Description:FIELD OF THE INVENTION
Embodiments of the present invention generally relates to fabrication technologies. More particularly the invention relates to a system for welding one or more first workpiece on a second workpiece aligning concentricity.
BACKGROUND OF THE INVENTION
Welding is joining together (usually, metal parts) by heating the surfaces to the point of melting with a blowpipe, electric arc, or other means, and uniting them by pressing, hammering, etc. However, while welding, alignment of two parts is of concern. And very often, there arise an issue of misalignment of the welded parts. For example, while joining two parts which are required to be concentric, the concentricity issue arrive frequently due to absence of locating pin or the guide pin not guiding or properly holding the parts together. Further, due to lack of holding capacity on the guide or locating pin, part loading issue occur because of less space in part. Currently, there are no prevention control available for concentricity checking due to part profile and electrode design. Due to lack of part guiding which is basically caused by less pin movement and electrode design constraints in a welding machine.
Further, after the parts are welded, the concentricity is checked in a later process which is time consuming and delays an assembly line in a manufacturing process. And if, after the checking of concentricity, the parts welded are not seems to be aligned, the whole welded part is regarded as useless and scraped out. Misalignment of parts causes a lot of wastage of material and wastage of time. For the alignment of the parts to be welded, also a taper pin cannot be used, due to height constraint and variable width constraints. Anyhow, stability of the joining parts is always have been an issue.
There exists a need of a system to properly align parts to be welded and hold them in order to form a properly welded part. This shall eliminate the need of concentricity checking in a manufacturing plant which can result in generation of lesser scrap metal and save time in assembly line. Therefore, there is required a system for welding one or more first workpiece on a second workpiece maintaining concentricity to address above mentioned issues.
OBJECT OF THE INVENTION
An object of the present invention is to provide a system for welding one or more first workpiece on a second workpiece aligning concentricity.
Another object of the present invention is to join two pieces having a common concentricity.
Yet another object of the present invention is to eliminate requirement of testing alignment of two or more welded parts.
Yet another object of the present invention is to reduction of fabrication waste.
SUMMARY OF THE INVENTION
This summary is provided to introduce a selection of concepts, in a simple manner, which is further described in the detailed description of the invention. This summary is neither intended to identify key or essential inventive concepts of the subject matter, nor to determine the scope of the invention.
According to an aspect of the present invention, a system for welding one or more first workpiece on a second workpiece aligning concentricity is provided. The system comprises one or more concentric holes disposed on the second workpiece, a first electrode, having a channel, disposed in between the one or more concentric holes. The one or more first workpiece to be welded is placed above the first electrode, and in line with the respective one or more concentric holes. Further, the system comprises a guide pin adapted to pass through the one or more concentric holes, the channel, and the one or more first workpiece thereby aligning and maintaining the concentricity of the one or more concentric holes with the one or more first workpiece, a switch, connected with the guide pin, configured to raise or lower the guide pin, controlling travel of the guide pin inside the one or more concentric holes and the one or more first workpiece, a second electrode, placed above the one or more concentric holes of the second workpiece. Further, the second electrode and the first electrode are adapted to form an electrical joint to weld the one or more first workpiece on the second workpiece, maintaining the concentricity with the one or more concentric holes.
In accordance with an embodiment of the present invention, the one or more first workpiece to be welded is placed over the one or more concentric holes and the first electrode.
In accordance with an embodiment of the present invention, the switch is moved to lower the guide pin there by facilitating removal of the second workpiece from the electrode.
In accordance with an embodiment of the present invention, the switch is connected with the guide pin using a spring adapted to facilitate rising and lowering of the guide pin.
In accordance with an embodiment of the present invention, the second electrode is adapted to move away from the second workpiece after the welding to facilitate removal of the second workpiece.
In accordance with an embodiment of the present invention, the system comprises a guide bush disposed along with the guide pin, configured to provide support and axial guidance to the guide pin.
In accordance with an embodiment of the present invention, the system comprises a KCF pin, disposed on the top of the guide pin, adapted to connected with the second electrode to form the electrical joint between the first electrode and the second electrode.
In accordance with an embodiment of the present invention, the system comprises an electrode cap disposed on the first electrode to ascertain precise placement of the second electrode over the first electrode and uphold sufficient contact with scalp of the second workpiece.
In accordance with an embodiment of the present invention, the system comprises an electrode holder, connected with the first electrode, adapted to hold the first electrode firmly with the second electrode while the welding.
In accordance with an embodiment of the present invention, the first electrode and/or the electrode holder are provided with inner linings configured to run a coolant to cool the first electrode.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above recited features of the present invention can be understood in detail, a more particular to the description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, the invention may admit to other equally effective embodiments.
These and other features, benefits and advantages of the present invention will become apparent by reference to the following text figures, with like reference numbers referring to like structures across the views, wherein:
Fig. 1 illustrates system for welding one or more first workpiece on a second workpiece aligning concentricity, in accordance with an embodiment of the present invention;
Fig. 2 illustrates a workpiece mounted on the system, in accordance with an embodiment of the present invention
Fig. 3 illustrates a lower portion, in accordance with an embodiment of the present invention;
Fig. 4 illustrates a switch and a guide pin, in accordance with an embodiment of the present invention;
Fig. 5 illustrates inner linings on a first electrode and/or an electrode holder, in accordance with an embodiment of the present invention; and
Fig. 6A and 6B illustrate working of the system illustrated in Fig. 1, in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF THE DRAWINGS
While the present invention is described herein by way of example using embodiments and illustrative drawings, those skilled in the art will recognize that the invention is not limited to the embodiments of drawing or drawings described and is not intended to represent the scale of the various components. Further, some components that may form a part of the invention may not be illustrated in certain figures, for ease of illustration, and such omissions do not limit the embodiments outlined in any way. It is implied that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the invention is to cover all modifications, equivalents, and alternatives falling within the scope of the present invention as defined by the appended claims. As used throughout this description, the word "may" is used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense, (i.e., meaning must). Further, the words "a" or "an" mean "at least one” and the word “plurality” means “one or more” unless otherwise mentioned. Furthermore, the terminology and phraseology used herein is solely used for descriptive purposes and should not be construed as limiting in scope. Language such as "including," "comprising," "having," "containing," or "involving," and variations thereof, is intended to be broad and encompass the subject matter listed thereafter, equivalents, and additional subject matter not recited, and is not intended to exclude other additives, components, integers or steps. Likewise, the term "comprising" is considered synonymous with the terms "including" or "containing" for applicable legal purposes. Any discussion of documents, acts, materials, devices, articles and the like is included in the specification solely for the purpose of providing a context for the present invention. It is not suggested or represented that any or all these matters form a part of the prior art base or were common general knowledge in the field relevant to the present invention.
The present invention is described hereinafter by various embodiments with reference to the accompanying drawings, wherein reference numerals used in the accompanying drawing correspond to the like elements throughout the description. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiment set forth herein. Rather, the embodiment is provided so that this disclosure will be thorough and complete and will fully convey the scope of the invention to those skilled in the art. In the following detailed description, numeric values and ranges are provided for various aspects of the implementations described. These values and ranges are to be treated as examples only and are not intended to limit the scope of the claims. In addition, a number of materials are identified as suitable for various facets of the implementations. These materials are to be treated as exemplary and are not intended to limit the scope of the invention.
Referring to the drawings, figure 1 illustrates a system (100) system (100) for welding one or more first workpiece on a second workpiece aligning concentricity, in accordance with an embodiment of the present invention. As shown in figure 1, the system (100) comprises a first electrode (102), a guide pin (104), a switch (106), one or more concentric holes (not shown in figure 1), and a second electrode (108).
Further, in accordance with an embodiment of the present invention, any of the first electrode (102) and the second electrode (108) may be made of material selected from, but not limited to, aluminium, steel such as stainless steel, carbon steel, and low-carbon mild steel, cast Iron, magnesium alloys, brass, copper, titanium or a combination thereof. The electrodes are used to conduct current through the on workpiece to fuse two pieces together. Depending upon the process, any of the electrodes are either consumable, in the case of gas metal arc welding or shielded metal arc welding, or non-consumable, such as in gas tungsten arc welding. In accordance with an embodiment, the first electrode (102) may have a channel (not shown) may be passing through the middle or a non-centric point of the first electrode (102).
Figure 2 illustrates the one or more first workpiece and the second workpiece (202) mounted on the system (100), in accordance with an embodiment of the present invention. As shown in figure 2, the second workpiece (202) may have the one or more concentric holes (2021) on which the one or more first workpiece is to be welded. The second workpiece (202) may be a part of automobile, a machine part, or a decorative piece made of but not limited to, a metal such as, but not limited to, steel, iron, aluminium, copper, titanium, brass, nickel or any metal or its alloy. Further, the one or more first workpiece may be a part with a cavity or a conduit to be welded over the second part. For example, the one or more first workpiece may be, but not limited to, a washer, a nut, a ring, a cap, a pipe, a cover etc. In an exemplary embodiment, the part may be a nut to be welded on an automobile part.
In accordance with an embodiment of the present invention, as shown in figure 2, the first electrode (102) may be in in a shape complimentary to the second workpiece (202). For example, in case the second workpiece (202) is curvaceous, or sharply edged the first electrode (102) may be in shape of, but not limited to, cylinder, sphere, rectangle, square accordingly. Similarly, a person skilled in the art may appreciate that the shape of the first electrode (102) is not a limitation of the present invention.
As shown in figure 2, the first electrode (102) may be disposed in between the one or more concentric holes (2021). The one or more first workpiece to be welded is placed above the first electrode (102), and in line with the respective one or more concentric holes (2021). Returning back to figure 1, in accordance with an embodiment of the present invention, connected with the first electrode (102) is an electrode holder (112) adapted to hold the first electrode (102) firmly with the second electrode (108) while the welding.
Further, as shown in figures 1 and 2, the second electrode (108) may be placed above the first electrode (102), over the one or more concentric holes of the second workpiece (202). However, a skilled address would appreciate that the first electrode (102) and the second electrode (108) may be arranged in multiple arrangements to properly accommodate the one or more first workpiece and the second work piece. The second electrode (108) and the first electrode (102) are adapted to form an electrical joint to weld the one or more first workpiece on the second workpiece (202). Further, as shown in figure 1, on the first electrode (102), an electrode cap (110) may be disposed. The electrode cap (110) may ascertain precise placement of the second electrode (108) over the first electrode (102) and uphold sufficient contact with scalp of the second workpiece (202). In accordance with an embodiment of the present invention, through the one or more concentric holes (2021), the channel, and the one or more first workpiece the guide pin (104) is adapted to pass. The guide pin (104) is adapted to align and maintain the concentricity of the one or more concentric holes with the one or more first workpiece.
Figure 3 illustrates a lower portion, in accordance with an embodiment of the present invention. As shown in figure 3, on the top of the guide pin (104), a ceramic or KCF pin (1042) is disposed. The KCF pin (1042) may be made of, but not limited to, Chromium, brass, copper, Aluminium, Titanium, Zirconium, Nickel, Magnesium, iron or a combination thereof. The KCF pin (1042) may be adapted to connected with the second electrode (108) to form the electrical joint between the first electrode (102) and the second electrode (108). Further, as shown in figure 3, along with the guide pin (104), a guide bush (1041) may be disposed. The guide bush (1041) may be configured to provide support and axial guidance to the guide pin (104). The guide bush (1041) supports the workpiece so close to the guide pin (104) that deflection due to the welding is essentially reduced to zero.
As shown in figure 3, connected with the guide pin (104) is a switch (106). Figure 4 illustrates the switch (106) and the guide pin (104), in accordance with an embodiment of the present invention. As shown in figure 4, the switch (106) may be connected with the guide pin (104) using a spring adapted to facilitate rising and lowering of the guide pin (104). The switch (106) is configured to raise or lower the guide pin (104), controlling travel of the guide pin (104) inside the one or more concentric holes (2021) and the one or more first workpiece. Further as shown in 4, a latch may be present in the electrode holder (112) to lock the switch (106) in a loaded position.
Further, in accordance with an additional or alternative embodiment, the first electrode (102) and/or the electrode holder (112) may be provided with inner linings (402). Figure 5 illustrates inner linings (402) on the first electrode (102) and/or the electrode holder (112), in accordance with an embodiment of the present invention. The inner linings (402) may be spread inside the first electrode (102) and/or the electrode holder (112). The inner linings (402) are configured to run a coolant to cool the first electrode (102). In accordance with an embodiment of the present invention, the coolant may be selected from a group comprising water, ethylene glycol, and/or propylene glycol.
The invention works in following manner:
Figures 6A and 6B illustrate working of the system (100) illustrated in Figure 1, in accordance with an embodiment of the present invention. Firstly, as shown in figure 6A, the second electrode (108) is set at a position to allow the one or more first workpiece, which is preferably a nut (204) in the present embodiment. The nut (204), as shown in the figure 6A, is placed over the second workpiece (202). As shown in figure 6A, the one or more concentric holes (2021) of the second workpiece (202) for example may be, but not limited to, C shaped, U shaped, E shaped, F shaped, with multiple parallel surfaces or substantially parallel surface are placed over the channel of the first electrode (102). As an example of a preferred embodiment, as shown in figure 2, a C shaped clip used for rear axle of a vehicle is being bolted on a nut. Flanges of the C shaped clips have concentric holes (2021) in them. The hole of the nut is aligned with the concentric holes (2021). The guide pin (104) is directed through the one or more concentric holes (2021), the channel and the nut (the first workpiece).
In an embodiment of the present invention, in order to align the concentricity of the one or more concentric holes (2021), the channel, and the one or more first workpiece, the switch (106) is released from the latch which forcefully aligns the concentricity of the one or more concentric holes of the second workpiece (202) and the one or more first work piece. As a result, the guide pin (104) along with the KCF pin (1042) passes through the channel of the first electrode (102), the one or more concentric holes (2021) of the second workpiece (202) and the nut (204) as shown in figure 6A. The guide bush (1041) disposed along with the guide pin (104) is configured to provide support and axial guidance to the guide pin (104).
After proper placement and the alignment of the one or more concentric holes (2021), the channel, and the one or more first workpiece, as shown in figure 6B, the second electrode (108) is lowered. The second electrode (108) is pressed onto the first electrode (102) to enable a flow of electricity for purpose of welding. The second electrode (108) and the first electrode (102) are adapted to form an electrical joint to weld the nut (204) (i.e., the one or more first workpiece) on the second workpiece (202). Further, the electrode cap (110) disposed on the first electrode (102) to ascertain precise placement of the second electrode (108) over the first electrode (102) and uphold sufficient contact with scalp of the second workpiece (202). The electrode cap (110) may be consumed during the welding in order to join the nut (204) (the first workpiece) and the second workpiece (202).
During the welding, a lot of heat may be produced in the first electrode (102) and the electrode cap (110), and eventually in the first workpiece (204) and the second workpiece (202). In this situation, the coolant may be released in the inner linings (402) of the electrode holder (112) and the first electrode (102). The coolant may remove excess heat from the first electrode (102) and also eventually from the first and the second workpiece (202). The coolant may be regularly supplied from a coolant reservoir to keep the first workpiece (204) and the second workpiece (202) cool and away from any deformation due to heat.
After properly welding the first workpiece onto the second workpiece (202), the switch (106) is moved down back into the latch to lower the guide pin (104) there by facilitating removal of the second workpiece (202) from the first electrode (102). Further, the second electrode (108) is adapted to move away from the second workpiece (202) after the welding to facilitate removal of the second workpiece (202). The second electrode (108) may be pulled back, away from the first electrode (102) to make space to remove the welded first workpiece and the second workpiece (202). After removal of the welded first workpiece (204) and the second workpiece (202), the alignment can be checked by inserting the guide pin (102) inside the one or more concentric holes (2021). If, the guide pin (102) is inserted smoothly, the concentric holes (2021) are aligned. For example, the system may align concentricity in range of offset condition of concentricity Ø=0.0-1.0.
The present invention has various advantages. The invention provides cost effective and time effective approach over the existing arts. Using the present invention, concentricity of the parts welded can be check on initial level. Further, the present invention provides proper hardware to hold the welding parts firmly hence part loading Issue is eliminated. Now, there is sufficient space for loading the parts to be welded. In case of lack of concentricity among parts, the misalignment can be detected at the place of welding alone at a primary state and there is no need of any further inspection. Due to rigidity and sturdiness of the guiding pin, no play or deflection occurs during welding of the first workpiece and the second work piece. Due to proper guiding, the first part is properly welded and the first workpiece shifting issue is controlled. Due to the KCF pin, the system works properly to prevent movement of the first workpiece.
Various modifications to these embodiments are apparent to those skilled in the art from the description and the accompanying drawings. The principles associated with the various embodiments described herein may be applied to other embodiments. Therefore, the description is not intended to be limited to the embodiments shown along with the accompanying drawings but is to be providing broadest scope of consistent with the principles and the novel and inventive features disclosed or suggested herein. Accordingly, the invention is anticipated to hold on to all other such alternatives, modifications, and variations that fall within the scope of the present invention and the appended claims.
, Claims:We Claim:

1. A system (100) for welding one or more first workpiece (204) on a second workpiece (202) aligning concentricity, the system (100) comprising:
one or more concentric holes (2021) disposed on the second workpiece (202);
a first electrode (102), having a channel, disposed in between the one or more concentric holes (2021), wherein the one or more first workpiece (204) to be welded is placed above the first electrode (102), and in line with the respective one or more concentric holes (2021);
a guide pin (104) adapted to pass through the one or more concentric holes (2021), the channel, and the one or more first workpiece (204) thereby aligning and maintaining the concentricity of the one or more concentric holes with the one or more first workpiece (204);
a switch (106), connected with the guide pin (104), configured to raise or lower the guide pin (104), controlling travel of the guide pin (104) inside the one or more concentric holes (2021) and the one or more first workpiece (204); and
a second electrode (108), placed above the one or more concentric holes of the second workpiece (202), wherein the second electrode (108) and the first electrode (102) are adapted to form an electrical joint to weld the one or more first workpiece (204) on the second workpiece (202), maintaining the concentricity with the one or more concentric holes (2021).
2. The system (100) as claimed in claim 1, wherein the one or more first workpiece (204) to be welded is placed over the one or more concentric holes and the second electrode (108).
3. The system (100) as claimed in claim 1, wherein the switch (106) is moved to lower the guide pin (104) there by facilitating removal of the second workpiece (202) from the electrode.
4. The system (100) as claimed in claim 1, wherein the switch (106) is connected with the guide pin (104) using a spring adapted to facilitate rising and lowering of the guide pin (104).
5. The system (100) as claimed in claim 1, wherein the second electrode (108) is adapted to move away from the second workpiece (202) after the welding to facilitate removal of the second workpiece (202).
6. The system (100) as claimed in claim 1, comprising a guide bush (1041) disposed along with the guide pin (104), configured to provide support and axial guidance to the guide pin (104).
7. The system (100) as claimed in claim 1, comprising a KCF pin (1042), disposed on the top of the guide pin (104), adapted to connected with the second electrode (108) to form the electrical joint between the first electrode (102) and the second electrode (108).
8. The system (100) as claimed in claim 1, comprising an electrode cap (110) disposed on the first electrode (102) to ascertain precise placement of the second electrode (108) over the first electrode (102) and uphold sufficient contact with scalp of the second workpiece (202).
9. The system (100) as claimed in claim 1, comprising an electrode holder (112), connected with the first electrode (102), adapted to hold the first electrode (102) firmly with the second electrode (108) while the welding.
10. The system (100) as claimed in claim 9, wherein the first electrode (102) and/or the electrode holder (112) are provided with inner linings (402) configured to run a coolant to cool the first electrode (102).