solution Approach 1:
A magnetic field serves as an intermediary for position detection, allowing the sensor to be positioned away from the welding zone while still accurately detecting the position of the magnetic marker, thus eliminating interference with weld creation
Solution Approach 2:
Mechanical contact-based displacement detection is replaced by magnetic field-based detection, allowing non-contact measurement that does not interfere with the welding process while maintaining detection accuracy
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A control device (10) for a welding tool (21) and a method for position control of a welding tool (21; 210; 2100) are provided. The control device (10) has a determination module (11) for determining a normalized displacement signal (Sn(t)) in which a bending of the pincer-shaped tool (21; 210; 2100) is compensated, which is generated by the action of a mechanical force (Fs(t)) on the tool (21; 210; 2100) during a work operation (S2, S3, S4; S5; S8; S13; S17; S20) with the pincer-shaped tool (21; 210; 2100), and a force control module (12) for controlling a curve of the force (Fs(t)) which the pincer-shaped tool (21; 210; 2100) exerts on at least one component (5, 6) during the work operation (S2, S3, S4; S5; S8; S13; S17; S20). exerts, wherein the force control module (12) is designed to control the course of the force (Fs(t)) during the work process (S8; S13; S17; S20) using the normalized displacement signal (Sn(t)).