CA2059812C - Welding apparatus for electrical welding - Google Patents

Welding apparatus for electrical welding

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Publication number
CA2059812C
CA2059812C CA 2059812 CA2059812A CA2059812C CA 2059812 C CA2059812 C CA 2059812C CA 2059812 CA2059812 CA 2059812 CA 2059812 A CA2059812 A CA 2059812A CA 2059812 C CA2059812 C CA 2059812C
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CA
Canada
Prior art keywords
base
arm
welding apparatus
welding
electrodes
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Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Fee Related
Application number
CA 2059812
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French (fr)
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CA2059812A1 (en
Inventor
Peter Ling
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Individual
Original Assignee
Individual
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Filing date
Publication date
Application filed by Individual filed Critical Individual
Priority to CA 2059812 priority Critical patent/CA2059812C/en
Publication of CA2059812A1 publication Critical patent/CA2059812A1/en
Application granted granted Critical
Publication of CA2059812C publication Critical patent/CA2059812C/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

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  • Resistance Welding (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)

Abstract

A welding apparatus including a pivotible and adjustable pressure compensator to bias the electrodes onto a workpiece, said compensator having a rigid base portion and underlying rigid lever arms integrally joined by a resilient flexible section.

Description

CA 020~9812 1998-01-07 Title: WELDING APPARATUS FOR ELECTRICAL
WELDING INVENTORS: l~ LING
FIELD OF THE INVENTION
The present invention relates to a welding apparatus and a method of welding and, more particularly, to an apparatus and a method useful for welding ultra-thin films, very small filaments for bulbs, fine crosswire screens, miniature electronic components, metal foam, metal 5 fibre in air bag applications and other similar materials which present difficult welding problems. The apparatus and methods of this invention may also be adapted to perform other related procedures such as reflow soldering, parallel gap welding, butt welding and the like.

BACKGROUND OF THE INVENTION
Various types of welding apparatus have been developed over the years to perform general purpose and specialized welding of metal parts. Different types of welding apparatus and methods of achieving a satisfactory weld have emerged to handle the characteristics and properties of different materials to be welded. In general terms, a welding apparatus 15 sends electrical current through an electrode or electrodes to the parts of the workpiece to be joined while holding and compressing the parts together at the joint. It is known that, during fusion of the joint, the thickness of the parts of the workpiece ordinarily will fluctuate slightly. It is desirable that the welding apparatus be able to respond to thickness fluctuations of the 20 workpiece in order to maintain a constant contact of the parts at the joint.
The response of the welding apparatus to the fluctuation should maintain the electrode or electrodes on the workpiece with a suitable compression force. If compression is not maintained at the desired level, splashing or smearing of the weld may result. The maintenance of the compression is 25 important in the welding of ultra-thin films and the like. The ability of the welding apparatus to respond to changes in thickness is opposed by the mass and the static and dynamic frictional forces of the moving elements of the welding apparatus. Multiple sources of friction complicate the ;:~

CA 020~9812 1998-01-07 predictability of dynamic response from time to time within the apparatus and, therefore, simplicity of construction is desirable. Similarly, where forces are generated within the apparatus to maintain the desired contact between the parts of the workpiece to be welded, it is important to be able to 5 predict and control to close tolerances the behaviour of the force generator in the dynamic condition. For example, where a spring is used to create a force to hold the parts of the workpiece in contact, non-linearity in the spring force and eccentricity in the direction of the force can cause inconsistent welding results.

Various approaches are found in the patent literature for improved welding devices for thin workpieces. See for example, U.S. Patent 2,675,454 to Warner, U.S. 4,343,981 to Connolly and U.S. 1,602,682 to Kochendorfen. It may be observed from these patents that springs and complicated mechanical parts are used in various combinations to maintain 15 contact between parts to be welded. It may also be observed that where springs are used it is common to precompress the springs to obtain the specified pressure but with limited travel of the electrodes. Therefore, the electrodes are not really "free floating" as might be suggested by Warner in U.S. 2,675,454.

In U.S. 3,393,288, Barstow et al. provides pressure by weight, however, there are many mechanical links in that combination which provide sources of friction.

In Japanese Patent 49,877, the inertia of a hydraulic cylinder used in the apparatus and the pressure fluctuation from its hydraulic supply introduce resistance and complexity.

None of these previous efforts seem to the inventor to provide the benefits attendant with the present invention. The present ~ '~

CA 020~9812 1998-01-07 invention provides an improved device for delivering a resilient force to maintain the electrodes in contact with the workpiece. The invention also overcomes many of the problems described above which result in welding inconsistencies and inaccuracies. Furthermore the elegant simplicity of the design of the invention minimizes the friction and inertia forces.

SUMMARY OF THE INVENTION
The present invention is an improved welding apparatus for joining metal parts particularly ultra-thin films and the like. The apparatus may be adapted to be operated manually or incorporated into an 10 automatic driving mechanism.

More particularly, in a welding apparatus having one or more charged electrodes mounted to move during welding in response to changes in thickness of a workpiece being welded, a pressure compensator to press the electrodes onto the workpiece comprising:
a substantially rigid base having two outside ends lying parallel in a plane which is perpendicular to movement of the electrodes;
one or more arms underlying a portion of the base, each arm being flexibly connected at one end thereof to one of the outside ends of the base; and the flexible connection permitting each such arm to flex resiliently with respect to the base and to transmit a spring force to the electrodes.

Moreover, the one or more arms comprises:
one or more pairs of arms, each arm underlying a portion 25 of the base, and each arm of the pair being flexibly connected at one end thereof to an opposite outside end of the base; and the flexible connection aligning the pairs of arms in a spaced apart relationship below the base.

CA 020~9812 1998-01-07 The present invention also provides in a welding apparatus having one or more pairs of oppositely charged electrodes, each such electrode being mounted on rods adapted for linear movement with respect to a workpiece to be welded, the improvement comprising a 5 pressure compensator to maintain constant pressure on the rods to drive the electrodes onto the workpiece, the pressure compensator comprising a "C" shaped device having a substantially rigid base and two overlapping substantially rigid arms, each arm being connected to the base by an integral flexible curved section, a central portion of the base being mounted on the 10 welding apparatus for limited linear movement parallel to the rods under the force of a spring and for limited rotational movement about an axis parallel to the plane of the workpiece and perpendicular to a plane of a pair of oppositely charged electrodes.

In a preferred embodiment the pressure compensator has 15 adjustable screws which provide a stop to limit the degree that each arm can flex in relation to the base. The screws are threaded through the base each over one arm and are adjusted simply by turning them to advance or retract as required. Locking nuts may be provided to fix the screw position after adjustment. The end of each screw extending beyond the base towards an 20 arm acts as a stop to limit movement of the arm towards the base.

The rods holding the electrodes abut in rolling contact against the underside of the arms. The arms exert a first pressure on the rods which is preset by a spring in the mounting of the base to the welding 25 apparatus. The rotational freedom of the mounting of the base permits the pressure compensator to adjust itself over the rods to equalize pressure of each of the arms on the rods. The arms resist small deflections of the rods caused by changes in thickness of the workpiece during welding. The simplicity of this pressure compensator minimizes the number of .. ..

CA 020~9812 1998-01-07 -components involved.

The pressure compensator can be made from any of a number of suitable materials that have the required strength and resiliency for the particular work being undertaken. It will be appreciated that 5 different workpieces will generate different forces to be contended with and, accordingly, the selection of suitable materials for the pressure compensator will be a matter of design within conventional art. Similarly, the dimensions of the pressure compensator will be determined in accordance with the materials selected and the resilience characteristics desired in any 10 particular application. The basic design of the pressure compensator of this invention permits a wide variety of force characteristics to be obtained for any particular application by material selection and dimensional variance.

A preferred construction of the welding apparatus of this invention has a plastic support block to separate and support within it the 15 rods in slidable connection. Plastic rollers may be used on the rod ends to make rolling contact with the arms of the pressure compensator. The plastic used in the block and rollers may be fibreglass filled polycarbonate, polyfomaldehyde or polyoxy-methylene resin or other suitable materials which provide sufficient electrical insulation between the electrode holder 20 rod and the other metal parts of the welding apparatus. It is desirable that the materials selected will have a low mass to reduce inertial forces.

BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the present invention and to show more clearly how it may be carried into effect, reference will now be 25 made, by way of example, to the accompanying drawings, which show a preferred embodiment of the present invention and in which:

Figure 1 is a perspective view of a preferred embodiment r CA 020~9812 1998-01-07 of welding apparatus of this invention with a single electrode holder rod assembly;

Figure 2 is a perspective view of a preferred embodiment of this invention with two electrode holder rod assemblies;

Figure 3 is a perspective view of a preferred embodiment of the electrode holder rod assembly showing the vertical slot and the plastic roller;

Figure 4 is a vertical fragmentary sectional view taken along the line 1-1 in Figure 1;

Figure 5 is a perspective view of a four arm pressure compensator of this invention; and Figure 6 is a welding apparatus of this invention having a four electrode holder rod assembly for four electrodes.

DETAILED DESCRIPTION OF THE INVENTION
Figure 1 illustrates a welding apparatus of this invention which includes a vertical support plate 20 to which is secured a base block 21 and a single electrode plastic support block 23. A flange 22 depends from the base block 21. The flange 22 may be mounted to slide vertically within base block 21 and may be resiliently biased downwardly by an adjustable spring (not shown). A pressure compensator 24 is pivotally mounted on flange 22 by a mounting pin 25. Adjusting screws 26 are located in threaded holes 27 of the pressure compensator 24. The single electrode plastic support block 23 supports in slidable connection an electrode holder rod 28.

As shown in the detail of Figure 3, each holder rod 28 has a CA 020~9812 1998-01-07 plastic roller 29, a roller pin 30 and a vertical slot 31. A guide pin 32 (See Figure 1) mounted in the single electrode plastic support block 23 guides and limits the vertical sliding motion of the electrode holder rods 28.

An electrode holder 33 is clamped to the lower portion of 5 the electrode holder rod 28 with screw 34 (See Figure 1). A welding electrode 35 is clamped into the electrode holder 33 by a screw (not shown). Welding electrode 35 is electrically connected by an electrical lead (not shown) to an electrical control means (not shown) through the electrode holder 33.

Figure 2 depicts a welding apparatus having two electrodes 10 which includes a vertical support plate 20, a base block 21, a two electrode plastic support block 36, a flange 22 a pressure compensator 24, mounting pin 25, and adjusting screws 26. Two electrode holder rods 28 are mounted in the two electrode plastic support block 36 to reciprocate vertically. Each ofthe electrode holder rods 28 has a plastic roller 29, a roller pin 30 and a vertical slot 31 (See Figure 3). There are two guide pins 37 (one not shown) and each pin is assembled through one of the vertical slots 31 from each side of the plastic support block 36. An electrode holder 38 is clamped to the lower portion of the electrode holder rod 28 by screw 39. The welding electrode 40 is fixed into the electrode holder 38 by screw 41. The two 20 welding electrodes 40 are electrically connected via electrical leads (not shown) to an electrical control means (not shown) through the electrode holders 38 and the screws 41.

Figure 4 illustrates a cross section of the pressure compensator 24 of this invention taken along lines 1-1 of Figure 1. It will be 25 observed that the holes 27 permit adjusting screws 26 to pass through the upper or base portion of the pressure compensator 24 to abut against the pressure compensator arms below. The screws 26 can therefore act as a limit stop against upward movement of the arms and thereby determine the CA 020~9812 1998-01-07 amount of flexure of the arms relative to the base of the pressure compensator. In this manner the spring force of the pressure compensator is applied only within limits as set by the screws 26. When these limits are exceeded the deflection is transmitted to the flange 22 and other resilient 5 means not shown.

Figure 5 shows an embodiment of the pressure compensator having four arms which is used in a welding apparatus having four electrodes as illustrated in Figure 6.

In operation, when the welding apparatus is brought 10 down, an electrode 35 is pressed against the workpiece and the electrode holder rod is pressed against the arms 45 of the pressure compensator 24.
The adjusting screws 26 limit the flexure of the arms. The pressure compensator 24 resiliently drives the electrode holder rod(s) 28 and electrode(s) 35 to respond to thickness changes of the workpiece during 15 welding.

The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, 20 indicated by the appended claims rather than by the foregoing description.

.,

Claims (6)

1. In a welding apparatus having one or more charged electrodes mounted to move during welding in response to changes in thickness of a workpiece being welded, a pressure compensator to press the electrodes onto the workpiece comprising:
a substantially rigid base having two outside ends lying parallel in a plane which is perpendicular to movement of the electrodes;
one or more arms underlying a portion of said base, each arm being flexibly connected at one end thereof to one of said outside ends of said base;
and said flexible connection permitting each such arm to flex resiliently with respect to the base and to transmit a spring force to the electrodes.
2. The welding apparatus of claim 1, wherein said one or more arms comprises:
one or more pairs of arms, each arm underlying a portion of said base, and each arm of said pair being flexibly connected at one end thereof to an opposite outside end of said base; and said flexible connection aligning said pairs of arms in a spaced apart relationship below the base.
3. The welding apparatus of claim 2, in which each electrode is clamped to a rod which reciprocates linearly in response to movement of the electrode by reason of changes in thickness of the workpiece during welding, each said rod abutting against the underside of an arm of the 25 pressure compensator in rolling contact.
4. The welding apparatus of claim 3, in which the rods are supported for sliding movement within a block of insulator material and each rod has a slot along its length within the block to receive a pin from the block which limits the movement of the rod with respect to the block.
5. The welding apparatus of claim 4, in which the pressure compensator has adjustable stop means extending from the base towards an arm to limit the deflection of the arm to the base.
6. The welding apparatus of claim 2, 3, or 4, in which the pressure compensator is mounted to pivot about a pin through a central portion of the base and to swing in a plane parallel to the plane of a pair of electrodes.
CA 2059812 1992-01-22 1992-01-22 Welding apparatus for electrical welding Expired - Fee Related CA2059812C (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CA 2059812 CA2059812C (en) 1992-01-22 1992-01-22 Welding apparatus for electrical welding

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
CA 2059812 CA2059812C (en) 1992-01-22 1992-01-22 Welding apparatus for electrical welding

Publications (2)

Publication Number Publication Date
CA2059812A1 CA2059812A1 (en) 1993-07-23
CA2059812C true CA2059812C (en) 1998-09-15

Family

ID=4149131

Family Applications (1)

Application Number Title Priority Date Filing Date
CA 2059812 Expired - Fee Related CA2059812C (en) 1992-01-22 1992-01-22 Welding apparatus for electrical welding

Country Status (1)

Country Link
CA (1) CA2059812C (en)

Also Published As

Publication number Publication date
CA2059812A1 (en) 1993-07-23

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