Angular Electrode Welding Burn Remover
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Solution Overview
Problem
Existing welding burn removal methods are labor-intensive and complex to automate, especially when dealing with large, distorted, or deformed workpieces, as they require manual operation and intricate control to effectively remove welding burns using electrolytic treatment.
Innovation Solution
A welding burn remover device equipped with an electrolytic end effector featuring an angularly displaceable electrode, supported by a movable body with actuators and a non-conductive short-circuit prevention cover, along with an electrolytic solution feeder and processing circuitry that automates the sliding of the electrode over the workpiece while supplying electrolytic solution, allowing for efficient removal of welding burns without complex control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual electrolytic treatment is used to remove welding burns, then the worker can directly control the electrode movement, but the workload increases significantly when the workpiece is large and the welding burn portion is wide
Solution Approach 1:
The patent replaces manual mechanical operation with an automated robotic system. The robot holder automatically positions and moves the electrode along the welding burn portion, eliminating the need for manual manual handling and reducing the workload for large workpieces.
Solution Approach 2:
The system enables self-service through automated control where the robot performs the electrolytic treatment without continuous manual intervention. The control unit automatically manages the electrode movement and treatment process, allowing the system to operate independently.
2Productivity
If automated electrolytic treatment is implemented, then productivity increases, but the control becomes complex especially when the workpiece surface is distorted or deformed
Solution Approach 1:
The patent applies dynamics by making the electrode angularly displaceable relative to the base through the coupler mechanism. This allows the electrode to dynamically adjust its angle and follow the contours of distorted or deformed workpiece surfaces automatically during the electrolytic treatment process.
Solution Approach 2:
The system changes operational parameters by allowing angular displacement of the electrode. The coupler mechanism enables the electrode to vary its angle relative to the base, adapting to different surface geometries without requiring complex control systems.
3Device complexity
If the electrode is fixed relative to the base, then the structure is simple, but the electrode cannot follow distorted or deformed workpiece surfaces
Solution Approach 1:
The patent introduces dynamic capability to the electrode support structure through the coupler mechanism that allows angular displacement. This enables the electrode to adapt to distorted or deformed workpiece surfaces while maintaining a relatively simple overall structure.
Solution Approach 2:
The electrode support is segmented into separable components: the base attached to the movable body and the electrode connected through the coupler. This segmentation allows the electrode to be angularly displaceable relative to the base, providing adaptability to different surface geometries.
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
The device enables automated electrolytic treatment of welding burns on distorted or deformed surfaces, reducing the time and effort required for removal and improving surface finish by allowing the electrode to smoothly follow the workpiece's contours, thus simplifying the process and enhancing efficiency.
Implementation Method 1
Japanese Laid-Open Utility Model Application Publication No. 4-48271 discloses a device that performs electrolytic removal of welding burns of metal, such as stainless steel, by electrochemical action.
Data Source
AI summary
A welding burn remover includes: a mover including a movable body to which a support of an electrolytic end effector is attached and at least one actuator that moves the movable body; and processing circuitry configured to control the actuator. The processing circuitry is configured to execute an electrolytic treatment in which the processing circuitry controls the actuator to slide an electrode on a welding burn portion of a welded workpiece through a short-circuit prevention cover while controlling a pump to supply an electrolytic solution to a boundary by an electrolytic solution feeder. The support of the electrolytic end effector includes: a base attached to the movable body of the mover; and a coupler connecting the electrode to the base such that the electrode is angularly displaceable relative to the base.