Welding Tongs Force Measurement with Disturbance Signal Cancellation
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Solution Overview
Problem
Existing methods for measuring electrode force in welding tongs are hindered by disturbance forces from outside sources, such as vibrations or movements, which degrade signal quality by superimposing on the actual welding force signal.
Innovation Solution
Measuring the force on both electrodes and adding these signals, which cancels out disturbance forces due to their opposite signs, resulting in a signal that represents only the welding force between the workpiece and electrodes, effectively doubling the amplitude and improving signal quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If force sensors are fitted to measure the force on individual electrodes, then the electrode force can be monitored, but disturbance forces from outside sources (vibrations, movements) superimpose on the measurement signal and degrade signal quality
Solution Approach 1:
The measurement system is segmented into two independent measurement channels, one for each electrode. By measuring the force on each electrode separately and then combining the measurements, the system can distinguish between actual welding forces and external disturbance forces, thereby improving measurement precision while filtering out harmful interference.
Solution Approach 2:
The patent combines the force measurements from both electrodes by addition. This merging of measurement signals amplifies the useful welding force signal while the disturbance forces, which act in opposite directions on the two electrodes, cancel each other out, thereby eliminating harmful factors and improving signal quality.
2Reliability
If disturbance forces are present during welding, then the measurement system captures both welding force and disturbance force, but this superposition reduces signal quality
Solution Approach 1:
The patent converts the harmful effect of disturbance forces into a beneficial filtering mechanism. By measuring both electrodes and adding the forces, the disturbance forces (which act in opposite directions) naturally cancel each other out, while the useful welding force signal is amplified. This transforms the previously harmful superposition into a useful signal separation and enhancement process.
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
This method enhances signal quality by eliminating disturbance forces, providing a clearer and more reliable measurement of the electrode force, particularly beneficial for X-tongs with weak force signals and C-tongs, by using sensors like piezo sensors and strain gages to capture axial forces on the electrode arms and holders.
Implementation Method 1
using sensors like piezo sensors and strain gages to capture axial forces on the electrode arms and holders
Implementation Method 2
using sensors like piezo sensors and strain gages to capture axial forces on the electrode arms and holders
Data Source
AI summary
The invention relates to a method for measuring the electrode force on welding tongs. The welding tongs have a first electrode arm with a first electrode and a second electrode arm with a second electrode, said second electrode arm lying opposite the first electrode arm. At least one workpiece is clamped between the electrodes during the welding process. The aim of the invention is to provide a method for measuring the electrode force, said method providing an improved signal quality. The method has the following steps: a) measuring a first force acting on the first electrode, b) measuring a second force acting on the second electrode, and c) adding the measured first force and the measured second force, wherein an electrode force signal transmitted from the welding point to the electrodes is amplified, and an interference force signal introduced into the at least one workpiece from the outside and transmitted to the electrodes is eliminated.