Welding system and welding method
The described welding system optimizes process time by simultaneously engaging multiple contacts and monitoring weld points with a single power source and control unit, addressing inefficiencies in traditional systems and reducing costs.
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- ISOLITE
- Filing Date
- 2025-11-27
- Publication Date
- 2026-06-11
AI Technical Summary
Current industrial resistance welding systems are limited by process time, contact speed, and positioning speed, leading to inefficient overall process times due to the mechanical dynamics and individual movement of each weld point, with existing solutions either compromising control or increasing costs.
A welding system with a distribution system that activates and deactivates supply lines for each welding point, allowing simultaneous engagement of multiple contacts and individual monitoring, while using a single welding power source and control unit, optimizing process time and maintaining control and monitoring capabilities.
The system significantly reduces overall process time by eliminating the need for multiple power sources and contacts, achieving a 3-10 times improvement over traditional methods, while maintaining control and monitoring, and reducing investment costs.
Smart Images
Figure EP2025084531_11062026_PF_FP_ABST
Abstract
Description
[0001] Powerwelder
[0002] Field of invention
[0003] The invention relates to a welding system, Powerwelder, and a corresponding welding process.
[0004] State of the art
[0005] Current industrial practice in resistance welding involves hand-held or robot-guided systems, each with a welding control, a welding power source, and a contact point for the workpiece.
[0006] This allows the process parameters for each welding point to be selected individually, and monitoring of each individual process is also possible.
[0007] To optimize this system in terms of process speed and process costs, three key parameters can currently be influenced:
[0008] 1. Welding process time
[0009] 2. Contact speed of the individual welding point
[0010] 3. Positioning speed between welding points
[0011] Item (1) of this list is limited by process capability. This means that below or below a minimum process time, a reliable welding process can no longer be guaranteed, and therefore the required quality of the weld and thus of the welding process cannot be achieved. For items (2) and (3) of this list, the mechanical dynamics of the welding system determine the maximum achievable speeds. The mechanical dynamics, and therefore items (2) and (3), affect item (1) of the list. That is, the process time from these items is added to the process time from item (1). Thus, the process time represents by far the largest component of the overall process time.
[0012] Since each weld point is typically performed with an individual movement, the total process time adds up significantly across the number of weld points on a component. Therefore, to optimize the overall process time, it is desirable to reduce the number of necessary contacts (see point (2)) and positioning movements (see point (3)).
[0013] FIG. 1 shows conventional elements of a welding system. The system shown in FIG. 1 performs the positioning movements by which the contact is moved from weld point to weld point.
[0014] FIG. 1 illustrates a welding system 10 with a welding controller 11, a welding power source 13, a contact point 15 and weld metal, in particular a component 17. The welding system 10 is operated by a user or an industrial robot.
[0015] In industrial mass production, an industrial robot, hereinafter referred to simply as a robot, is typically used to guide a welding actuator to the component; in less common cases, the component is guided to the actuator. After an employee has transferred the components to be joined into a clamping device of the system, the safety circuit closes and the process sequence starts.
[0016] The welding actuator is guided by the robot to component 17 and repositioned weld point by weld point. At each welding position, the contact is closed and the welding process is carried out. After the welding process is complete, the contact is opened again and the industrial robot repositions the welding actuator to the next position.
[0017] There are several alternative solutions to the system shown, some of which are listed below and schematically illustrated in FIG. 2.
[0018] A) Series connection of two welding points
[0019] System A in FIG. 2 essentially corresponds to System 10 in FIG. 1. System A comprises a welding controller 11A, which is connected to and can control a welding power source 13A. The welding power source 13A is connected to a component 17A via a contact 15A. Two contact 15A are shown for System A. In this configuration, the welding current from the welding power source 13A is routed through a maximum of two welding points in System A, with the supply and return current each connected to a separate contact 15A. This allows the number of contact points (see point (2)) and positions (see point (3) to be halved, but eliminates the possibility of individual control and monitoring of the process. Furthermore, the process is geometrically limited by the actuators.
[0020] B) Use of multiple welding power sources on one welding controller
[0021] System B in FIG. 2 shows a welding controller 11B, several welding power sources 13B, several contact points 15B, and a workpiece / component 17B. The number of welding power sources 13B and corresponding contact points 15B is purely exemplary. A control voltage is switched, which transmits the signals from the welding controller 11B to the welding power sources 13B. For system B in FIG. 2, by connecting several welding power sources 13B to a single welding controller 11B, all welding points on the workpiece 17B can be contacted simultaneously. This eliminates the need to consider points (2) and (3) of the list above. However, a disadvantage of this solution is the requirement for an individual welding power source 13B for each contact point 15B. This makes the use of this alternative uneconomical for larger numbers of welding points.
[0022] C) Multiple contacts on one welding power source
[0023] System C in FIG. 2 shows a welding controller 11C, a welding power source 13C, and several contacts 15C connected to the component 17C. In the alternative according to System C, all contacts 15C are directly connected to a (single?) welding power source 13C. This eliminates the need to consider points (2) and (3) of the list above. However, various test setups have demonstrated that process capability is not achieved because the welding current is not distributed evenly across the contacts. Another disadvantage of this alternative is the lack of individual parameterization and monitoring of the welding points.
[0024] D) Use of several, often similar, welding systems
[0025] System D in FIG. 2 shows a welding system D, which is composed of a group of identical welding systems. System D comprises several welding controllers 11D, correspondingly several welding power sources 13D, and furthermore correspondingly several contact points 15D, each connected to the component 17D. In other words, in System D, the respective elements of the systems, such as controller 11D, power source 13D, and contact point 15D, are used in parallel to each other.
[0026] In system D of FIG. 2, either all welding points are individually contacted and equipped with control unit 11D and welding power source 13D, or several, mostly robot-guided, systems are used, each performing a certain proportion of the total welding points. With regard to the list above, points (2) and (3) are reduced by a factor of "number of welding systems used," while material usage increases, possibly considerably.
[0027] For variants System B and System D of FIG. 2, it should also be noted that welding on the same component is not carried out simultaneously. This prevents interactions between the welding power sources.
[0028] Description of the invention
[0029] In view of the disadvantages outlined in the prior art, the object of the present invention is to minimize these disadvantages and to optimize, in particular reduce, the process time of the welding process.
[0030] This problem is solved by a welding system according to claim 1 and a corresponding method according to claim 5.
[0031] The present invention provides:
[0032] A welding system for carrying out a welding process, comprising: a welding control; a welding power source; one or more contacts, wherein one or more, in particular all, contacts are engaged with a component to be welded; a distribution system, wherein the distribution system comprises a corresponding supply line for each of the contacts; wherein the distribution system is configured to activate the supply line corresponding to the contact for each welding point and to direct the welding current to the contact via the corresponding supply line and to deactivate it again after the welding point has been placed on the component.
[0033] The welding system as described above can also be configured to select the supply lines for carrying out the welding process according to a predefined program.
[0034] In the welding system as described above, the predefined program can be provided by the welding control system. In the welding system as described above, the contacts can include active, in particular driven, contacts and / or passive, in particular spring-loaded, contacts and / or active, in particular driven, groups of several passive contacts.
[0035] The invention further provides a welding method with a welding system as described above, wherein the method comprises the following steps: for all contacts engaged with a component to be welded: disconnecting the supply line corresponding to a contact by the distribution; performing the welding for the disconnected contact; reporting the completion of the welding for the contact, including setting a status indicator with regard to the successful execution of the welding; disconnecting the contact for the weld point.
[0036] The welding process as described above may further include: after separating the contact for the welding point, checking the status indicator; if the welding was successfully performed, the status indicator will indicate that the welding process is continuing with the next contact; otherwise, an error condition will be indicated and the error condition will be processed.
[0037] In the welding process as described above, dealing with the defect condition may include: repeating the defective weld point, or skipping the defective weld point and proceeding to the next weld point; or aborting the welding process for the component, in particular subsequently continuing the welding process for another component.
[0038] In the welding process as described above, the processing of the fault condition can be carried out by the welding control and / or by an external monitoring system.
[0039] In the welding process as described above, the process can, after processing all contacts, output a signal indicating that the welding process was successful and then terminate the welding process.
[0040] In the welding process as described above, the welding process may further include a step of checking predefined starting conditions. Description of the figures
[0041] Fig. 1 illustrates conventional elements of a welding system.
[0042] Fig. 2 illustrates various alternative welding systems to the system in FIG. 1.
[0043] Fig. 3 illustrates an embodiment of a welding system according to the present invention.
[0044] Fig. 4 illustrates a method according to the invention for a welding process with a welding system according to FIG. 3.
[0045] Fig. 5 illustrates a comparison of the alternatives from the systems shown in FIG. 1 and FIG. 2 with the system according to the invention shown in FIG. 3 and FIG. 4.
[0046] Detailed description
[0047] FIG. 3 shows an embodiment of a welding system 100 according to the present invention. The welding system 100 according to the invention comprises a welding controller 111 and one or more, in particular a single, welding power source 113. FIG. 2 further shows the workpiece / component 117 to be machined. The welding system 100 also comprises one or more, in particular a plurality of, contacts 115. In the welding system 100 according to the invention, the welding current from the welding power source 113 is switched between the welding power source 113 and the contacts 115. One or more, in particular all, contacts 115 are engaged simultaneously. From the welding power source 113, the welding current is routed to a distribution unit 114, which has one output for each contact 115. For each welding point, the respective supply line to the contact 115 is activated and, after the welding process is complete, deactivated again.
[0048] This essentially eliminates the problems regarding contact speed, see point (2) of the list above, and also the problems regarding positioning speed, see point (3) of the list above. Individual parameterization and monitoring of the welding points are retained. This allows the process speed, see point (1) of the list above, to be increased and the process time to be optimized. System 100 and the associated process are fundamentally independent of both the welding controller and the welding power source used and can therefore be used universally and in a scalable manner. The only remaining limiting factor for the process time is the welding process time, see point (1), as a function of the power of the welding controller 111 and the welding power source 115.
[0049] A further advantage, particularly compared to the alternative of system B in FIG. 2, is that the need to use multiple welding power sources is eliminated. This also means that the switching technology used only needs to be implemented once per system.
[0050] Furthermore, compact and reduced contact arrangements can be useful for implementing the invention in order to achieve even greater optimization of the process time compared to the prior art. For this purpose, both individually active (i.e., driven) contact arrangements and / or purely passive contact arrangements, for example spring-loaded contact arrangements, or active (i.e., driven) groups of passive contact arrangements can be used.
[0051] The reference system shown is a standard robotic welding cell with simple existing contacts and power technology. The invention promises improved cycle times while simultaneously reducing investment costs. The power connection is located closest to the system operator; the operator starts the entire process, similar to how the automation sequence is initiated on a robotic system in which the welding system is integrated.
[0052] Figure 4 below illustrates an exemplary sequence of a power switching process according to the invention for a welding system according to Figure 3. In the selected example in Figure 4, several welding points, for example 3 or even n, are to be executed with the same welding program and evaluated individually. In the event of a welding error, the power switching process can be reset by issuing an error message, "Reset". In this reset situation, the process would start again at "Start".
[0053] Figure 4 illustrates a power connection process. Figure 4 shows three columns: the left column refers to messages, the middle column to the actual power connection (i.e., the steps of the process), and the right column to the actual welding process (i.e., the welding power source and welding control). The welding power source and welding control can be from the system shown in Figure 3. The process depicted in Figure 4 corresponds to a so-called recipe. This recipe typically specifies which contacts are currently engaged; only those contacts are then executed. It is understood that the process can alternatively extend to all contacts.
[0054] FIG. 4 shows a process start / beginning block at the beginning and a process end at the end of the procedure; in between, the contacts 1, 2, ... n-1, n are processed.
[0055] The inventive method shown in FIG. 4 begins with the process start in step S201. Optionally, it is first checked in step S203 whether the predefined start conditions are met. If the predefined start conditions are not met, the method terminates with an error message in step S205. Otherwise, the method continues.
[0056] The procedure now includes, for all contacts engaged with a component to be welded, or alternatively for all contacts: Disconnecting, step S211, the first contact. This allows welding to proceed for the weld point associated with this contact, step S213.
[0057] In step S214, the completion of the welding process for the contact is reported, and a status indicator, such as a flag, is transmitted to confirm successful welding. The status indicator can be "OK," meaning the weld is successful, or "NG," meaning not good (not okay), meaning the weld is not successful. In the subsequent step S215, the contact is then disconnected.
[0058] Optionally, in the subsequent step S217, the previously transmitted status indicator can be evaluated. If the status indicator displays the value "NG", an error can be output in step S219. In FIG. 4, a reset is indicated in step S219. The process can then initiate a retry of the faulty weld point, i.e., attempt the weld point again. Or the process can skip the faulty weld point and proceed to the next weld point. Or the process can abort the welding process for the component, and subsequently, the process can continue the welding process for another component. FIG. 4 shows that the process now proceeds to the next contact point, here contact point 2. Thus, steps S223 and S224 correspond to steps S213 and S214 for the first contact point.Steps S225, S227 and S229 during the second contact correspond to steps S215, S217, and S219 during the first contact.
[0059] The process shown in FIG. 4 continues until the nth contact point. In the last block, the end of the process, step S231 optionally checks whether the entire welding process was / is correct and outputs a corresponding signal, S235. The process ends with step S233.
[0060] Proof
[0061] In the experimental setup to demonstrate the function and applicability on an industrial scale, spring-loaded contacts were chosen, which are activated by the closing mechanism of a clamping device.
[0062] The switching mechanism was initially implemented for ten welding points; scaling is possible without negatively impacting the performance data.
[0063] This is also illustrated in FIG. 5, where a reference is compared with alternatives A, B, C, and D as described above, as well as with the system and method according to the invention. In FIG. 5, the columns in the lower part show the welding time, and those in the upper part show the time per weld point. The curve shown indicates the investment costs for the individual systems.
[0064] Compared to a state-of-the-art robot-guided solution, a reduction in the overall process time for a reference component of a factor of 3 was easily achieved; with the selection of a more suitable welding control system, a reduction of a factor of 10 compared to the reference is expected.
Claims
Patent claims 1. Welding system (100) for carrying out a welding process, comprising: a welding control (111); a welding power source (113); one or more contacts (115), wherein one or more, in particular all, contacts are engaged with a component (117) to be welded; a distribution (114), wherein the distribution (114) comprises a corresponding supply line for each of the contacts; wherein the distribution (114) is configured to activate the supply line corresponding to the contact for each welding spot and to direct the welding current to the contact via the corresponding supply line and to deactivate it again after the welding spot has been placed on the component (117).
2. Welding system (100) according to claim 1, wherein the welding system (100) is configured to select the supply lines for carrying out the welding process according to a predefined program.
3. Welding system (100) according to claim 2, wherein the predefined program is provided by the welding control.
4. Welding system (100) according to at least one of claims 1 - 3, wherein the contacts may comprise active, in particular driven contacts and / or passive, in particular spring-loaded contacts and / or active, in particular driven groups of several passive contacts.
5. Welding method with a welding system according to claim 1, the method comprising the steps: for all contacts engaging with a component (117) to be welded: Activating (S211) the supply line corresponding to a contact for contacting through the distribution (114); Execution (S213) of welding for the activated contacting; Reporting (S214) the completion of welding for contacting, including setting a status indicator with regard to the successful execution of the welding; Separation (S215) of the contact for the welding point.
6. Welding method according to claim 5, further comprising: after separating (S215) the contact for the welding point checking (S217) the status indicator, if welding is successfully indicated by the status indicator continuing the welding process with the next contact (S223), otherwise indicating (S219) a fault condition and processing the fault condition.
7. Welding method according to claim 6, wherein processing the defect condition comprises: Repeating the faulty weld point, or Skip the faulty weld point and proceed to the next weld point; or Terminating the welding process for the component (117), in particular subsequently continuing the welding process for another component.
8. Welding method according to claim 6 or 7, wherein the processing of the defect condition can be carried out by the welding control (111) and / or by an external monitoring system.
9. Welding method according to at least one of claims 5 to 8, wherein the method, after processing all contacts engaging with the component (117) to be welded, outputs a signal (S231 , S235) indicating that the welding process was successful and then terminates the welding process (S233).
10. Welding method according to at least one of claims 5 to 9, wherein the welding method further comprises a step (S203) of checking predetermined starting conditions.